ALERT

BULLETIN A53-232

FUSELAGE - Main Frame - Inspect/Repair Aft Fuselage Ventral Pressure Bulkhead

Tee.

This page transmits Revision 2 for DC-9 Alert Service Bulletin A53-232 to

incorporate the following changes:

NOTE: This revision constitutes a complete reissue and reflects

current operators of affected aircraft at time of issue.

Reason for Revision: To add two aircraft to this Alert Service Bulletin

Effectivity which are affected by this modification.

No additional work is required by this revision for

aircraft previously inspected/repaired by prior issue

of this Alert Service Bulletin.

Pages 2

and 8:

Added two aircraft to Service Bulletin effectivity as follows:

OPR FUS (FSN)

AM 718 (47602)

OPR FUS (FSN)

ZXE 173 (47016)

Page 15: Revised Approval.

Page 55: Revised supplier address in paragraph 3.C.(1).

Revision Sequence:

Original

Revision

Revision

Date

1

2

March 28/90

June 25/93

April 28/95

ENW

AMM-3

DOUGLAS AIRCRAFT COMPANY

MCDONNELL DOUGLAS CORPORATION

PRODUCT SUPPORT

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 1 of 1
ALERT

BULLETIN A53-232

FUSELAGE - Main Frame - Inspect/Repair Aft Fuselage Ventral Pressure

Bulkhead Tee.

NOTE

This Alert Service Bulletin is affected by Federal

Aviation Administration Airworthiness Directive

No. 89-16-12: Amendment 39-6287, effective

September 7, 1989.

This Alert Service Bulletin is applicable only

to aircraft equipped with ventral aft pressure

bulkhead which have accumulated 35,000 or more

landings.

Replacement of all six aft pressure bulkhead tee

sections with new improved parts per this Alert

Service Bulletin constitutes closing action for

the repetitive inspection requirements of this

Alert Service Bulletin.

This Alert Service Bulletin supersedes but does

not cancel the requirements of DC-9 Alert Service

Bulletin A53-191. Only aircraft listed in this

Alert Service Bulletin that are contained in the

Effectivity of Alert Service Bulletin A53-191 are

affected by this contingency.

This Alert Service Bulletin is issued as a partial

record-type change. A service rework drawing or

aperture cards are furnished in lieu of

illustrations.

March 28/90

Revision 2 April 28/95

Bulletin A53-232

Page 1 of 58
ALERT

1. Planning Information:

A. Effectivity:

(1) Aircraft Affected:

DC-9, Series 10, 20, 30, 40, 50, and C-9,

DC-9-81. -82. and -83 (MD-81. -82. and -83)

(a) Operator and Aircraft Number:

Operator Factory Serial No.

ALERT

ODerator Factory Serial No.

AA 49145

49155

49158

49161

49167

49171

49251

49253

49269

49286

49331

AM 47006

47106

47394

47501

47549

47594

47602

47607

47609

47650

48067

48083

48125

48150

49149

49188

AO 47076

47080

47090

47452

47455

47461

47504

47542

47556

47637

and

thru

and

thru

thru

thru

thru

and

49159

49163

49168

49181

49259

49273

49329

49332

thru 48069

thru 48130

and 48151

thru 49190

thru 47092

AO 47640

(cont) 47642

47675

47678

47704

47707

48104

AS 48079

49103

49111

49126

49231

49363

49386

AU 47262

47365

47446

47454

48024

AY 47604

47613

47694

47736

47771

48134

49150

49252

49284

AZ 47038

47046

47101

47128

47222

47228

47283

thru 47644

thru 48106

and 48080

and 49104

thru

thru

and

and

and

thru

and

thru

thru

thru

thru

thru

and

and

and

thru

thru

49236

49365

49387

47447

48025

47606

47614

47696

47738

47773

48136

49152

47039

47047

47129

47226

47238

Bulletin A53-232 March 28/90

Page 2 Revision 2 April 28/95
ALERT ALERT

Operator Factory Serial No. Operator Factory Serial No.

AZ 47311

(cont) 47339

47432

47502

47518

47533

47544

47553

47575

47591

47641

47653

49192

thru 47438

and 47519

thru 49218

BD 47484

47523

47555

47559

47648

47666

BVZ 47430

47468

47516

BW 49390

CBF 49415

49425

49428

49502

CEA 49140

49355

49501

and 49141

CO 47539

(cont) 47638

47765

47788

47797

48022

48027

48044

48056

48062

48066

48073

48111

49102

49112

49116

49120

49125

49127

49222

49229

49246

49249

49260

49370

49391

49478

thru 47799

and 48045

and 48063

and 48074

thru 48113

thru

thru

thru

and

thru

and

thru

thru

49114

49118

49122

49250

49265

49371

49394

49482

EA 47120

EZ 47044

47061

47191

47194

47279

CO 45789

45791

45847

47094

47110

47218

47281

47487

47490

47520

47524

47531

47535

thru 45793

thru 47112

and 47219

and 47521

FP 45731

GA 47385

47481

47569

47601

47635

47701

47722

47730

47740

47744

47789

and 47386

thru 47795

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 3
ALERT

Operator Factory Serial No.

GB 45717

47003

47008

47065

47072

47084

47176

47201

47203

47257

47273

47291

47314

47317

47325

47363

47380

47419

47426

47462

47464

47492

47497

47509

47522

47528

47543

47550

47608

47612

47615

47619

47759

GEC

and 47004

and 47009

and 47258

and

and

and

and

thru

thru

thru

47364

47381

47427

47465

47494

47499

47512

thru 47552

and

and

47616

47620

47783

GH 47755

HA 47204

47654

47658

47661

47689

47726

47735

47742

47763

47784

47796

48122

and 47662

ALERT

Operator Factory Serial No.

IB 47037

47079

47088

47093

47312

47368

47453

47456

47702

47706

48103

IG 47655

47713

49247

JD 47760

47767

47780

48029

48070

49280

and 47089

and 47313

thru

thru

and

thru

and

and

thru

thru

thru

47657

47715

49248

47762

47768

47781

48033

48072

49283

JP 47239

47530

47570

48046

48048

48087

49379

49440

JU 47460

47470

47532

47562

47567

47571

47582

and 47563

and 47568

KE 49373 and 49374

49416 and 49417

LM 49123 and 49124

and 47764

LV 47000

47703

47705

47712

47719 thru 47721

Bulletin A53-232 March 28/90

Page 4 Revision 2 April 28/95
ALERT ALERT

Operator Factory Serial No. Operator Factory Serial No.

LV 47727

(cont) 47752

47770

47782

49395

NK 45788

47113

47131

47478

47526

47547

NW 45787

45790

45827

47031

47042

47063

47073

47078

47083

47103

47114

47138

47149

47160

47171

47175

47178

47205

47244

47246

47252

47263

47280

47282

47286

47315

47337

47346

47362

47369

47382

47389

47395

47404

and 47064

thru 47117

and 47150

thru 47180

and 47206

and

thru

and

thru

and

and

and

and

and

thru

and

thru

47247

47256

47264

47288

47316

47338

47347

47370

47383

47391

47396

47406

NW 47415

(cont) 47425

47439

47450

47458

47469

47472

47479

47517

47566

47572

47647

47651

47659

47664

47682

47708

47716

47724

47729

47739

47756

47769

47774

47785

48054

48057

48086

48088

48100

48107

48121

48148

49110

OS 48015

48059

49115

49164

49278

49372

thru 47417

and

and

47440

47459

and 47473

and 47480

and

and

and

47573

47652

47660

thru 47710

thru 47718

thru 47758

thru

thru

and

thru

thru

thru

47776

47787

48055

48091

48102

48110

and 48149

thru 48021

and 49279

QA 47018

QD 47278

47319

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 5
ALERT ALERT

Operator Factory Serial No. Operator Factory Serial No.

SK 47301

47305

47360

47513

47596

47599

47610

47623

47626

47646

47725

47747

47750

47766

47777

49381

49420

49422

49436

SR 48002

49100

49356

TK 47397

47442

TW 45772

45798

47001

47027

47033

47035

47107

47172

47248

47324

47343

47357

47411

47491

47589

47603

47617

47669

47676

47686

47688

47693

thru

thru

and

47303

47308

47361

and 47597

and 47624

thru 47634

and 47748

thru 47779

thru 49385

an d 49423

thru 48014

thru 49358

and 45773

and 45799

thru 47030

thru

thru

thru

47109

47174

47251

thru 47345

and

and

47412

47618

TW 47711

(cont) 47728

47731

47746

47749

47751

47753

48123

49153

49156

49160

49165

49169

49182

49230

49245

49266

49366

US 47026

47050

47099

47130

47146

47207

47212

47310

47332

47334

47371

47420

47429

47505

47507

47564

47574

47576

47583

47588

47590

47593

48026

48028

48034

48049

48052

48092

48114

48131

thru 47734

and

and

and

and

and

thru

48124

49154

49157

49166

49170

49187

and 49267

thru 49369

thru 47052

thru 47210

thru

thru

and

and

47336

47375

47421

47508

thru 48043

and 48053

thru 48099

thru 48120

Bulletin A53-232 March 28/90

Page 6 Revision 2 April 28/95
ALERT ALERT

ODerator Factory Serial No. Operator Factory Serial No.

US 48138

(cont) 48154

49119

49138

49142

49237

49429

49443

thru 48147

thru 48159

ZAF

and 49139

and 49143

VC 47098

47679

47743

47745

47241

47295

47297

47366

47448

47467

47471

47475

47495

47536

47540

47668

47670

and 47242

thru

and

and

47300

47367

47449

thru 47538

and 47541

and 47671

VE 45710

47104

47121

47665

47683

47685

47692

XLL

XQQ

XYX

XZD

X5A

YBB

and 47105

ZBM

ZB2

47087

47276

ZCA 45785 and 45786

ZCH

49402 ZEZ

49380

49421

49424

45841

47102

47132

47190

47672

47680

48132

ZE9

47169

47525

47527

47548

ZIG 47595

47600

and 47133

and 47673

and 48133

ZKG

ZNA

ZNV

45826

47011

47152

45828

47014

47055

47086

47153

47240

49101

49277

47690 and 47691

47418

47410

47428

47431

47474

47476

47496

47545

47565

47577

47580

47584

47681

47684

47687

47698

48137

48165

and

and

and

thru

47477

47578

47581

47587

thru 47700

and 48166

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 7
Operator Factory Serial No.

ZOQ

Z09

ZQO

47274

47284

Operator Factory Serial No.

ZVQ 47486

(cont) 47488

47534

47674

47723

47663

47677

48051

48058

47193

ZQ9 47005

47156

47168

47170

47202

47326

47514

ZRS 45797

ZUS

ZVQ

45732

45774

47177

47261

47275

47277

47285

47318

47320

47359

47377

47443

47451

Z5B

Z6K

Z6R

thru 47323

thru 47379

thru 47445

Z8F

47007

47358

49396

47697

47754

47010

47015

1K 47012

47062

and 47013

(b) Other Aircraft:

Factory Serial No.

47260

48000

NOTE: Aircraft listed under Other Aircraft are

affected by this Service Bulletin but were

not assigned to any specific operator at

time of Service Bulletin issue.

Bulletin A53-232 March 28/90

Revision 2 April 28/95

ALERT ALERT

and 47489

ZVX

ZW7

49144

47466

ZXE 47016

47045

47154

and

and

47017

47155

ZXH

ZXU

47067

47259

Z4U 47529

Page 8
ALERT

(c) Manufacturer's Fuselage and Factory Serial Numbers:

FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN)

20 (45717)

30 (45772)

34 (45731)

39 (45773)

41 (45732)

46 (45841)

51 (45797)

59 (45798)

64 (45785)

69 (45799)

79 (45826)

81 (47004)

83 (47000)

86 (47003)

87 (47007)

90 (45786)

94 (47001)

97 (47010)

98 (47008)

99 (47006)

100 (45710)

102 (47011)

108 (47098)

111 (47063)

115 (47012)

118 (47050)

119 (47026)

120 (47064)

121 (47037)

127 (45787)

129 (47013)

131 (47051)

132 (47027)

134 (47076)

135 (45827)

136 (47038)

141 (47014)

142 (47052)

143 (47067)

145 (47028)

146 (47078)

147 (47033)

149 (47094)

151 (47005)

152 (47009)

154 (47039)

156 (47015)

157 (47029)

161 (47073)

163 (47079)

164 (47080)

165 (47044)

167 (47110)

168 (47046)

170 (47152)

171 (45788)

173 (47016)

174 (47030)

177 (47083)

178 (47035)

179 (47084)

180 (47088)

182 (47111)

183 (47047)

184 (47045)

185 (47153)

186 (47017)

187 (47031)

189 (47089)

190 (47090)

194 (47055)

195 (47101)

197 (47099)

198 (47102)

199 (47112)

201 (47154)

202 (47149)

203 (47018)

205 (47103)

206 (47091)

207 (47061)

209 (47120)

210 (47128)

211 (47130)

213 (47113)

214 (47131)

216 (47155)

217 (45789)

218 (47114)

219 (47086)

220 (47104)

221 (47105)

222 (47092)

223 (47062)

225 (47129)

226 (47146)

228 (47156)

229 (47132)

230 (47133)

234 (47087)

235 (47106)

236 (47107)

237 (47093)

240 (47190)

241 (47160)

242 (45828)

244 (47251)

245 (47204)

250 (47205)

251 (47108)

252 (47109)

257 (47248)

261 (47115)

262 (47312)

263 (47172)

264 (45790)

268 (47313)

269 (47065)

270 (47072)

273 (47173)

277 (47121)

279 (47314)

280 (47191)

281 (47241)

284 (47150)

286 (47174)

292 (47246)

293 (47207)

294 (47252)

295 (47253)

297 (47249)

298 (47175)

299 (47222)

300 (47223)

301 (47254)

304 (47242)

307 (47208)

308 (47116)

309 (47250)

310 (47255)

311 (47193)

312 (47218)

314 (47176)

316 (47224)

317 (47225)

318 (47138)

319 (47117)

320 (47263)

323 (47178)

324 (47194)

325 (47219)

326 (47256)

327 (47209)

328 (47206)

329 (47264)

330 (47177)

333 (47226)

335 (47179)

336 (45774)

337 (47279)

340 (47295)

341 (47210)

342 (47247)

343 (47291)

346 (47240)

347 (47273)

348 (47274)

349 (45791)

354 (47180)

355 (47228)

356 (47229)

359 (47286)

363 (47275)

364 (47287)

368 (47212)

369 (47288)

372 (45792)

373 (47276)

377 (47297)

379 (47277)

380 (47278)

381 (45793)

382 (47301)

385 (47317)

386 (47257)

387 (47258)

394 (45847)

395 (47230)

396 (47231)

397 (47283)

398 (47311)

399 (47298)

400 (47202)

401 (47203)

409 (47259)

410 (47260)

411 (47261)

412 (47262)

413 (47284)

414 (47285)

415 (47337)

416 (47338)

421 (47299)

4£2 (47302)

423 (47168)

424 (47169)

425 (47170)

426 (47318)

427 (47281)

428 (47232)

429 (47233)

432 (47303)

433 (47315)

434 (47319)

435 (47234)

436 (47235)

437 (47339)

438 (47300)

439 (47316)

441 (47305)

445 (47363)

446 (47282)

449 (47310)

450 (47236)

451 (47237)

454 (47320)

455 (47321)

456 (47322)

458 (47394)

459 (47201)

460 (47343)

461 (47332)

462 (47306)

463 (47307)

464 (47346)

465 (47238)

466 (47239)

468 (47323)

469 (47324)

472 (47344)

473 (47171)

474 (47308)

475 (47360)

476 (47357)

477 (47358)

478 (47347)

479 (47382)

480 (47410)

484 (47364)

485 (47345)

486 (47042)

487 (47405)

488 (47361)

489 (47389)

490 (47390)

491 (47391)

492 (47362)

493 (47334)

494 (47335)

495 (47359)

496 (47377)

498 (47244)

499 (47406)

500 (47336)

501 (47439)

502 (47440)

504 (47365)

505 (47368)

506 (47371)

508 (47378)

509 (47379)

511 (47415)

512 (47416)

513 (47372)

514 (47380)

515 (47325)

516 (47326)

518 (47417)

519 (47381)

520 (47431)

522 (47373)

523 (47374)

March 28/90 Bulletin A53-232

Revision 2 April 28/95

ALERT

Page 9
ALERT ALERT

FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN)

524 (47442)

525 (47432)

526 (47433)

527 (47488)

528 (47489)

529 (47369)

530 (47366)

531 (47375)

532 (47429)

533 (47411)

534 (47412)

535 (47450)

537 (47434)

538 (47383)

539 (47367)

540 (47435)

541 (47436)

542 (47385)

544 (47437)

545 (47438)

547 (47451)

548 (47448)

549 (47459)

550 (47386)

551 (47370)

552 (47449)

553 (47487)

554 (47404)

555 (47395)

556 (47420)

557 (47396)

558 (47421)

559 (47492)

560 (47490)

561 (47446)

562 (47493)

563 (47447)

564 (47462)

565 (47453)

566 (47498)

567 (47454)

568 (47499)

569 (47476)

570 (47418)

571 (47501)

572 (47426)

573 (47427)

574 (47502)

575 (47464)

577 (47443)

578 (47444)

579 (47455)

580 (47456)

583 (47517)

584 (47465)

585 (47445)

586 (47505)

589 (47425)

590 (47469)

591 (47470)

593 (47523)

594 (47507)

595 (47508)

596 (47472)

597 (47280)

598 (47473)

599 (47491)

600 (47474)

601 (47494)

602 (47419)

603 (47526)

604 (47497)

605 (47479)

606 (47522)

607 (47480)

609 (47430)

610 (47535)

611 (47468)

612 (47478)

613 (47477)

614 (47518)

615 (47519)

616 (47481)

617 (47528)

618 (47527)

619 (47514)

621 (47466)

622 (47547)

623 (47550)

624 (47530)

625 (47529)

626 (47532)

627 (47460)

628 (47486)

629 (47521)

630 (47516)

631 (47525)

632 (47524)

633 (47548)

634 (47551)

635 (47520)

636 (47397)

637 (47539)

638 (47531)

639 (47549)

640 (47552)

641 (47533)

642 (47553)

643 (47509)

644 (47534)

645 (47510)

646 (47458)

647 (47467)

648 (47484)

650 (47471)

651 (47504)

652 (47542)

653 (47475)

654 (47543)

656 (47495)

657 (47556)

659 (47536)

660 (47452)

662 (47537)

663 (47461)

665 (47538)

667 (47555)

668 (47540)

669 (47428)

670 (47541)

671 (47545)

672 (47559)

673 (47496)

675 (47565)

676 (47544)

677 (47511)

678 (47512)

679 (47513)

680 (47575)

681 (47564)

682 (47576)

683 (47569)

684 (47570)

685 (47562)

686 (47577)

687 (47563)

688 (47567)

689 (47568)

690 (47574)

691 (47566)

692 (47581)

694 (47573)

695 (47571)

696 (47584)

697 (47583)

698 (47585)

699 (47588)

700 (47587)

701 (47582)

702 (47578)

703 (47590)

704 (47580)

705 (47593)

706 (47591)

707 (47586)

708 (47572)

709 (47595)

710 (47600)

711 (47589)

713 (47597)

714 (47596)

715 (47601)

716 (47599)

717 (47594)

718 (47602)

720 (47603)

721 (47607)

722 (47604)

723 (47609)

724 (47605)

725 (47610)

727 (47606)

728 (47623)

730 (47638)

731 (47637)

732 (47608)

733 (47624)

734 (47640)

736 (47612)

738 (47626)

739 (47627)

740 (47628)

742 (47613)

743 (47631)

744 (47629)

745 (47630)

746 (47641)

747 (47614)

748 (47632)

749 (47642)

750 (47643)

751 (47615)

752 (47633)

754 (47635)

755 (47646)

756 (47634)

757 (47654)

759 (47616)

760 (47653)

761 (47648)

762 (47617)

763 (47655)

764 (47618)

765 (47668)

767 (47644)

768 (47619)

769 (47670)

771 (47650)

772 (47666)

773 (47647)

774 (47671)

775 (47664)

776 (47669)

777 (47620)

778 (47672)

779 (47673)

780 (47651)

781 (47680)

782 (47675)

783 (47656)

784 (47681)

785 (47676)

786 (47684)

787 (47657)

788 (47682)

789 (47678)

790 (47658)

791 (47677)

792 (47683)

793 (47674)

794 (47685)

795 (47687)

796 (47665)

797 (47679)

798 (47652)

799 (47688)

800 (47686)

801 (47699)

802 (47689)

803 (47692)

804 (47693)

805 (47694)

806 (47695)

807 (47659)

808 (47696)

809 (47698)

810 (47660)

811 (47700)

812 (47661)

813 (47708).

814 (47709)

815 (47712)

816 (47697)

817 (47702)

818 (47710)

819 (47704)

820 (47713)

821 (47706)

822 (47701)

823 (47707)

824 (47714)

825 (47715)

826 (47722)

827 (47736)

828 (47730)

829 (47737)

830 (47738)

831 (47725)

832 (47716)

833 (47717)

834 (47718)

835 (47740)

837 (47744)

838 (47723)

839 (47747)

840 (47691)

841 (47703)

842 (47705)

843 (47690)

844 (47711)

845 (47719)

846 (47720)

847 (47721)

848 (47727)

849 (47726)

850 (47662)

851 (47663)

852 (47739)

853 (47724)

854 (47729)

Bulletin A53-232 March 28/90

Page 10 Revision 2 April 28/95
ALERT ALERT

FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN) FUS (FSN)

855 (47748)

856 (47754)

857 (47742)

858 (47728)

859 (47743)

860 (47731)

861 (47732)

862 (47733)

863 (47745)

864 (47746)

865 (47749)

866 (47751)

867 (47753)

868 (47734)

869 (47735)

870 (47750)

871 (47759)

872 (47752)

873 (47756)

874 (47760)

875 (47761)

876 (47762)

877 (47757)

878 (47755)

879 (47763)

880 (47758)

881 (47769)

882 (47764)

883 (47771)

884 (47774)

885 (47767)

886 (47766)

887 (47768)

888 (47775)

889 (47776)

890 (47772)

891 (47773)

892 (47770)

893 (47782)

894 (47780)

895 (47781)

896 (47777)

897 (47778)

898 (47779)

899 (47783)

900 (47765)

901 (47788)

902 (47784)

903 (47796)

904 (47785)

905

90

90

90

90

91

911

91

91

91

915

916

91

91

92

921

922

923

924

925

926

927

928

929

930

931

932

933

934

935

936

937

938

939

940

941

942

943

944

945

946

947

948

949

950

951

952

953

954

955

5 (47786)

(47789)

7 (47790)

8 (47791)

9 (48000)

(47792)

1 (47793)

2 (47787)

3 (47797)

(47798)

5 (47794)

6 (47795)

(47799)

(48114)

(48115)

(48116)

(48117)

(48111)

(48015)

(48103)

(48112)

(48100)

(48104)

(48105)

(48113)

(48101)

(48102)

(48106)

(48123)

(48121)

(48107)

(48108)

(48002)

(48109)

(48131)

(48016)

(48118)

(48119)

(48003)

(48110)

(48034)

(48125)

(48024)

(48120)

(48004) 1

(48126) 1

(48025) 1

(48029) 1

(48124) 1

(48035) 1

95

95

95

95

96

96

96

96

96

96

96

96

96

96

97C

971

972

973

974

975

976

977

978

979

980

981

982

983

984

985

986

987

988

990

991

992

993

994

995

996

997

999

1000

1001

1002

1003

1004

1005

1006

1007

6 (48132

7 (48005

(48017

(48133:

(48026:

1 (48127

(48030

3 (48036

4 (48128

5 (48037

6 (48006

(48044

(48129)

(48031)

(48045)

(48007)

(48122)

(48027)

(48052)

(48051)

(48130)

(48046)

(48032)

(48028)

(48134)

(48008)

(48137)

(48049)

(48148)

(48009)

(48053)

(48135)

(48033)

(48149)

(48058)

(48010)

(48136)

(48011)

(48018)

(48054)

(48012)

(48070)

(48013)

(48019)

(48038)

(48039)

(48071)

(48048)

(48040)

(48055)

) 1008 (48041

) 1009 (48042

) 1010 (48043

1011 (48072:

) 1012 (48056

) 1013 (48014:

1014 (48150

1015 (48062:

1016 (48079

1017 (48151)

1018 (48073)

1019 (48066

1020 (48063)

1021 (48138)

1022 (48080)

1023 (48057)

1024 (48139)

1025 (49100)

1026 (48074)

1027 (48140)

1028 (48067)

1029 (48086)

1030 (48141)

1031 (48068)

1032 (48069)

1033 (48142)

1034 (48092)

1035 (48087)

1036 (48143)

1037 (48088)

1038 (48089)

1039 (48144)

1040 (48090)

1041 (48091)

1042 (48145)

1043 (48083)

1044 (48146)

1045 (48020)

1046 (48154)

1047 (48059)

1048 (48147)

1049 (48093)

1050 (48155)

1051 (49101)

1052 (48156)

1053 (48094)

1054 (48157)

1055 (48095)

1056 (48158)

1057 (48096)

) 1058 (48159)

) 1059 (48097)

) 1060 (48098)

) 1061 (49116)

1062 (49110)

1063 (49117)

1064 (49111)

1065 (49118)

1066 (49114)

1067 (48099)

1068 (49112)

1069 (49113)

1070 (49119)

1071 (49120)

1072 (49121)

1073 (49122)

1074 (49125)

1075 (49123)

1076 (49102)

1077 (49124)

1078 (48021)

1079 (48022)

1080 (49126)

1081 (48165)

1082 (49127)

1083 (49103)

1084 (48166)

1085 (49104)

1086 (49149)

1087 (49150)

1088 (49151)

1089 (49152)

1090 (49138)

1091 (49139)

1092 (49140)

1093 (49141)

1094 (49142)

1095 (49143)

1096 (49144)

1097 (49145)

1098 (49166)

1099 (49167)

1100 (49168)

1101 (49153)

1102 (49154)

1103 (49155)

1104 (49156)

1105 (49157)

1106 (49158) 1

1107 (49159) 1

110

110

111

111

1112

111

1114

1115

1116

1117

1118

1119

1120

1121

1122

1123

1124

1125

1126

1127

1128

1129

1130

1131

1132

1133

1134

1135

1136

1137

1138

1139

1140

1141

1142

1143

1144

1145

1146

1147

1148

1149

1150

1151

1152

1153

1154

1155

1156

1157

March 28/90 Bulletin A53-232

Revision 2 April 28/95

(49160)

9 (49161)

(49162)

(49163)

(49171)

(49172)

49173)

(49174)

(49175)

(49165)

(49169)

(49170)

(49176)

(49177)

(49178)

(49179)

(49180)

(49181)

(49192)

(49193)

(49182)

(49183)

(49194)

(49184)

(49185)

(49186)

(49187)

(49115)

(49195)

(49196)

(49197)

(49222)

(49229)

(49230)

(49198)

(49199)

(49237)

(49245)

(49246)

(49200)

(49201)

(49249)

(49260)

(49247)

(49248)

(49261)

(49251)

(49253)

(49254)

(49255)

Page 11
ALERT ALERT

FUS (FSN)

1184

1185

1186

1187

1188

1189

1190

1191

1192

1193

1194

1195

1196

1197

1198

1199

1200

1201

1202

1203

1204

1205

1206

1207

1208

1209

(49205)

(49265)

(49250)

(49288)

(49206)

(49207)

(49208)

(49209)

(49210)

(49289)

(49280)

(49290)

(49366)

(49367)

(49368)

(49369)

(49281)

(49373)

(49211)

(49233)

(49234)

(49379)

(49370)

(49371)

(49374)

(49284)

FUS (FSN)

1210

1211

1212

1213

1214

1215

1216

1217

1218

1219

1220

1221

1222

1223

1224

1225

1226

1227

1228

1229

1230

1231

1232

1233

1234

(49291)

(49292)

(49293)

(49294)

(49295)

(49296)

(49297)

(49298)

(49299)

(49300)

(49301)

(49302)

(49303)

(49304)

(49355)

(49380)

(49305)

(49306)

(49307)

(49308)

(49279)

(49381)

(49382)

(49212)

(49235)

FUS (FSN)

1235

1236

1237

1238

1239

1240

1241

1242

1243

1244

1245

1246

1247

1248

1249

1250

1251

1252

1253

1254

1255

1256

1257

1258

1259

(49236)

(49383)

(49384)

(49266)

(49267)

(49425)

(49428)

(49429)

(49213)

(49385)

(49214)

(49309)

(49310)

(49311)

(49312)

(49356)

(49357)

(49372)

(49215)

(49420)

(49313)

(49314)

(49315)

(49316)

(49317)

FUS (FSN)

1260

1261

1262

1263

1264

1265

1266

1267

1268

1269

1270

1271

1272

1273

1274

1275

1276

1277

1278

1279

1280

1281

1282

1283

1284

(49415)

(49402)

(49216)

(49421)

(49422)

(49318)

(49319)

(49320)

(49217)

(49390)

(49391)

(49416)

(49392)

(49321)

(49218)

(49363)

(49364)

(49365)

(49417)

(49393)

(49322)

(49323)

(49282)

(49423)

(49424)

This modification will be incorporated prior to delivery on all applicable DC-9, Series MD-80; MD-88 aircraft, manufacturer's

fuselage number 1310 and subsequent.

(2) Spares Affected:

None.

B. Reason:

Eight operators have reported cracks in the ventral aft pressure bulkhead attach tee sections on eight aircraft. The affected aircraft

had accumulated between 45,492 and 60,969 landings when the cracks were found. The predominate areas of cracks are at the upper pylon attach

angle between longerons 13 and 14 (6 cases) and lower pylon attach

angle between longerons 16 and 17 (2 cases). Longerons 2, 7, 11, and 18 each had one crack. The cracks exhibited similar behavior, cracking circumferentially approximately 1.9 inches outboard of the inboard edge of the upstanding leg of the bulkhead attach tee sections. Cracks were found up to 8.8 inches in length. Analysis of failed parts revealed

that the cracks initiated at multiple sites on the forward surface of the upstanding leg of the tee as the result of fatigue due primarily to bending loads. If cracks are not detected and repaired, they could

progress to the point that rapid decompression could occur. Inspection of high cycle aircraft and accomplishment of repairs based on condition

will allow continued flight operation.

Bulletin A53-232 March 28/90

1158

1159

1160

1161

1162

1163

1164

1165

1166

1167

1168

1169

1170

1171

1172

1173

1174

1175

1176

1177

1178

1179

1180

1181

1182

1183

(49256)

(49262)

(49257)

(49258)

(49259)

(49263)

(49269)

(49270)

(49271)

(49272)

(49273)

(49252)

(49202)

(49264)

(49188)

(49189)

(49203)

(49286)

(49287)

(49231)

(49232)

(49204)

(49190)

(49277)

(49164)

(49278)

1285

1286

1287

1288

1289

1290

1291

1292

1293

1294

1295

1296

1297

1298

1299

1300

1301

1302

1303

1304

1305

1306

1307

1308

1309

(49394)

(49395)

(49386)

(49387)

(49324)

(49325)

(49443)

(49501)

(49478)

(49358)

(49326)

(49327)

(49479)

(49480)

(49283)

(49502)

(49328)

(49329)

(49436)

(49440)

(49396)

(49331)

(49332)

(49481)

(49482)

FUS (FSN)

Page 12 Revision 2 April 28/95
ALERT ALERT

C. Description:

This Service Bulletin accomplishes the following on the fuselage aft

pressure bulkhead.

Option I (Inspection from aft side of bulkhead)

Performs visual and low frequency eddy current inspections for cracked

aft pressure bulkhead web-to-fuselage tee sections around entire

periphery of the fuselage from aft side of bulkhead and accomplishes

the following:

Condition 1 (No Crack)

Repetitively visually and low frequency eddy current inspects for cracks

from aft side of bulkhead at intervals specified in Compliance paragraph.

Condition 2 (Crack)

Replaces cracked tee section with new like or improved part and

repetitively visually and low frequency eddy current inspects for cracks

from aft side of bulkhead at intervals specified in Compliance paragraph.

ODtion II (Inspection from forward side of bulkhead)

Performs high and low frequency eddy current inspections for cracked

aft pressure bulkhead web-to-fuselage tee sections around the entire

periphery of the fuselage from the forward side of the bulkhead and

accomplishes the following:

Condition 1 (No crack)

Repetitively high and low frequency eddy current inspects for cracks

from forward side of bulkhead at intervals specified in Compliance

paragraph.

Condition 2 (Crack)

Replaces cracked tee section with new like or improved part and

repetitively high and low frequency eddy current inspects for cracks

from forward side of bulkhead at intervals specified in Compliance

paragraph.

NOTE: Replacement of all six aft pressure

bulkhead tee sections with new improved

parts constitutes closing action for

the repetitive inspection requirements

of this Alert Service Bulletin.

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 13
ALERT ALERT

D. Compliance:

It is recommended that initial inspection/repair of aft pressure

bulkhead tee per Option I or II be accomplished as follows on

aircraft having logged over 35,000 landings.

Accumulated Landings

35,000 to 49,999

50,000 to 59,999

60,000 and over

Initial Inspection

Within 1500 landings from

issue date of this Service

Bulletin.

Within 1000 landings from

issue date of this Service

Bulletin.

Within 300 landings from

issue date of this Service

Bulletin.

When aft pressure bulkhead tee section is replaced with new like part,

the repetitive inspection for that section of tee may be discontinued

until the aircraft has accumulated an additional 35,000 landings at

which time the repetitive inspection for that section of tee are

reinstated along with the ongoing repetitive inspections of the

remaining original sections of tee.

When aft pressure bulkhead tee section is replaced with new improved

part per this Service Bulletin, the repetitive inspection for that

section of tee may be discontinued as this constitutes closing action

for that section of tee. Perform the recommended Option I or Option

II repetitive inspections on the remaining original tee sections.

Replacement of

improved parts

action for the

all six aft pressure bulkhead tee sections with new

per this Alert Service Bulletin constitutes closing

inspection requirements of this Alert Service Bulletin.

It is recommended that repetitive inspection/repair of aft pressure

bulkhead tee be accomplished per Option I or II as follows:

Option I (Inspection from aft side of bulkhead)

It is recommended that repetitive low frequency eddy current inspection

for cracks of side areas above floor between longerons 7 and 17 on

fuselage left and right sides, be accomplished at intervals not to

exceed 1500 landings.

It is recommended that repetitive visual inspection for cracks of top

and lower areas from longeron 7 left side to longeron 7 right side,

and lower fuselage longeron 17 to longeron 20 on fuselage left and

right sides, be accomplished at intervals not to exceed 1500 landings.

Bulletin A53-232 March 28/90

Page 14 Revision 2 April 28/95
ALERT ALERT

It is recommended that repetitive visual inspection for cracks of

bottom areas from longeron 20 left side to longeron 20 right side,

be accomplished at intervals not to exceed 3500 landings.

It is recommended that cracked tee section be replaced prior to further pressurized flight.

Option II (Inspection from forward side of bulkhead)

It is recommended that repetitive high and low frequency eddy current

inspection for cracks around entire periphery of fuselage from forward

side of bulkhead be accomplished at intervals not to exceed 2500

landings.

It is recommended that cracked tee section be replaced prior to further

pressurized flight.

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 Aircraft Certification Office,

FAA Northwest Mountain Region, on April 28, 1995, and is approved as an alternate means of compliance with paragraphs A and B of Airworthiness

Directive 89-16-12.

F. Manpower:

NOTE: Man-hours are estimated based on work to be performed

by skilled personnel on aircraft/unit which has been

placed in a maintenance status. Only actual work

performed on aircraft/unit is accounted for in man-hour

estimates. No man-hours have been estimated to perform

the following or other incidental work required to

accomplish this Service Bulletin:

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.

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 15
ALERT ALERT

Option I (Inspection from aft side of bulkhead)

Optically aided visual inspection from the aft side of the fuselage

aft pressure bulkhead may be accomplished in approximately 22.0

man-hours or 11.0 elapsed hours per aircraft.

Low frequency eddy current inspection from the aft side of the

fuselage aft pressure bulkhead may be accomplished in approximately

11.5 man-hours or 5.8 elapsed hours per aircraft.

Man-hours do not include time for fabrication of flexible borescope

guide tube.

Option II (Inspection from forward side of bulkhead)

Removal and reinstallation of lavatories, equipment, and sealant for

access to the forward side of the fuselage aft pressure bulkhead tee

may be accomplished in approximately 140.1 man-hours or 52.9 elapsed

hours per aircraft.

High and low frequency eddy current inspection from the forward

side of the fuselage aft pressure bulkhead may be accomplished

in approximately 8.0 man-hours or 4.0 elapsed hours per aircraft.

Man-hours do not include time for fabrication of eddy current

reference standard.

Maximum total man-hours and elapsed hours are given for inspection per aircraft. Actual man-hours and elapsed hours for repair are contingent

upon inspection findings and are to be estimated by the operator.

G. Material - Cost and Availability:

(1) Aircraft:

Parts and materials required to accomplish this modification are

listed in paragraph 3.A and are to be procured as indicated. Parts

bearing Douglas Aircraft Company part numbers are proprietary parts

and must be procured under the spare parts article of the purchase

agreement, unless methods of manufacture are shown.

Cost and availability of parts are to be negotiated between the

operator and Douglas Aircraft Company. Reference this Service

Bulletin number and direct inquiries to:

Douglas Aircraft Company

P.O. Box 1771

Long Beach, California 90801

Attn: Parts Sales - Commercial 35-12

(DC-9 Alert Service Bulletin A53-232)

(2) Spares:

Not applicable.

Bulletin A53-232 March 28/90

Page 16 Revision 2 April 28/95
ALERT ALERT

H. Tooling - Price and Availability:

Option I (Inspection from aft side of bulkhead)

(1) Special test equipment is required to accomplish the low frequency

eddy current inspection per Option I outlined in this Service

Bulletin. Special test equipment is to be procured from operator's

stock, or sources indicated in paragraph 3.C.

(2) Douglas eddy current reference standard shown in Figure 2 and

listed in paragraph 3.C is required to accomplish low frequency

eddy current inspection per Option I and will be made available

to the operator at no charge.

Procurement and availability of SB09530231-9 eddy current reference

standard should be negotiated between the operator and the Douglas Aircraft Company. Specify this Service Bulletin number and direct

inquiries to:

Douglas Aircraft Company

910 East 236th Street

Carson, California 92805

Attn: Group Leader - Recovery

and Modification Services 35-35

(DC-9 Alert Service Bulletin A53-232)

Option II (Inspection from forward side of bulkhead)

(3) Test equipment required to accomplish high and low frequency

eddy current inspections per Option II is listed in service sketch

3683D. Choice of test equipment is at operator's option and is to

be procured from operator's stock or sources indicated in service

sketch 3683D.

(4) Reference standard required to accomplish high and low frequency

eddy current inspections per Option II is shown in service sketch

3683D. Reference standard may be procured from operator's stock,

fabricated by the operator, or purchased from source indicated in

paragraph 3.D.

I. Weight and Balance:

Weight change at appropriate fuselage stations by incorporation of

any part of this Service Bulletin is contingent upon the modification

of each particular aircraft. Weight data is to be computed by the

operator by weighing parts installed and parts removed during modification. Necessary revisions should be made to the appropriate - weight and balance document.

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 17
ALERT ALERT

J. References:

(1) Federal Aviation Administration Airworthiness Directive

No. 89-16-12: Amendment 39-6287, effective September 7, 1989.

(2) Alert Service Bulletins A53-147 and A53-191.

(3) Data used in preparation of this Alert Service Bulletin:

Data Identification

DMS 2082

J060157

J060157

MM Chapters 6, 20,

21, 25, 26, 36,

49, 52, and 53

NDT Chapter 1-3

SRM Chapters 51 and 53

SR09530001

SR09530001

SR09530048

SR09530056

SR09530056

SR09530083

3683D

5910130

5930760

Change Type of Data

A

B

C

D

New

C

D

New

DY

AM

Douglas Material Specification

Service Rework Shoring

Advance E.O.

Maintenance Manual

Nondestructive Testing Manual

Structural Repair Manual

Service Rework Drawing

Advance E.O.

Service Rework Drawing

Service Rework Drawing

Advance E.O.

Service Rework Drawing

Service Sketch (attached)

Drawing

Drawing

(4) Data supplied in support of this Alert Service Bulletin:

Data Identification

J060157

J060157

SR09530001

SR09530001

SR09530048

SR09530056

SR09530056

SR09530083

Change Type of Data

A

B

C

D

New

C

D

New

Service

Advance

Service

Advance

Service

Service

Advance

Service

Rework Shoring

E.O.

Rework Drawing

E.O.

Rework Drawing

Rework Drawing

E.O.

Rework Drawing

NOTE: Listed data are being furnished

to each affected operator.

K. Publications Affected:

The modification outlined in this Service Bulletin affects

the DC-9 Weight and Balance Documents.

L. Electrical Load Data:

Not affected.

M. Software Accomplishment Summary:

Not affected.

Bulletin A53-232

Page 18

March 28/90

Revision 2 April 28/95
ALERT ALERT

2. Accomplishment Instructions:

WARNING: TO AVOID INJURY TO MAINTENANCE 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.

GENERAL NOTES:

1. Replacement of all six aft pressure bulkhead tee sections with

new improved parts constitutes closing action for the repetitive inspection requirements of this Alert Service Bulletin.

If replacing all six aft pressure bulkhead tee sections, replacement should be accomplished one tee section at a time.

2. Refer to sections of the Maintenance Manual (MM), Structural

Repair Manual (SRM), and Non-Destructive Testing Manual (NDT).

3. Refer to the following manual chapters for applicable operations:

Manual Chapter Operation

MM 20-30-0 Sealant Application

NDT 1-3 Eddy Current Inspection

SRM 51-10-4 Drilling And Countersinking SRM 51-30-1 Installing Bolts, Screws, and Washers SRM 51-30-2 Removing And Installing Rivets

SRM 51-30-3 Removing And Installing Lockbolts

SRM 51-30-5 Removing And Installing Pins

4. For approved fastener and process material substitutions, see DC-9 SRM chapter 51-60-0, paragraph entitled "Interchangeability of Fasteners" and "Interchangeability of Materials."

5. If the length of the fasteners specified in this Service Bulletin do not meet acceptable installation standards, fasteners of the

same type, or approved substitutions, one increment longer or shorter in length may be used.

6. A combined total of two (maximum) 1/16-inch thick washers or four (maximum) 1/32-inch thick washers or any combination thereof not exceeding 1/8-inch total stackup thickness of the washer types called for in this Service Bulletin may be used under fastener head or nut to counteract accumulation of tolerances.

7. If substitutions are used other than those in Douglas approved publications, operator must obtain FAA approval from local

authorized agency.

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 19
ALERT ALERT

Option I (Inspection from aft side of bulkhead)

A. Operator's Option - Access doors may be installed in skin on bottom

of fuselage forward of auxiliary power unit (APU) door per service

rework drawing SR09530048 to facilitate inspection.

B. Operator's Option - Fabricate guide tube (to be used with flexiscope)

from flexible or thin wall tubing to fit outside diameter of flexiscope

as shown on Figure 1.

C. Operator's option - Fabricate reference standard as shown on Figure 2.

D. Gain access to inspection areas on aft side of bulkhead by opening or

removing and retaining the following access doors/panels as applicable

to accomplish visual and/or low frequency eddy current inspection:

Access No. Access Area MM Chapter

5806A Auxiliary Exit Door, 6-12-0

Non-Ventral Bulkhead

5901A Thrust Reverser Control 6-11-4

Valve (Left Side)

5902A Thrust Reverser Control 6-11-4

Valve (Right Side)

5903A APU Service (Left Side) 6-11-4

5904A APU Service (Right Side) 6-11-4

5910A Ventral Stair Ceilling 6-12-0

5911A Ventral Stair (Right Side) 6-12-0

5912A Ventral Stair (Left Side) 6-12-0

NOTE: The following paragraphs 2.D through 2.H

may be accomplished at operator's option

and are applicable to visual inspection

requirements.

E. Remove and retain APU and attaching parts. (See MM chapter 49-10-0,

paragraph entitled "Removal/Installation Power Plant.")

F. Remove and retain APU compartment enclosure and attaching parts.

(See MM chapter 53-20-5, paragraph entitled "Removal/Installation

APU Compartment Enclosure.")

Bulletin A53-232 March 28/90

Page 20 Revision 2 April 28/95
ALERT ALERT

G. Remove and retain lower firex bottle and attaching parts. (See

MM chapter 26-20-1, paragraph entitled "Removal/Installation Fire

Extinguishing Containers.")

H. Remove and retain right pneumatic crossfeed valve pushrod and

attaching parts. (See MM chapter 36-10-3, paragraph entitled

"Removal/Installation Pneumatic Crossfeed Valve.")

I. Remove and retain two upper conditioned air duct assemblies, check

valves, and attaching parts aft of pressure bulkhead center ceiling.

(See MM chapter 21-20-2, paragraph entitled "Removal/Installation

Conditioned and Cold Air Check Valve.")

J. Roll back or remove and retain insulation blankets from aft side of

aft pressure bulkhead. (See MM chapter 25-22-0, paragraph entitled

"Removal/Installation Insulation Blankets.")

K. Perform optically aided visual and low frequency eddy current

inspection/repair of the aft pressure bulkhead web to fuselage skin

attach tee sections from the aft side of the bulkhead as follows:

(1) Inspect the upstanding leg of 5910130 ventral bulkhead tee

sections from aft side of bulkhead around the periphery of

the bulkhead as shown on Figure 3 and accomplish the following:

Condition 1 (No Crack)

(2) Perform repetitive visual and/or low frequency eddy current

inspections from aft side of bulkhead at intervals specified in Compliance paragraph.

Condition 2 (Crack)

(3) Replace cracked tee section with new like or improved part

per Figure 4 (See Table I for configuration) prior to further

pressurized flight. Perform repetitive visual and/or low

frequency eddy current inspections from aft side of bulkhead

at intervals specified in Compliance paragraph.

(4) If any tee section is to be replaced, remove and retain

engines 1 and 2. (See MM chapter 71-00-0, paragraph

entitled "Removal/Installation Power Plant.")

NOTE: If replacing all six aft pressure

bulkhead tee sections, replacement

should be accomplished one tee

section at a time.

(5) Shore aircraft as shown on Figure 5.

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 21
ALERT ALERT

L. Record and report all results, both negative and positive of inspection

to DAC. Include fuselage number, factory serial number, crack location, crack length, flight-hours, and accumulated landings of aircraft.

Forward to:

Douglas Aircraft Company

P.O. Box 1771

Long Beach, California 90801

Attn: Business Unit Manager

Customer Services - Airframe

Product Support 35-35

(DC-9 Alert Service Bulletin A53-232)

M. Apply PR-1422 B-2 sealant around entire periphery of the bulkhead

tee sections, as applicable.

N. Reinstall retained insulation blankets on aft side of aft

pressure bulkhead. (See MM chapter 25-22-0, paragraph entitled

"Removal/Installation Insulation Blankets.")

O. Reinstall right pneumatic crossfeed valve pushrod and attaching

parts as applicable. (See MM chapter 36-10-3, paragraph entitled

"Removal/Installation Pneumatic Crossfeed Valve.")

P. Reinstall two upper conditioned air duct assemblies, check valves, and attaching parts as applicable. (See MM chapter 21-20-2, paragraph entitled "Removal/Installation Conditioned and Cold Air Check Valve.")

Q. Reinstall lower firex bottle and attaching parts as applicable. (See MM chapter 26-20-1, paragraph entitled "Removal/Installation

Fire Extinguishing Containers.")

R. Reinstall APU compartment enclosure, as applicable. (See MM chapter 53-20-5, paragraph entitled "Removal/Installation APU Compartment Enclosure.")

S. Reinstall APU and attaching parts as applicable. (See MM chapter 49-10-0, paragraph entitled "Removal/Installation Power Plant.")

T. Reinstall engines 1 and 2 as applicable. (See MM chapter 71-00-0, paragraph entitled "Removal/Installation Power Plant.")

U. Remove shoring as shown on Figure 5 as applicable.

V. Close/reinstall access doors/panels as outlined under Option I

paragraph 2.C.

Bulletin A53-232 March 28/90

Page 22 Revision 2 April 28/95
ALERT ALERT

ODtion II (Inspection from forward side of bulkhead)

A. Perform high and low frequency eddy current inspections of the aft

pressure bulkhead web to fuselage skin attach tee sections from the

forward side of the bulkhead as follows:

(1) Operator's Option - Fabricate eddy current reference standard

as shown on service sketch 3683D, Figure 5.

(2) Remove and retain items as outlined in service sketch 3683D,

Table I, as applicable.

(3) Inspect the standing leg of ventral bulkhead tee sections from

forward side of bulkhead around the entire periphery of the

bulkhead as shown on service sketch 3683D, and accomplish the

following:

Condition 1 (No Crack)

Perform repetitive high and low frequency eddy current inspections from forward side of bulkhead at intervals specified in Compliance paragraph.

Condition 2 (Crack)

Replace cracked tee section with new like or improved part

per Figure 4 (See Table I for configuration) prior to further

pressurized flight. Perform repetitive high and low frequency

eddy current inspections from forward side of bulkhead at

intervals specified in Compliance paragraph.

(4) If any tee section is to be replaced, remove and retain

engines 1 and 2. (See MM chapter 71-00-0, paragraph entitled

"Removal/Installation Power Plant.") Shore aircraft as shown

on Figure 5.

NOTE: If replacing all six aft pressure

bulkhead tee sections, replacement

should be accomplished one tee

section at a time.

B. Record and report all results, both negative and positive of inspection

to DAC. Include fuselage number, factory serial number, crack location, crack length, flight-hours, and accumulated landings of aircraft.

Forward to:

Douglas Aircraft Company

P.O. Box 1771

Long Beach, California 90801

Attn: Business Unit Manager

Customer Services - Airframe

Product Support 35-35

(DC-9 Alert Service Bulletin A53-232)

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 23
ALERT ALERT

C. Apply PR-1422 B-2 sealant around entire periphery of the bulkhead

tee sections, as applicable.

D. Reinstall engines 1 and 2 as applicable. (See MM chapter 71-00-0,

paragraph entitled "Removal/Installation Power Plant.")

E. Remove shoring as shown on Figure 5 as applicable.

F. Close/reinstall retained items as outlined in service sketch 3683D

Table I, as applicable.

Bulletin A53-232

Page 24

March 28/90

Revision 2 April 28/95
ALERT

FLEXIBLE BORESCOPE GUIDE TUBE - FABRICATION AND USE

March 28/90 1

Revision 2 April 28/95

Bulletin A53-232

Page 25

ALERT
ALERT ALERT

DETAIL SB09530231-9 EDDY CURRENT REFERENCE

STANDARD MAKE FROM 1D0008S TEE-EXTRUDED

SECTION (2024-0) HEAT TREAT TO 2024T42.

GENERAL NOTES:

1. EDM NOTCH MAXIMUM WIDTH .010-INCH (.25 MM).

2. NOTCH TO BE ON AND PERPENDICULAR TO FORWARD

SURFACE.

3. SCALE NONE.

4. THIS SB09530231-9 EDDY CURRENT REFERENCE

STANDARD REQUIRED TO ACCOMPLISH OPTION I

WILL BE MADE AVAILABLE BY DAC AT NO CHARGE,

SEE PARAGRAPH 1.H.

TOLERANCES

IN. = INCHES MM = MILLIMETERS

ANGLES 0° 30'

3 PLACE DECIMAL .015 IN. (0.38 MM)

2 PLACE DECIMAL .03 IN. (0.8 MM)

OPTION I EDDY CURRENT REFERENCE STANDARD - FABRICATION

Bulletin A53-232

Page 26 Revisio

March 28/90

n 2 April 28/95
ALERT ALERT

GENERAL NOTES:

1. PERFORM INSPECTION PROCEDURE A, SEQUENCES 1 THROUGH 3 BEFORE CLEANING THE TEE AND AFTER CLEANING THE TEE AS NOTED.

2. PROCEDURE A - DESCRIBES AN OPTICALLY AIDED VISUAL INSPECTION OF DC-9 AFT PRESSURE BULKHEAD

WEB TO FUSELAGE SKIN ATTACH TEE SECTIONS TO DETECT FATIGUE CRACKS IN THE UPSTANDING LEG OF TEE SECTIONS.

3. PROCEDURE B - DESCRIBES A LOW FREQUENCY EDDY CURRENT INSPECTION OF DC-9 AFT PRESSURE

BULKHEAD WEB TO FUSELAGE SKIN ATTACH TEE SECTIONS TO DETECT FATIGUE CRACKS IN THE UPSTANDING LEG OF TEE SECTIONS.

4. INSPECTION OF THE BULKHEAD TEE FOR CRACKS BY PROCEDURE A OR B IS MADE FROM THE AFT SIDE OF THE AFT PRESSURE BULKHEAD.

5. INSPECTION BY PROCEDURE A IS DIVIDED INTO THREE SEQUENCES BASED ON ACCESS LOCATION.

6. INSPECTION BY PROCEDURE B IS DIVIDED INTO TWO SEQUENCES BASED ON INSPECTION PROBE DESIGN.

a. INSPECTION PROCEDURE B, SEQUENCE 1, INSPECTS THE TEE ACUTE ANGLE TANGENT AREA OF THE UPSTANDING LEG OF TEE USING A MOLDED PROBE THAT CONFORMS TO THE RADIUS.

b. INSPECTION PROCEDURE B, SEQUENCE 2, INSPECTS EXTENDED AREA OF UPSTANDING LEG OF TEE. AREA EXTENDS FROM THE VICINITY OF THE INBOARD ROW OF ATTACHMENTS INSTALLED THROUGH THE TEE UPSTANDING LEG AND THEN EXTENDS OUTBOARD TO AND OVERLAPS THE AREA INSPECTED IN SEQUENCE 1. INSPECTION IS MADE USING A 90 DEGREE PROBE.

7. SIGNS OF NICOTINE STAINS MAY INDICATE CRACKS.

8. THE FOLLOWING EQUIPMENT OR EQUIVALENT IS REQUIRED:

SEE PARAGRAPH 3.C FOR TEST EQUIPMENT SUPPLIERS.

VISUAL EQUIPMENT:

a. FLASHLIGHT.

b. INSPECTION MIRROR WITH ADJUSTABLE VIEWING ANGLE.

ENDOSCOPE EQUIPMENT:

c. ONE 70 OR 90 DEGREE ENDOSCOPE OF ANY DIAMETER WITH 18-INCH (457.2 MM) MINIMUM LENGTH AND LIGHT SOURCE SUCH AS:

(1) ENDOSCOPE MODEL 10320D, 70 DEGREE (FOREOBLIQUE) ANGLE, 19-INCH (482.6 MM) LONG,

0.217-INCH DIAMETER.

(2) FIBER OPTIC LIGHT BUNDLE MODEL 495NL.

(3) ENDOSCOPE LIGHT SOURCE NUMBER 00482 (110 OR 220 VOLT) OR NUMBER E0590 (110 VOLT

ONLY).

(4) SYLVANIA PROJECTOR LAMP (150 WATT, 120 VOLT).

AFT PRESSURE BULKHEAD TEE - INSPECTION

March 28/90 FIGURE 3 (SHEET 1 OF 17) Bulletin A53-232

Revision 2 April 28/95 Page 27
ALERT ALERT

FLEXIBLE BORESCOPE:

d. ONE FORWARD VIEWING ENDOSCOPE OF ANY DIAMETER WITH 30 INCH MINIMUM

LENGTH SUCH AS:

(1) OLYMPUS MODEL 1F8D3, 29.8-INCH (757 MM) LONG, 0.315-INCH DIAMETER.

(2) COLD LIGHT SUPPLY NUMBER 1LK-4 (100 TO 230 VOLT).

EDDY CURRENT EOUIPMENT:

e. ONE EDDY CURRENT FLAW DETECTOR WITH IMPEDANCE PLANE DISPLAY SUCH AS:

STAVELEY INSTRUMENTS EDDY CURRENT INSTRUMENT, TYPE NDT-18 OR NDT-19

OR

ZETEC EDDY CURRENT INSTRUMENT, MIZ-20A

f. LOW FREQUENCY EDDY CURRENT PROBES SUCH AS:

(1) MOLDED PROBE OPERATING BETWEEN 5 AND 50 kHz: CATALOG NUMBER

935-0120, PART NUMBER APB/MSP, ZETEC INCORPORATED; OR MODEL

SPO-4080 STAVELEY INSTRUMENTS. (SEE SHEET 6.)

NOTE: IF SERVICE BULLETIN 53-147 HAS BEEN

ACCOMPLISHED, SUBSTITUTE STAVELEY

INSTRUMENTS SPO-5222 IN PLACE OF

PROBES LISTED IN PARAGRAPH F.(1).

(SEE SHEET 7.)

(2) PENCIL 90 DEGREE ANGLE PROBE OPERATING BETWEEN 5 AND 50 kHz:

CATALOG NUMBER 910-5830, PART NUMBER APB-5830, ZETEC INCORPORATED;

OR MODEL SPO-4081 STAVELEY INSTRUMENTS. (SEE SHEET 8.)

g. SB09530231-9 EDDY CURRENT REFERENCE STANDARD.

AFT PRESSURE BULKHEAD TEE - INSPECTION

Bulletin A53-232 FIGURE 3 (SHEET 2 OF 17) March 28/90

Page 28 Revision 2 April 28/95
ALERT ALERT

INSPECTION PROCEDURE

A. VISUAL INSPECTION PROCEDURE A:

SEQUENCE 1:

(1) PERFORM MIRROR/FLASHLIGHT OR ENDOSCOPE INSPECTION OF UPPER FUSELAGE TEE

SECTIONS FROM LONGERON L7 LEFT SIDE TO LONGERON L7 RIGHT SIDE, LOWER

FUSELAGE LONGERON L17 LEFT SIDE TO LONGERON L20 LEFT SIDE, AND LONGERON

L17 RIGHT TO LONGERON L19 RIGHT SIDE.

(2) PERFORM ENDOSCOPE OR FLEXIBLE BORESCOPE INSPECTION OF LOWER FUSELAGE

TEE SECTIONS FROM LONGERON L19 RIGHT SIDE TO LONGERON L20 RIGHT SIDE.

SEQUENCE 2:

(1) PERFORM MIRROR/FLASHLIGHT OR ENDOSCOPE INSPECTION OF LOWER

TEE SECTION THROUGH THRUST REVERSER LOCKOUT ACCESS OPENING

LONGERON L20 LEFT SIDE TO LONGERON L23 LEFT SIDE.

(2) PERFORM MIRROR/FLASHLIGHT OR ENDOSCOPE INSPECTION OF LOWER

TEE SECTION THROUGH THRUST REVERSER LOCKOUT ACCESS OPENING

LONGERON L20 RIGHT SIDE TO LONGERON L24 RIGHT SIDE.

FUSELAGE

5901A FROM

FUSELAGE

5902A FROM

NOTE: SEQUENCE 2 AND 3 MAY BE ACCOMPLISHED

USING INSPECTION MIRROR AND FLASHLIGHT

IF SUFFICIENT ACCESS IS AVAILABLE.

SEQUENCE 3:

(1) PERFORM VISUAL INSPECTION OF LOWER FUSELAGE TEE SECTIONS WITH

FLASHLIGHT FROM LONGERON L23 LEFT SIDE TO LONGERON L24 RIGHT SIDE.

REMOVE SEALANT FROM INSPECTION AREA OF TEE SECTIONS THAT MAY HINDER

INSPECTION. CLEAN DIRT, GREASE, AND ALL FOREIGN MATERIALS FROM INSPECTION

AREA OF TEE SECTIONS USING LINT-FREE WIPER AND 1,1,1 TRICHLOROETHANE SOLVENT

OR EQUIVALENT. PERFORM INSPECTION SEQUENCES 1 THROUGH 3 AFTER CLEANING THE

TEE SECTIONS.

B. LOW FREOUENCY EDDY CURRENT INSPECTION PROCEDURE B:

NOTE: PROCEDURE B, LOW FREQUENCY EDDY CURRENT

INSPECTION PROCEDURE IS APPLICABLE TO AREA

OF TEE SECTION BETWEEN LONGERONS L7 AND L17

ON LEFT AND RIGHT SIDES OF FUSELAGE THAT ARE

NOT COVERED BY SPLICE PLATES OR SHOVEL CLIPS.

AFT PRESSURE BULKHEAD TEE - INSPECTION

March 28/90 FIGURE 3 (SHEET 3 OF 17) Bulletin A53-232

Revision 2 April 28/95 Page 29
ALERT ALERT

SEQUENCE 1

(1) CALIBRATE EDDY CURRENT EQUIPMENT AS FOLLOWS:

(a) CONNECT MOLDED PROBE TO EDDY CURRENT INSTRUMENT AND SET OPERATING

FREQUENCY AT 7 kHz PER MANUFACTURER'S INSTRUCTIONS.

NQTE: IF SERVICE BULLETIN 53-147 HAS BEEN

ACCOMPLISHED, USE STAVELEY INSTRUMENT

SPO-5222 PROBE. IF SERVICE BULLETIN

53-147 HAS NOT BEEN ACCOMPLISHED, USE

MOLDED PROBE LISTED IN PARAGRAPH

F.(1). SEE SHEETS 6 AND 7.)

(b) PLACE MOLDED PROBE ON REFERENCE STANDARD IN AN AREA FREE FROM

NOTCH OR EDGE EFFECTS. NULL/BALANCE THE INSTRUMENT AND ADJUST

LIFT-OFF PER MANUFACTURER'S INSTRUCTIONS.

(c) SCAN ACROSS REFERENCE STANDARD EDM NOTCH 1 WITH MOLDED PROBE AND

ADJUST SENSITIVITY AND PHASE CONTROLS TO OBTAIN A DISPLAY SIMILAR

TO THAT SHOWN ON SHEET 15 FOR STANDARD PROBE OR SHEET 16 FOR

MODIFIED PROBE.

(2) PERFORM EDDY CURRENT INSPECTION OF AFT PRESSURE BULKHEAD TEE AS FOLLOWS:

(a) PLACE MOLDED PROBE IN THE RADIUS OF UPSTANDING LEG OF TEE AFT SIDE IN AREA FREE FROM EDGE OR FASTENER EFFECTS, SCAN THE TANGENT AREA

OF TEE, AND RENULL/BALANCE INSTRUMENT.

NOTE: THE MOLDED PROBE WILL NOT FIT INTO THE

TEE RADIUS IN THE AREA OF LONGERON SHOVEL

CLIPS. PORTIONS OF THESE AREAS WILL BE

INSPECTED IN SEQUENCE 2 PROCEDURE.

(b) PROGRESSIVELY SCAN ENTIRE LENGTH OF TEE TANGENT AREA BETWEEN

LONGERONS L7 AND L17 ON FUSELAGE LEFT AND RIGHT SIDES.

NOTE: ONE TECHNICIAN IS TO OPERATE THE PROBE

WHILE ANOTHER TECHNICIAN EVALUATES THE

EDDY CURRENT RESPONSE. THE TECHNICIAN

WATCHING THE DISPLAY SHOULD PERIODICALLY

ERASE LIFT-OFF TRACE TO AVOID MISSING A

SMALL CRACK INDICATION.

TECHNICIAN WATCHING DISPLAY MUST BE IN

CONSTANT COMMUNICATION WITH TECHNICIAN

OPERATING PROBE TO MAKE SURE PROBE IS

MAKING GOOD CONTACT WITH TEE SECTION

SURFACE.

AFT PRESSURE BULKHEAD TEE - INSPECTION

Bulletin A53-232 FIGURE 3 (SHEET 4 OF 17) March 28/90

Page 30 Revision 2 April 28/95
ALERT

March

ALERT

SEOUENCE 2:

(1) CALIBRATE EDDY CURRENT EQUIPMENT AS FOLLOWS:

(a) CONNECT 90 DEGREE PROBE TO EDDY CU RRENT INSTRUMENT AND SET

OPERATING FREQUENCY AT 10 kHz PER MANUFACTURER'S INSTRUCTIONS.

(b) PLACE 90 DEGREE PROBE ON REFERENCE STANDARD IN AN AREA FREE FROM

NOTCH OR EDGE EFFECTS. NULL/BALANCE THE INSTRUMENT AND ADJUST

LIFT-OFF PER MANUFACTURER'S INSTRUCTIONS.

(C) SCAN ACROSS REFERENCE STANDARD EDM NOTCH 2 WITH 90 DEGREE PROBE

AND ADJUST SENSITIVITY AND PHASE CONTROLS TO OBTAIN A DISPLAY

SIMILAR TO THAT SHOWN ON SHEET 17.

(2) PERFORM EDDY CURRENT INSPECTION OF AFT PRESSURE BULKHEAD TEE AS FOLLOWS:

(a) PLACE 90 DEGREE PROBE ON AFT SIDE OF TEE UPSTANDING LEG IN AN

AREA FREE OF FASTENER EFFECTS, SCAN AND RENULL/BALANCE INSTRUMENT.

(b) PROGRESSIVELY SCAN THE EXTENDED AREA OF THE UPSTANDING LEG OF TEE

FROM THE VICINITY OF THE INBOARD ROW OF ATTACHMENTS THROUGH THE

TEE UPSTANDING LEG THEN OUTBOARD TO AND OVERLAPPING THE TANGENT

AREA SCANNED IN SEQUENCE 1.

MQTE: SCAN ONLY THOSE AREAS WHERE THE PROBE

WILL FIT EASILY IN THE AREA OF LONGERON

SHOVEL CLIPS.

ONE TECHNICIAN IS TO OPERATE THE PROBE

WHILE ANOTHER TECHNICIAN EVALUATES THE

EDDY CURRENT RESPONSE. THE TECHNICIAN

WATCHING THE DISPLAY SHOULD PERIODICALLY

ERASE LIFT-OFF TRACE TO AVOID MISSING A

SMALL CRACK INDICATION.

TECHNICIAN WATCHING DISPLAY MUST BE IN

CONSTANT COMMUNICATION WITH TECHNICIAN

OPERATING PROBE TO MAKE SURE PROBE IS

MAKING GOOD CONTACT WITH TEE SECTION

SURFACE.

RAPID SCANNING OF TEE SURFACE CAN

GENERATE EXCESSIVE NOISE WHICH

COULD MASK A SMALL CRACK INDICATION.

(C) ANY INDICATION WHICH EXHIBITS SAME RELATIVE PHASE ANGLE AND AN

AMPLITUDE EQUAL TO OR GREATER THAN 50 PERCENT OF THAT OBTAINED

FROM REFERENCE STANDARD IS CONSIDERED A CRACK.

(d) RECORD LENGTH AND LOCATION OF EACH CRACK AND DISTANCE BETWEEN

MULTIPLE CRACKS. REPORT ALL CRACK INDICATIONS TO DAC AS NOTED

IN PARAGRAPH 2.K.

AFT PRESSURE BULKHEAD TEE - INSPECTION

28/90 FIGURE 3 (SHEET 5 OF 17) Bulletin A53

Revision 2 April 28/95

-232

Page 31
ALERT

Bulletin A53-232

Page 32

ALERT

ZETEC INCORPORATED C/N 935-0120 P/N APB/MSP

LOW FREQUENCY EDDY CURRENT PROBE OR EQUIVALENT

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 6 OF 17) March 28/90

Revision 2 April 28/95
ALERT

AFT PRESSURE BULKHEAD TEE - INSPECTION

March 28/90 FIGURE 3 (SHEET 7 OF 17)

Revision 2 April 28/95

Bulletin A53-232

Page 33

ALERT
ALERT

Bulletin A53-232

Page 34

ALERT

ZETEC INCORPORATED C/N 910-5830 P/N APB/90DP

LOW FREQUENCY EDDY CURRENT PROBE OR EQUIVALENT

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 8 OF 17) March 28/90

Revision 2 April 28/95
ALERT

VISUAL INSPECTION PROCEDURE A SEQUENCES

FOR AFT PRESSURE BULKHEAD TEE

AFT PRESSURE BULKHEAD TEE - INSPECTION

March 28/90 FIGURE 3 (SHEET 9 OF 17)

Revision 2 April 28/95

Bulletin A53-232

Page 35

ALERT
ALERT

Bulletin A53-232

Page 36

ALERT

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 10 OF 17) March 28/90

Revision 2 April 28/95
ALERT ALERT

DC-9 VENTRAL AFT PRESSURE BULKHEAD SCHEMATIC DIAGRAM SHOWING TEE LOCATIONS

March 28/90

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 11 OF 17)

Revision 2 April 28/95

Bulletin A53-232

Page 37
ALERT

SEQUENCE 1 VISUAL AND ENDSCOPE INSPECTION OF BULKHEAD TEE

Bulletin A53-232

'age 38

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 12 OF 17) March 28/90

Revision 2 April 28/95

ALERT
ALERT

AFT PRESSURE BULKHEAD TEE - INSPECTION

March 28/90 FIGURE 3 (SHEET 13 OF 17)

Revision 2 April 28/95

Bulletin A53-232

Page 39

ALERT
ALERT

Bulletin A53-232

Page 40

ALERT

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 14 OF 17) March 28/90

Revision 2 April 28/95
ALERT ALERT

March 28/90

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 15 OF 17) Bulletin A53-232

Revision 2 April 28/95 Page 41
ALERT

Bulletin A53-232

Page 42

ALERT

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 16 OF 17) March 28/90

Revision 2 April 28/95
ALERT ALERT

March 28/90

AFT PRESSURE BULKHEAD TEE - INSPECTION

FIGURE 3 (SHEET 17 OF 17) Bulletin A53-232

Revision 2 April 28/95 Page 43
ALERT ALERT

GENERAL NOTES:

1. FINAL SHAPE AND SIZE OF MODIFICATION TO BE DETERMINED BY THE OPERATOR AND TRIMMED ON ASSEMBLY.

2. SMOOTH AND BLEND OUT ALL EVIDENCE OF CORROSION, 63-MICROINCH FINISH.

3. 125-MICROINCH SURFACE FINISH TYPICAL.

4. BREAK ALL SHARP EDGES .020/.030-INCH RADIUS.

5. SHIM AS REQUIRED TO RELIEVE PRELOAD.

6. PROTECT MODIFICATION AREA AGAINST CORROSION AND DISSIMILAR METALS PER SRM CHAPTER 51-10-3.

7. APPLY A FAYING SURFACE SEAL OF PR-1422 B-2 SEALANT BETWEEN ALL DOUBLERS, FILLERS, 

BOLTS, HI-LOKS, 

SPLICES, SHIMS, ANGLES, STIFFENERS, TEES, AND FITTINGS. INSTALL AND RIVETS WET WITH SEALANT UNDER HEADS, BETWEEN WASHERS AND MATING SURFACES PER SRM CHAPTER 51-20-0.

8. LOCATE ATTACHMENTS FROM PART EDGES AS FOLLOWS:

2D + .06-INCH (1.5 MM) FOR DETAIL PARTS.

2D MINIMUM ACCEPTABLE ON ASSEMBLY.

9. ADDED ATTACHMENTS TO BE LOCATED 2D FROM JOGGLES.

10. "EQUAL SPACED" ATTACHMENT TOLERANCE TO BE WITHIN .06-INCH (1.5 MM).

11. OVERSIZE ATTACHMENT MUST BE USED WHEN THE EXISTING HOLE DIAMETER EXCEEDS THE MAXIMUM DIAMETER SPECIFIED FOR THE ATTACHMENT.

12. SEE TABLE III FOR REPLACEMENT FASTENERS. SEE SERVICE REWORK DRAWING

SR09530083 FOR REPLACEMENT FASTENERS IF DC-9 SERVICE BULLETIN 53-147 HAS BEEN ACCOMPLISHED.

13. IT IS PERMISSIBLE TO USE SELF-ALIGNING NUTS IN PLACE OF NAS679A3 OR MS21042L3 NUTS.

14. SPLICING OF TEE IS ACCEPTABLE TO FACILITATE INSTALLATION AND ASSEMBLY, SPLICE 

MANUAL 

PER SERVICE REWORK DRAWING SR09530001 AND/OR STRUCTURAL REPAIR CHAPTERS 51-10 AND 53-03.

15. AT 

CHAPTER 

OPERATORS OPTION IT IS PERMISSIBLE TO CUT 5910163-73 ANGLE AND USE SRM

ACCESS 

53-03 FIGURE 14 TO FABRICATE A MODIFICATION SPLICE IN ANGLE TO GAIN IN RESTRICTED AREA ON FORWARD SIDE OF TEE SECTION. A MAXIMUM OF ONE SPLICE PER SIDE IS PERMITTED.

AFT PRESSURE BULKHEAD TEE - MODIFICATION

Bulletin A53-232 FIGURE 4 (SHEET 1 OF 6) March 28/90

Page 44 Revision 2 April 28/95
ALERT ALERT

TABLE I

QUANTITY PER VENTRAL BULKHEAD CONDITION

DOUBLER CONFIGURATION WITH 9918572 DOUBLER WITHOUT 9918572 DOUBLER

PART NO. KEY WORD QTY QTY

HL325-5-4 PIN 4 4

HL325-5-5 PIN 57 131

HL325-5-6 PIN 57 132

HLT335-6-6 PIN 20 10

HLT335-6-7 PIN 10

HLT41-5-5 PIN 234

HLT41-5-6 PIN 234

HLT434-6-6 PIN 20 20

HLT435-6-4 PIN 5 5

HLT435-6-6 PIN 18 18

HLT436-6-5 PIN 15

HLT436-6-6 PIN 72 15

HLT436-6-7 PIN 72

HLT634-6-6 PIN 120 120 HLT634-6-7 PIN 120 120 HLT635-6-5 PIN 198 237 HLT635-6-6 PIN 260 275

HLT635-6-7 PIN 72 40 MS20470AD5-6 RIVET 214 186

MS20470AD5-7 RIVET 267 239

MS20470AD6-6 RIVET 123 115

MS20470AD6-7 RIVET 114 97 MS21042L3 NUT 87 551 NAS1097AD5-9 RIVET 50 50 NAS1097AD6-10 RIVET 10 NAS1097AD6-9 RIVET 280 375 NAS1252-10L WASHER 275 S2931983-30A06 WASHER 297 297 S4931919-6-3 PIN 12 12 S4931919-6-4 PIN 4 4 S4931919-6-5 PIN 315 71 S4931919-6-6 PIN 300 56

S4931919-6-7 PIN 30

S4931920-6-5 PIN 55 33 S4931920-6-6 PIN 73 33 S4931920-6-7 PIN 18

SR09530056-3 TEE 1 1

OR

5910163-389

SR09530056-5 TEE 1 1

OR

5910163-391

SR09530056-6 TEE 1 1 OR

5910163-392

SR09530056-7 TEE 1 1

OR

5910163-393

SR09530056-8 TEE 1 1

OR

5910163-394

SR09530056-9 TEE 1 1

OR

5910163-387

3D0006-08 NUT ASSY 8 472

3D0006-3 NUT ASSY 1368 728

AFT PRESSURE BULKHEAD TEE - MODIFICATION

March 28/90 FIGURE 4 (SHEET 2 OF 6) Bulletin A53-232

Revision 2 April 28/95 Page 45
ALERT ALERT

TABLE II

VENTRAL AFT PRESSURE BULKHEAD

OLD PART NO.

5910130-51

OR

5919130-389

5910130-53

OR

5910130-391

5910130-54

OR

5910130-392

5910130-55

OR

5910130-393

5910130-56

OR

5910130-394

5910130-47

OR

5910130-387

AFT PRESSURE BULKHEAD TEE

MAY BE REPLACED WITH

NEW IMPROVED GLASS

SHOT PEENED PART NO.

SR09530056-3 TEE

OR

5910163-389

SR09530056-5 TEE

OR

5910163-391

SR09530056-6 TEE

OR

5910163-392

SR09530056-7 TEE

OR

5910163-393

SR09530056-8 TEE

OR

5910163-394

SR09530056-9 TEE

OR

5910163-387

- MODIFICATION

Bulletin A53-232 FIGURE 4 (SHEET 3 OF 6)

Page 46 Revision 2

March 28/90

April 28/95
ALERT ALERT

AFT PRESSURE BULKHEAD TEE - MODIFICATION

March 28/90 FIGURE 4 (SHEET 4 OF 6)

Revision 2 April 28/95

Bulletin A53-232

Page 47
ALERT ALERT

TABLE III

FASTENER TO

BE REMOVED

HL326-5-X PIN,

S4933653-3 NUT ASSY

HL329-5-X PIN,

S4933653-08 NUT ASSY

HL328-5-X PIN,

S4933653-08 NUT ASSY

MS20427M4 RIVET

MS20427M5 RIVET

MS20470AD5-X RIVET

MS20470AD6-X RIVET

MS20470DD5-X RIVET

HL328-5-X PIN,

NAS1252-8L WASHER,

MS21042L08 NUT

S4931920-6-X PIN,

S4933653-3 NUT ASSY

MS20615M4 RIVET

REPLACE WITH

FASTENER

S4931920-6-X PIN,

3D0006-3 NUT ASSY

S4931919-6-X PIN,

3D0006-08 NUT ASSY

S4931920-6-X PIN,

3D0006-3 NUT ASSY

HLT41-5-X PIN,

3D0006-08 NUT ASSY

S4931919-6-X PIN,

3D0006-3 NUT ASSY

SAME, OR

S4931920-6-X PIN,

NAS1252-10L WASHER,

MS21042L3 NUT

SAME, OR

HLT634-6-X PIN,

S2931983-30A06 WASHER,

MS21042L3 NUT

S4931919-6-X PIN,

3D0006-3 NUT ASSY

S4931920-6-X PIN,

NAS1252-10L WASHER,

MS21042L3 NUT

HLT334-6-X PIN,

3D0006-3 NUT ASSY

HL325-5-X PIN,

3D0006-08 NUT ASSY

Bulletin A53-232

Page 48

AFT PRESSURE BULKHEAD TEE - MODIFICATION

FIGURE 4 (SHEET 5 OF 6) March 28/90

Revision 2 April 28/95

REFERENCE

CODE USED

ON DRAWING

5910130
ALERT ALERT

TABLE III (CONT)

REFERENCE

CODE USED

ON DRAWING

5910130

FASTENER TO

BE REMOVED

MS20615-5M RIVET

NAS1097AD5-X RIVET

NAS1097AD6-X RIVET

NAS1097DD5-X RIVET

S4579428-5-X RIVET

S4579428-6-X RIVET

S4931920-6-X PIN,

S4932389-3 NUT

4931919-6-X PIN,

S4932389-3 NUT

S4579428DD6 RIVET

S4931920-6-X PIN,

S4933653-3 NUT ASSY

REPLACE WITH

FASTENER

S4931919-6-X PIN,

3D0006-3 NUT ASSY

SAME, OR

NAS1097AD6-X RIVET

SAME, OR

HLT635-6-X PIN,

3D0006-3 NUT ASSY

HLT335-6-X PIN,

3D0006-3 NUT ASSY

S4931919-6-X PIN,

3D0006-3 NUT ASSY

HLT635-6-X PIN,

3D0006-3 NUT ASSY

HLT436-6-X PIN,

S2931983-30A06 WASHER

MS21042L3 NUT

HLT635-6-X PIN,

S2931983-30A06 WASHER

MS21042L3 NUT

HLT635-6-X PIN,

3D0006-3 NUT ASSY

HLT436-6-X PIN,

3D0006-3 NUT ASSY

AFT PRESSURE BULKHEAD TEE - MODIFICATION

March 28/90 FIGURE 4 (SHEET 6 OF 6)

Revision 2 April 28/95

Bulletin A53-232

Page 49
ALERT ALERT

GENERAL NOTES:

1. THE PURPOSE OF THIS FIGURE IS TO PROVIDE SPECIFIC MINIMUM RECOMMENDED

SHORING PROVISIONS FOR THE SPLICING IN OR REPLACEMENT OF A CRACKED 5910130/5930760 (FUSELAGE NUMBER 1071 AND SUBSEQUENT) TEE, VENTRAL AFT PRESSURE BULKHEAD, PER DAC SERVICE REWORK DRAWING SR09530001 OR SR09530056.

2. RAISE AND LEVEL AIRCRAFT AND SHORE AS SHOWN. REFER TO THE DC-9 MAINTENANCE

MANUAL AND APPLICABLE LIFTING, LEVELING AND SHORING INSTRUCTIONS, CAUTIONS AND LIMITATIONS:

(A) 7-11-0 "WING AND FUSELAGE LIFTING"

BB) 7-20-0 "SHORING"

(C) 8-10-0 "LEVELING"

AIRCRAFT TO BE LEVEL WITHIN 2 DEGREES.

3. INSTALL CRADLE FOR AIRCRAFT WITH VENTRAL PRESSURE BULKHEAD.

CAUTION: THE AFT FUSELAGE CRADLE RESTS

AGAINST SLOPING FUSELAGE SKIN

SURFACE. RESTRAIN AIRCRAFT AND

CRADLE FROM SLIPPAGE IF REQUIRED.

4. JACK AT AFT FUS JACK POINT SHALL BE REMOVED DURING MODIFICATION OR REPAIR OF AFT PRESSURE BULKHEAD.

5. USE -1 SHORING CONFIGURATION ONLY FOR SIDE TEE REPLACEMENT BETWEEN LONGERON 6.5 TO LONGERON 22.5 (LEFT AND RIGHT SIDES), PART NUMBERS 5910130-53, -54, -55 OR -56. DO NOT REPLACE LEFT AND RIGHT SIDES TEES AT SAME TIME.

6. ADD -501 SHORING CONFIGURATION FOR UPPER TEE REPLACEMENT BETWEEN LONGERON 6.5 (LEFT SIDE) AND LONGERON 6.5 (RIGHT SIDE), PART NUMBER 5910130-51. ALSO

FOR LOWER TEE REPLACEMENT BETWEEN LONGERON 22.5 (LEFT SIDE) AND LONGERON 22.5 (RIGHT SIDE), PART NUMBER 591013047.

7. REMOVE TAILCONE PER MAINTENANCE MANUAL 53-50-3.

8. INSTALL DAC SERVICE REWORK DRAWING J060157 SHORING PROVISIONS ON AFT CANTED FRAME.

9. AFTER INSTALLING SUPPORT AT AFT CANTED FRAME, ACCOMPLISH THE FOLLOWING:

a. APPLY 50 + 25 POUND FORCE PRELOAD TO PROVIDE POSITIVE UP LOAD ON JACK.

b. MEASURE GAP BETWEEN SKINS PRIOR TO REMOVAL OF ANY ATTACHMENTS

(TYPICALLY .010 TO .120).

c. AFTER START OF ATTACHMENT REMOVAL, CHECK GAP AND POSSIBLE HOLE

MISALIGNMENT. APPLY LOAD TO JACK AS REQUIRED TO MAINTAIN GAP

BETWEEN SKINS NOTED PREVIOUSLY.

SHORING INSTRUCTIONS - VENTRAL AFT PRESSURE BULKHEAD TEE REPLACEMENT

Bulletin A53-232 FIGURE 5 (SHEET 1 OF 3) March 28/90

Page 50 Revision 2 April 28/95
ALERT ALERT

CAUTION:

INSTALL CRADLES ONLY AFTER AIRCRAFT IS LEVEL AND ON WING AND

AFT FUSELAGE JACKS.

REMOVE CRADLES BEFORE RELEASING WING AND AFT FUSELAGE JACKS.

SEVERE STRUCTURAL DAMAGE WILL OCCUR IF WING JACKS ARE RELEASED

WHEN CRADLE AND JACK AT AFT FUSELAGE JACK POINTS ARE INSTALLED.

-1 SHORING CONFIGURATION

SHORING INSTRUCTIONS - VENTRAL AFT PRESSURE BULKHEAD TEE REPLACEMENT

March 28/90 FIGURE 5 (SHEET 2 OF 3) Bulletin A53-232

Revision 2 April 28/95 Page 51
ALERT ALERT

-501 SHORING CONFIGURATION

SHORING INSTRUCTIONS - VENTRAL AFT PRESSURE BULKHEAD TEE REPLACEMENT

Bulletin A53-232 FIGURE 5 (SHEET 3 OF 3) March 28/90

Page 52 Revision 2 April 28/95
ALERT 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: Parts requirements are contingent upon

inspection findings indicating the existence

of crack(s) in a tee section. Maximum

quantities required per Figure 4, Table I,

are listed. Actual parts requirements are

to be determined by the operator. Quantities

listed are for record purposes only.

Parts within parentheses are

equivalent part numbers.

Part No.

SR09530056-3

(5910163-389)

SR09530056-5

(5910163-391)

SR09530056-6

(5910163-392)

SR09530056-7

(5910163-393)

SR09530056-8

(5910163-394)

SR09530056-9

(5910163-387)

S2931983-30A06

S4931919-6-3

S4931919-6-4

S4931919-6-5

S4931919-6-6

S4931919-6-7

S4931920-6-5

S4931920-6-6

S4931920-6-7

3D0006-08

3D0006-3

production

Otv Key Word

1 Tee

1 Tee

1 Tee

1 Tee

1 Tee

1 Tee

297

12

4

315

300

30

55

73

18

472

1368

Washer

Pin

Pin

Pin

Pin

Pin

Pin

Pin

Pin

Nut Assembly

Nut Assembly

(2) Fastener kit consists of the following parts and may be

purchased from DAC or may be procured from operator's stock

or source indicated. Maximum quantities are listed, actual

fasteners required are contingent upon inspection findings

and are to be determined by the operator.

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 53
Part/Material

HLT335-6-6 Pin

HLT335-6-7 Pin

HLT41-5-5 Pin

HLT41-5-6 Pin

HLT434-6-6 Pin

HLT435-6-4 Pin

HLT435-6-6 Pin

HLT436-6-5 Pin

HLT436-6-6 Pin

HLT436-6-7 Pin

HLT634-6-6 Pin

HLT634-6-7 Pin

HLT635-6-5 Pin

HLT635-6-6 Pin

HLT635-6-7 Pin

HL325-5-4 Pin

HL325-5-5 Pin

HL325-5-6 Pin

ALERT

Qty Kit

SB09530232-3

20

10

234

234

20

5

18

15

72

72

120

120

237

275

72

4

131

132

Suppl ier

73197 Hi-Shear Corporation

2600 Skypark Drive

Torrance, California

90506

MS20470AD5-6 Rivet

MS20470AD5-7 Rivet

MS20470AD6-6 Rivet

MS20470AD6-7 Rivet

MS21042L3 Nut

NAS1097AD5-9 Rivet

NAS1097AD6-10 Rivet

NAS1097AD6-9 Rivet

NAS1252-1OL Washer

(3) Material to be procured from operator's stock or source indicated.

Part/Material

PR-1422 B-2 Sealant

(DMS 2082)

or

Equivalent

1 Qt 83574 Courtaulds Aerospace

5430 San Fernando Road

Glendale, California

91209

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

None.

Bulletin A53-232 March 28/90

Revision 2 April 28/95

ALERT

214

267

123

114

551

50

10

375

275

Qty CAGE SuDD1 er

Page 54
ALERT ALERT

C. The basis for the following tooling data is per ooerator.

(1) Option I - Test equipment to be procured from operator's

stock or sources indicated.

NQIE: One 70 or 90 degree endoscope of any

diameter with 18-inch (457.2 MM)

minimum length and matching light

source may be used.

Test Equipment Tyee Supplier

Endoscope 70 Degree

(Fore oblique) Angle

19-Inch (482.6 MM) Long

0.217-Inch

Diameter

or

Equivalent

Fiber Optic

Light Bundle

and

Endoscope Light Source

110 or 220 Volt

and

Sylvania Projector Lamp

150 Watt, 120 Volt

Model

10320D

Model

1F8D3

1 54341 Expanded Optics,

Incorporated

7382 Bolsa Avenue

Westminster, California

92683

1

No. 00482

or

No. E0590

1

NOTQIE: Similar or equivalent endoscopes

and illuminators may be obtained

from the following sources.

Alva Ingenieros

Velazquez 121

Madrid 6, Spain

or

Automation Instruments

Service

47 Birch Street

Bankston 2200, Australia

or

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 55
ALERT ALERT

Test Equipment

Flexible Borescope

29.8-Inch (757 MM) Long

0.315-Inch

Diameter

Cold Light Supply

100 to 230 Volt

or

Equivalent

Eddy Current Flaw

Detector with

Impedance Plane

Display

or

Zetec Eddy Current

Instrument

or

Equivalent

CAGE Suppl er

3 G Electronics

Sede Commercial 20135

Milano Via Perugino 9,

Italy

or

50958 Richard Wolf

Medical Instrument

Corporation

7046 Lyndon Avenue

Rosemont, Illinois

60018-3410

or

Inspection Instruments

NDT Limited

10-12 Emerald Street

London WC1, England

or

Karl Storz KG

D 7200 Tuttlingen

West Germany

Model

1F8D3

No. 1LK-4

NDT-1 8

or

NDT-19

MIZ-20A

1 32212 Olympus Corporation

Scientific Products Group

2 Nevada Drive

New Hyde Park, New York

11040

1

1 29192 Staveley Instruments

Incorporated

421 North Quay Street

Kennewick, Washington

99336-7735

51327 Zetec Incorporated

1320 North West Mall

P.O. Box 140

Issaquah, Washington

98027-8921

Eddy Current Low

Frequency Molded

Probe 5-50 kHz

Operating Frequency

or

Model

C/N 935-0120

P/N APB/MSP

1 (Zetec Incorporated)

Bulletin A53-232 March 28/90

Revision 2 April 28/95 Page 56
ALERT

Test Equipment

Eddy Current Low

Frequency Molded

Probe 5-50 kHz

Operating Frequency

or

Eddy Current Low

Frequency Molded

Probe 5-50 kHz

Operating Frequency

(To be used after

Service Bulletin

53-147 has been

accomplished.)

ALERT

Suppli er

Model

SPO-4080

Model

SPO-5222

(Staveley Instruments

Incorporated)

(Staveley Instruments

Incorporated)

Eddy Current Low

Frequency 90 Degree

Probe 5-50 kHz

Operating Frequency

Model

C/N 910-5830

P/N APB/90DP

1 (Zetec Incorporated)

or

Eddy Current Low

Frequency 90 Degree

Probe 5-50 kHz

Operating Frequency

Model

SPO-4081

(Staveley Instruments

Incorporated)

NOTE: When ordering eddy current probes specify

type of eddy current instrument the probe

will be used with so that proper mating

connectors or adapter will be provided.

(2) Option I - One SB09530231-9 eddy current reference standard

required to accomplish Option I low frequency eddy current

inspection will be made available at no charge. (See paragraph 1.H.)

(3) Option II - Test equipment required to accomplish Option II high

and low frequency eddy current inspections including procurement

sources, is listed in service sketch 3683D. Choice of equipment

is at operator's option and is to be procured from operator's

stock or sources indicated in service sketch 3683D.

March 28/90 Bulletin A53-232

Revision 2 April 28/95 Page 57
ALERT ALERT

(4) Option II - The following reference standard required to accomplish

the Option II high and low frequency eddy current inspections is to

be_procured from operator's stock or as indicated.

InstructionsPart No. Otv Key Word Disposition

MS20470AD5-6 2 Rivet

MS20470AD5-7 4 Rivet

SB09530231-11 1 Plate

SB09530231-13 1 Web

SB09530231-15 1 Tee

SB09530231-17 1 Reference

Standard Assy

May be purchased from: VM Products Incorporated CA

11298 62nd Avenue 60761

Puyallup, Washington 98373

or

May be fabricated by the operator. (See service sketch 3683C.)

May be procured from operator's stock.

Detail of SB09530231-17 reference standard assembly.

May be fabricated by the operator from 7075-T6 clad aluminum

sheet Material Specification QQ-A-250/13 Temper T6 or 7075-T6

bare aluminum plate Material Specification QQ-A-250/12 Temper

T6, .047/.053 x 2-1/4 x 3 inches. (See service sketch 3683D.)

May be fabricated by the operator from 7075-T6 clad aluminum

sheet Material Specification QQ-A-250/13 Temper T6 or 7075-T6

bare aluminum plate Material Specification QQ-A-250/12 Temper

T6, .039/.045 x 2-1/4 x 4-1/2 inches. (See service sketch 3683D.)

May be fabricated by the operator from 2024-T3 clad aluminum

sheet Material Specification QQ-A-250/5 Temper T3 or 2024-T4

bare aluminum plate Material Specification QQ-A-250/4 Temper

T4, .075/.085 x 3 x 4-1/2 inches. (See service sketch 3683C.)

Any inquiries regarding accuracy, timeliness, completeness, and

legibility of this Service Bulletin should be directed to the

local DAC Field Representative, or:

Douglas Aircraft Company

P.O. Box 1771

Long Beach, California 90801

Attn: Business Unit Manager

Service Bulletins

Maintenance and Modification Engineering

Product Support 35-35

(DC-9 Alert Service Bulletin A53-232)

ENW/CAS/ENW

LL/AMM

Bulletin A53-232 March 28/90

Page 58 Revision 2 April 28/95