BULLETIN A53-?

44

FUSELAGE - Aerodynamic Fairings - Functionally Check the Tailcone Release System.

This page transmits Revision 1 for MD-80 Alert Service Bulletin A53-244 to
incorporate the following changes:

NOTE: This revision constitutes a complete reissue and reflects current

operators of affected aircraft at time of issue.

Although this is the first release of the formal (blue copy)

Alert Service Bulletin, it does contain MD-80-COM-2/GDT, dated
January 22, 1991, (original information) revised as noted below;
therefore, this first (blue copy) is Revision 1.

Reason for Revision: To revise accomplishment instructions which will reduce

redundant work steps and add clarification to method of
measuring force to actuate tailcone release system.
No additional work is required by this revision for
aircraft modified by prior issue of this Alert Service
Bulletin.

Pages 1 Added NOTE under Title.

and 2: Added paragraphs B and C to References.

Added fuselage 909 to Effectivity.

Deleted 55 aircraft from Effectivity.
Added new paragraph 2 to Description, reidentified subsequent
paragraphs accordingly, and added new paragraph 5.
Revised Compliance.
Revised Approval.

Pages 3 Completely revised Accomplishment Instructions to add

thru 7: inspection/modification instructions (if required) for
exterior tailcone release handle and interior release
pin, and revised sequence of steps to minimize redundancy.
Page 8: Added FIGURE 1.
Page 9: Added FIGURE 2.
Pages 10 Completely revised Material Information.
and 11:

GDT
ENW -1

January 22/91 Bulletin A53-244

Revision 1 February 8/91 Page 1 of 1

 BULLETIN A53-244

FUSELAGE - AERODYNAMIC FAIRINGS - FUNCTIONALLY CHECK TIE TAILCONE RELEASE SYSTEM.

REFERENCES:

A. DC-9 lAINTENANCE MANUAL, CHAPTERS 7, 11, AND 53.

B. DC-9 SERVICE BULLETIN 53-134.

C. MD-80-COM1-2/GDT, DATED JANUARY 22, 1991.

The following wire was forwarded on January 22, 1991, to all operators
of MD-80aircraft.
"JANUARY 22 , 1 8]

THIS TELEX CONSTITUTES MD-80 ALERT SERVICE BULLETIN A53-244.

EFFECTIVITY:

THIS ALERT SERVICE BULLETIN AFFECTS MD-80 AIRCRAFT MANUFACTURER'S FUSELAGE

INUMBERS 909, 924, 938, 941, 944, 946, 948, 950, 952, 953, 955, 957, 958, 960,
962, 963, 965 THRU 967, 969 THRU 971, 973 THRU 975, 977 THRU 979, 981, 983,
985, 986, 988, 991, 992, 994 THRU 997, 999 THRU 1013, 1015, 1016, 1018 THRU
1020, 1022, 1023, 1025, 1026, 1028, 1029, 1031, 1032, 1034, 1035, 1037, 1038,
1041, 1043, 1045, 1047, 1049, 1051, 1053, 1055, 1057, 1059 THRU 1080, 1082,
1083, 1085 THRU 1536, 1538 THRU 1567, 1569 THRU 1588, 1590 TIIRU 1608, 1610
THRU 16?1, 1623 THRU 1632, 1634 TIIRU 1646, 1648 T RII 1653, 1655 THRU 1657,
165 ) TH R 16 ,, 1668 TIIRU 1610, AN 167? TIIRII 1 7/1.

[IlIS Al l RI S RVI I I111.1 IN IS Al'l ICA L ONLY 10 LISI AIR RAI 1.

January 22/91 Bulletin A53-244

Revision 1 February 8/91 Page 1 of 11
REASON:

O E OPERATOR REPORTED INSTANCES IN ITS FLEET WHERE DISCREPANCIES EXISTED WITHIN

T E TAILCONE RELEASE SYSTErl. DISCREPANCIES CONSISTED OF MISRIGGED CABLES AND
I XC SSIVI PUL FORCE REQUIRED TO ACTIVATE TIIE SYSTE . IF THESE DISCREPANCIES
ARI N)OT CORRI CI , XCESSIV
I FORCE lAY BE REQUIRED TO RELEASE T E TAILCONE.
I lINCI ()rlAI Y IIICKIN( T il 1AIl (ONI R LEASE SYSTFM WILL DETERMINE HETHI R
IAI CONI RFI- A SYS [ IS OPERATING PRO ERLY.

CRIP1 ION:

THIS ALERT SERVICE BULLETIN ACCOlPLISHES THE FOLLOWING:

1. PERFORlS FUNCTIONAL CHECK OF THE TAILCONE RELEASE SYSTE USING THE AFT
PASSENGER DOOR EMERGENCY OPERATING HANDLE.

2. PERFORMS VISUAL INSPECTION OF THE INTERIOR AND EXTERIOR TAILCONE RELEASE

HANDLES FOR CRACKED/BROKEN CONDITION AND REPLACES IF REQUIRED.

3. PERFORMS FUNCTIONAL CHECK OF THE TAILCONE RELEASE SYSTEM USING THE INTERIOR
RELEASE HANDLE.

4. CHECKS IIANDLES, CABLES, AND LATCHES FOR DISCREPANCIES.

. PERFORMS VISUAL CIIECK OF THE INTERIOR AND EXTERIOR "ElERGENCY EXIT" MARKINGS
AND REPAINTS IF REQUIRED.

COIPLIANCE:

IT IS RECOMMENDED TIIAT THIS ALERT SERVICE BULLETIN BE ACCO PLISHED ITHIN

120 DAYS AFTER THE RECEIPT OF THIS ALERT SERVICE BULLETIN.

APPROVAL:

THE RESULTANT CHECKS DESCRIBED HEREIN HAVE BEEN SHOWN TO COMPLY WITH THE
APPLICABLE FEDERAL AVIATION REGULATIONS AND REVISION 1 IS APPROVED BY THE
M ANAGER, LOS ANGELES AIRCRAFT CERTIFICATION OFFICE, FAA NORTH WEST MOUNTAIN
REGION, ON FEBRUARY 7, 1991.

IIANPOWER:

THIS ALERT SERVICE BULLETIN MAY BE ACCOMlPLISHED IN APPROXIMlATELY 15.0 AN-HOUURS

OR 7. I APSFD I OURS PER AIRCRAFT.

Bulletin A53-244 January 22/91

' Revision 1 February 8/91

 MAKE CERTAIN THAT TAIL JACK IS PROPERLY
INSTAI LED AS REQUIRED AT AFT FUSELAGE
JACKING POINT TO MAINTAIN FUSELAGF IAI.AN(C,
Bl IORL PERFORMING MAINIENANC E IN TAIL OF
AIRCRAFT (SEE MAINTENANCE MANUAL,
CHAPTER 07-11-00)

CAUTION: ELECTRICALLY GROUND THE AIRCRAFT.

DO NOT PULL THE RELEASE HANDLE UNLESS

THE TAILCONE IS PROPERLY SUPPORTED.

NOTE: CHAPTERS WITHIN PARENTHESIS REFER TO

CHAPTERS IN THE MAINTENANCE MANUAL.

A. SUPPORT THE TAILCONE SUFFICIENTLY TO PREVENT DAMAGE WHEN TAILCONE DROPS

AWAY FROM FUSELAGE OR INSTALL TAILCONE TEST SLING (REF CHAPTER 53-50-03,
PARAGRAPH ENTITLED "REMOVAL/INSTALLATION TAILCONE.")

CAUTION: BEFORE PULLING TAILCONE RELEASE HANDLE ON

AIRCRAFT WITH EVACUATION SLIDE INSTALLED,
MAKE CERTAIN THAT SLIDE DEPLOYMENT LANYARD
IS DISCONNECTED FROM TAILCONE TO AVOID
INADVERTENT DEPLOYMENT OF SLIDE.

B. WITH PASSENGER AFT ENTRANCE DOOR IN THE CLOSED POSITION, ROTATE EMERGENCY
OPERATING HANDLE TO DOOR OPEN POSITION.

C. ATTACH SCALE TWO INCHES FROM THE FREE END OF HANDLE.

D. SLOWLY APPLY FORCE REQUIRED TO OPEN DOOR. OPENING FORCE SHOULD BE 10 TO 20

POUNDS. CHECK FOR THE FOLLOWING:

1. MAKE CERTAIN THAT TAILCONE LATCHES ROTATE TO THE FULL OPEN POSITION.

2. MAKE CERTAIN THAT LOCKPINS OF LOWER LATCHES DISENGAGE BEFORE LOCKPINS

OF UPPER LATCHES.

January 22/91 Bulletin A53-244

Revision 1 February 8/91 Page 3

 .
AII I A IACII INI .

1. II CK IAILC( NI RLL.ASE CA LI S FOR CORROSION (SL CHAI R 12 FO CABLE

PRESERVATION AND LUBRICATION).

5. C CK THAT LOCKING CABLE CLAMP CLEARS LOWER END OF CONDUITS AT LEAST

1/? IN WITII I ATCIIES IN TIIE FUII OPEN POSITION. CONDUITS AY I E
RI P I I I N FOR CLEARANCE.

E. RMOVE COVER ADJACENT TO INTERIOR RELEASE HANDLE INSIDE THE AFT ACCESSORY
CO PART ENT.

NOTE: SO E AIRCRAFT HAVE QUICK

RELEASE HINGED COVER.

F. CLOSE AND LATCH AFT PASSENGER DOOR AND INSTALL PLASTIC COVER OVER E ERGENCY
HANDLE.

G. ROTATE EMERGENCY EXIT DOOR ARl TO THE NORlAL STOWEI POSITION ABOVE DOOR
(RI F CIIAP ER 53- 0-03).

NOTE: THIS AY BE MORE EASILY ACCOMPLISHED IF

A SECOND AN SIMULTANEOUSLY PULLS AFT ON
E ERGENCY PULL CABLE TO PREVENT TWISTING.

H. SAFETY STOP BOLT AND AR WITH .025-INCH COPPER SAFETY WIRE.

I. CLOSE COVER OVER E ERGENCY OPERATING ARM ABOVE DOOR.

J. DEACTIVATE THE INTERIOR AND EXTERIOR TAILCONE RELEASE HANDLES BY

DISCONNECTING CLEVIS (7) FRO SUPPORT (4). RETAIN ATTACH ENTS FOR
REINSTALLATION (SEE CHAPTER 53-50-03, PARAGRAPH ENTITLED "ADJUSTMENT/TEST
TAILCONE.")

K. INSERT BALL END OF LOCKING CABLE IN LOCKING CABLE RETAINING HOLE, AND PUSH
TO DEPRESS SPRING LOADED PLUNGER. RETURN PIN (11) TO THE STOWED POSITION.
PULL SHARPLY ON THE LOCKING CABLE TO VERIFY THAT IT IS PROPERLY ENGAGED AND
RETAINED BY THE PIN (SEE CHAPTER 53-50-03, PARAGRAPH ENTITLED
"ADl ST NT/TST TAILCONE.")

Bulletin A53-244 January 22/91

Page 4 Revision 1 February 8/91

L. USING A SCALE, MEASURE THE FORCE REQUIRED TO PULL THE INTERIOR RELEASE
HANDLE FRO ITS RETAINING CLIPS AND CONTINUE TO PULL TO RELEASE PIN (11)
FROM ITS RETAINING CLIPS. FORCE REQUIRED SHALL BE 25 TO 35 POUNDS FOR EACH
SET OF CLIPS. ADJUST CLIPS UNTIL 25 TO 35 POUNDS FORCE CAN BE OBTAINED.

NOTE: THE 25 TO 35 POUND FORCE REQUIREMENT

SUPERSEDES 9/32 INCH DIMENSION REFERENCED
IN TIIE MAINTENANCE MANUAL.

IF FORCE REQUIREI) TO PULL HANDLE FROM CI IPS

EXCEEDS 35 POUNDS AND ADJUSTMENT OF CLIPS DOES
NOT CORRECT THE PROB LE , INSPECT THE SIAFT ON
RELEASE PIN (11) FOR INDENTATIONS CAUSE) BY THE
BALL ON END OF LOCKING CABLE. IF INDENTATIONS
EXIST, MODIFY THE PIN PER FIGURE 1.

M. VISUALLY INSPECT THE RELEASE PIN (11) SUPPORT FITTING HOLE. THE HOLE SHOULD
NOT HAVE ANY BLOCKAGE AND ENSURE THAT THE LOCKING CABLE BALL MOVES FREELY IN
AND OUT OF THE FITTING (SEE CHAPTER 53-50-03, PARAGRAPH ENTITLED
"ADJUSTMENT/TEST TAILCONE.")

CAUTION: DO NOT LUBRICATE PLUNGER AS DIRT WILL

COLLECT AND ADHERE TO PLUNGER.

N. INSERT BALL END OF LOCKING CABLE IN LOCKING CABLE RETAINING HOLE, AND PUSI
TO DEPRESS SPRING LOADED PLUNGER. RETURN PIN (11) AND INTERIOR RELEASE
HANDLE TO THE STOWED POSITION. PULL SHARPLY ON THE LOCKING CABLE TO VERIFY
THAT IT IS PROPERLY ENGAGED AND RETAINED BY THE PIN (REF CHAPTER 53-50-03).

O. USING A SCALE, MEASURE THE FORCE REQUIRED TO PULL THE EXTERIOR RELEASE
HANDLE FRO M ITS RETAINING CLIPS. FORCE REQUIRED SHALL BE 25 TO 35 POUNDS.
ADJUST CLIPS UNTIL 25 TO 35 POUNDS FORCE CAN BE OBTAINED.

NOTE: THE 25 TO 35 POUND FORCE REQUIREMENT

SUPERSEDES 9/32 INCH DIMENSION REFERENCED
IN THE MAINTENANCE MlANUAL.

IF FORCE REQUIRED TO PULL HANDLE FROM CLIPS

EXCEEDS 35 POUNDS AND ADJUSTMENT OF CLIPS DOES
NOT CORRECT THE PROBLEM, INSPECT SHAFT ON THE
HANDLE FOR INDENTATIONS CAUSED BY THE BALL ON
END OF LOCKING CABLE. IF INDENTATIONS EXIST,
MODIFY THE HANDLE PER FIGURE 2.

January 22/91 Bulletin A53-244

Revision 1 February 8/91 Page 5

P. VISUALLY INSPECT THE EXTERIOR HANDLE SUPPORT FITTING HOLE. THE HOLE SHOULD
NOT HAVE ANY BLOCKAGE AND ENSURE THAT THE LOCKING CABLE BALL MOVES FREELY
IN AND OUT OF THE FITTING. (SEE CHAPTER 53-50-03, PARAGRAPH ENTITLED
"ADJUSTMENT/TEST TAILCONE.")

CAUITION: DO NOT LU BRICATE PLIINGER AS DIRT WILL

COLLECT AND A)DHERE TO PLUNGER.

Q. VISUALIY INSPECT TIIE EXTERIOR RELEASE HANI)LE SHAFT FOR BROKEN/CRACKEI

CONDITION. PAY PARTICULAR ATTENTION TO T EH GROOVE AROUND THE SHAFT.
RFPLACE BR OKLN/CRACKII) IIANILES WITII NEW 3918323-505 HANDLE PER OPERATOR'S
S OI PRACTICE.

R. REINSTALL TAILCONE (SEE CHAPTER 53-50-03, PARAGRAPH ENTITLED

"REMOVAL/INSTALLATION TAILCONE.")

S. INSERT THE BALL END OF THE LOCKING CABLE IN THE LOCKING CABLE RETAINING
HOLE AND PUSH TO DEPRESS SPRING LOADED PLUNGER. STOW THE EXTERIOR RELEASE
HANDLE. PULL SHARPLY ON THE LOCKING CABLE TO VERIFY THAT IT IS PROPERLY
ENGAGED AND RETAINED BY THE RELEASE HANDLE.

T. REACTIVATE INTERIOR AND EXTERIOR TAILCONE RELEASE HANDLES BY CONNECTING

CLEVIS (7) TO SUPPORT (4) USING RETAINED ATTAC HMENTS, (SEE CHAPTER 53-50-03,
PARAGRA PII ENTITLED "ADJUSTMENT/TEST TAILCONE.")

11. R' MOVI' 111 IN

(LI

V. USING A SCALE, SLOWLY APPLY FORCE REQUIRED TO DROP THE TAILCONE USING THE.
INTERIOR RELEASE HANDLE. FORCE REQUIRED TO RELEASE RIGGED TAILCONE SHOULD
BE 25 TO 35 POUNDS. CHECK FOR THE FOLLOWING: (SEE CHAPTER 53-50-03,
PARAGRAPH ENTITLED "CHECK TAILCONE.")

1. MAKE CERTAIN THAT LOCKPINS OF LOWER LATCHES DISENGAGE BEFORE LOCKPINS

OF UPPER LATCHES.

2. ENSURE THAT CABLES OPERATE SMOOTHLY OVER PULLEYS WITH NO BINDING AT

CABLE ATTACH POINTS.

3. CHECK TAILCONE RELEASE CABLES FOR EXCESSIVE CORROSION (SEE CHAPTER 12

FOR CABLE PRESERVATION AND LUBRICATION).

4. CIIHCK TIIAT LOCKING CABLE CLAMP CLEARS LOWER END OF CONDUITS AT LEAST
1/2 INCH WITII LATCHES IN THE FU LL OPEN POSITION. CONDUITS MAY BE
REPOSITIONEI) FOR CLEARANCE.

Bulletin A53-244 January 22/91

Page 6 Revision 1 I ebruary 8/91

 W. IF INTERIOR RELEASE HANDLE PULL FORCE EXCEEDS 35 POUNDS OR IS LESS THAN 25
POUNDS, LUBRICATE AND/OR ADJUST TAILCONE LATCHES UNTIL A PULL FORCE BETWEEN
25 ANI 3 POUNDS IS OBTAINED. (SEE CHAPTER 53-50-03, PARAGRAPH ENTITLED
"RI'LMOVAL/INSTALLATION TAILCONE.")

X. REINSTALL TAILCONE. (SEE PARAGRAPH 53-50-03, PARAGRAPH ENTITLED

"REMOVAL/INSTALLATION TAILCONE.")

Y. CONNECT EVACUATION SLIDE DEPLOYMENT LANYARD TO TAILCONE.

Z. REMOVE TAILCONE TEST SLING, IF INSTALLED.

AA. REINSTALL ACCESS DOOR 6101A, IF REMOVED FOR SLING INSTALLATION.

BB. VERIFY THAT "EMERGENCY EXIT" EXTERIOR MARKINGS ARE LEGIBLE, AND ARE OF
CONTRASTING COLORS, (SEE CHAPTERS 11-14-01 AND 11-14-02). REPAINT AS
REQUIRED USING DMS 2112 (SEE MATERIAL INFORMATION).

CC. VERIFY THAT "EMERGENCY EXIT" INTERIOR MARKINGS ARE LEGIBLE, AND ARE OF
CONTRASTING COLORS, (SEE CHAPTERS 11-32-01 AND 11-34-03). REPAINT AS
REQUIRED USING DMS 2112 (SEE MATERIAL INFORMATION).

DD. REPORT THE FOLLOWING INFORMATION TO DAC FIELD REPRESENTATIVES OR ADDRESS

LISTED BELOW:

1. DID THE TAILCONE DROP USING BOTH PRESSURE BULKHEAD EMERGENCY HANDLE
AND INTERIOR RELEASE HANDLE?

2. WHAT WAS THE FORCE REQUIRED TO RELEASE TAILCONE AT EACH HANDLE?

3. WHAT WAS THE CORRECTIVE ACTION TAKEN IF DISCREPANCIES WERE FOUND?

January 22/91 Bulletin A53-244

Revision 1 February 8/91 Page 7

 INTERIOR RELEASE PIN - MODIFICATION
Bulletin A53-244
FIGURE 1 January 22/91
Page 8 Revision 1 February 8/91
 EXTERIOR RELEASE HANDLE - MODIFICATION

January 22/91 FIGURE 2 Bulletin A53-244

Revision 1 February 8/91 Page 9

 MlATERIAL INFORMATION:

NOTE: CAGE INDICATES COMMERCIAL AND GOVERNMENT

ENTITY CODE FOR MANUFACTURERS/DISTRIBUTORS.

THE BASIS FOR THE FOLLOWING MATERIAL DATA IS PER AIRCRAFT.

PARTS ANI) MATERIAL TO BE PROCURED FROM OPERATOR'S STOCK OR SOURCE INI CATED.

NOTE: QUANTITY INDICATEI) IS MAXIMlrl. ACTUAL

QUANTITY IS TO IBE DETERMINED BY TIE
OPERATOR BASED ON INSPECTION FINDINGS.

INSTRUCTIONS-
PART/MATERIAL QTY KEY WORD OLD PART NO. DISPOSITION

3918323-505 2 HANDLE 3918323-1 1/ 4/

OR
3918323-501
OR
3918323-503

3951072-501 1 PIN 3951072-1 1/ 4/

OR
3951072-501

AA92-R-101 (RED) 4 OZ PAINT 2/ 3/

OR
AA92-W-2A (WHITE)
OR
AA92-Y-95 (YELLOW)
WITH
AA92-C-39 (CATALYST)
AND
T-732 (THINNER)
(DMS 2112)
OR
AA92R249 (RED)
OR
AA92W91 (WIIITE)
OR
EQUIVALENT

January 22/91 Bulletin A53-244

Revision 1 February 8/91 Page 10

NOTE: OPERATORS REQUIRING PAINT COLORS OTHER THAN THOSE
LISTED SHOULD CONTACT SUPPLIER FOR AVAILABILITY.

1/ MAY BE PURCHASED FROM TIIE DOUGLAS AIRCRAFT COMPANY AS AN END ITEM SPARE.

2/ MAY BE PROCURED FROM OPERATOR'S STOCK.

3/ MAY BE PURCHASED FROM: U.S. PAINT CORPORATION CAGE

831 SOUTH 21ST STREET NOT AVAILABLE
ST. LOUIS, MISSOURI 63103

4/ RETAIN HANDLES AND PIN FOR POSSIBLE FUTURE MODIFICATION.

ANY INQUIRIES REGARDING ACCURACY, TIMELINESS, COMPLETENESS, AND LEGIBILITY

OF THIS ALERT SERVICE BULLETIN SHOULD BE DIRECTED TO THE LOCAL DAC FIELD
REPRESENTATIVE, OR:

GDT
ENUl

Bulletin A53-244 ry 22/91

Page 11 Revision 1 February 8/91