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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-53A0233 Original Issue: February 19, 2010 ATA System: 5330 SUBJECT: FUSELAGE - Fuselage Skin - Inspection of the Fuselage Skin for Scribe Lines Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
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Original Issue: February 19, 2010 727-53A0233 1 of 192
2.0
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Original Issue: February 19, 2010 727-53A0233 2 of 192 BOEING SERVICE BULLETIN 727-53A0233
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 4 E. Compliance .............................................. 1 6 F. Approval ............................................... 4 8 G. Manpower .............................................. 4 8 H. Weight and Balance Changes .................................... 5 1 I. Electrical Load Data ......................................... 5 1 J. References .............................................. 5 1
1. Existing Data: ......................................... 5 1
2. Data supplied with this Service Bulletin: ........................... 5 1
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 2 K. Publications Affected ........................................ 5 2 L. Interchangeability and Intermixability of Parts ........................... 5 2
2. MATERIAL INFORMATION ........................................ 5 3 A. Material - Price and Availability ................................... 5 3 B. Industry Support Information .................................... 5 3 C. Parts Necessary For Each Airplane ................................. 5 3
1. Kits/Parts: ........................................... 5 3
2. Parts and Materials Supplied by the Operator: ........................ 5 3
3. Parts Modified and Reidentified: ............................... 5 3
4. Parts Removed and Not Replaced: .............................. 5 3 D. Parts Necessary to Change Spares ................................. 5 4 E. Special Tooling - Price and Availability ............................... 5 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 5 A. GENERAL INFORMATION ..................................... 5 5 B. WORK INSTRUCTIONS ....................................... 5 7 FIGURE 1: FUSELAGE - SKIN LAP JOINTS - ZONE 1 INSPECTION [Group 1] ............ 8 6 FIGURE 2: FUSELAGE - SKIN LAP JOINTS - ZONE 1 INSPECTION [Group 2] ............ 8 9 FIGURE 3: FUSELAGE - SKIN LAP JOINTS - ZONE 1 INSPECTION [Group 3] ............ 9 2 FIGURE 4: FUSELAGE - SKIN LAP AND SKIN BUTT JOINTS - ZONE 1 INSPECTION [Group 4] . . 97 FIGURE 5: FUSELAGE - SKIN LAP JOINTS - ZONE 2 INSPECTION [Group 1] ........... 1 0 1 FIGURE 6: FUSELAGE - SKIN LAP JOINTS - ZONE 2 INSPECTION [Group 2] ........... 1 0 4 FIGURE 7: FUSELAGE - SKIN LAP AND SKIN BUTT JOINTS - ZONE 2 INSPECTION [Group 3] . 107 FIGURE 8: FUSELAGE - SKIN LAP AND SKIN BUTT JOINTS - ZONE 2 INSPECTION [Group 4] . 112 FIGURE 9: FUSELAGE - SKIN LAP AND SKIN BUTT JOINTS - ZONE 3 INSPECTION [Group 1] . 116 FIGURE 10: FUSELAGE - SKIN LAP JOINTS - ZONE 3 INSPECTION [Group 2] ........... 1 1 9 FIGURE 11: FUSELAGE - SKIN LAP JOINTS - ZONE 3 INSPECTION [Group 3] ........... 1 2 2 FIGURE 12: FUSELAGE - SKIN LAP AND SKIN BUTT JOINTS - ZONE 3 INSPECTION [Group 4] . 126
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FIGURE 13: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION [Group 1] . . 129 FIGURE 14: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION [Group 2] . . 132 FIGURE 15: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION [Group 3] . . 135 FIGURE 16: FUSELAGE - EXTERNAL APPROVED REPAIRS - ZONE 1 INSPECTION [Group 4] . . 139 FIGURE 17: FUSELAGE - EXTERNAL FEATURES - ZONE 1 INSPECTION [Group 1] ........ 1 4 2 FIGURE 18: FUSELAGE - EXTERNAL FEATURES - ZONE 1 INSPECTION [Group 2] ........ 1 4 5 FIGURE 19: FUSELAGE - EXTERNAL FEATURES - ZONE 1 INSPECTION [Group 3] ........ 1 4 8 FIGURE 20: FUSELAGE - EXTERNAL FEATURES - ZONE 1 INSPECTION [Group 4] ........ 1 5 3 FIGURE 21: FUSELAGE - DECALS AND FAIRINGS - ZONE 1 INSPECTION [Group 3] ........ 1 5 6 FIGURE 22: FUSELAGE - DECALS AND FAIRINGS - ZONE 1 INSPECTION [Group 4] ........ 1 5 9 FIGURE 23: FUSELAGE - DECALS AND FAIRINGS - ZONE 2 INSPECTION [Group 1] ........ 1 6 1 FIGURE 24: FUSELAGE - DECALS AND FAIRINGS - ZONE 2 INSPECTION [Group 2] ........ 1 6 3 FIGURE 25: FUSELAGE - DECALS AND FAIRINGS - ZONE 2 INSPECTION [Group 3] ........ 1 6 5 FIGURE 26: FUSELAGE - DECALS AND FAIRINGS - ZONE 2 INSPECTION [Group 4] ........ 1 6 8 FIGURE 27: FUSELAGE - DECALS AND FAIRINGS - ZONE 3 INSPECTION [Group 1] ........ 1 7 0 FIGURE 28: FUSELAGE - DECALS AND FAIRINGS - ZONE 3 INSPECTION [Group 2] ........ 1 7 2 FIGURE 29: FUSELAGE - DECALS AND FAIRINGS - ZONE 3 INSPECTION [Group 3] ........ 1 7 4 FIGURE 30: FUSELAGE - DECALS AND FAIRINGS - ZONE 3 INSPECTION [Group 4] ........ 1 7 7 Appendix A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN. 179 Appendix B: REPORTING TEMPLATE - AIRPLANES WITH SCRIBE LINES .............. 1 8 7 Appendix C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES ............ 1 8 9 Appendix D: SCRIBE LINE SAMPLE .................................... 1 9 1
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Original Issue: February 19, 2010 727-53A0233 4 of 192 BOEING SERVICE BULLETIN 727-53A0233
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Commercial Airplanes 727 Service Bulletin ALERT SummaryNumber: 727-53A0233Original Issue: February 19, 2010 ATA System: 5330 SUBJECT: FUSELAGE - Fuselage Skin - Inspection of the Fuselage Skin for Scribe Lines
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions to inspect for scribe lines in the fuselage skin at lap joints, external approved repairs, decals, fairings, and external features such as antennas. Instructions are also given to inspect the splice plate at certain butt joints. Fatigue cracks can develop at scribe line locations. Any crack that remains undetected could grow large and cause a rapid decompression of the airplane.
Boeing has received reports of scribe line related cracks on two 727 airplanes. One report was on a 727-100 airplane with 44,171 cycles. The crack was near a repair and caused rapid decompression of the airplane.
Another report was on a 727-100 airplane with 51,195 cycles. The crack was at station 1090-1110, stringer 4L lap joint. This also resulted in rapid decompression of the airplane.
A scribe line is a narrow, shallow, distinct line of damage (typically up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (lap joints and butt joints, respectively). A more detailed definition of a scribe line is included in Accomplishment Instructions Paragraph 3.B. - Identification of a "Typical" Scribe Line.
A review of fleet activity yields two separate scenarios that are suspected to have caused scribe lines to the fuselage skin.
The first scenario involves the paint stripping and repainting of airplanes. In the process of stripping and preparing the airplane for paint, tools were used to remove sealant and paint buildup at lap joints, at certain external approved repair doublers or door scuff plates, or around external features. Tools like scrapers (steel, wood, hard plastic, etc.), knives, or utility knives can damage the skin. Fatigue cracks can develop at scribe line locations.
The second scenario is decal application on/or removal from the fuselage. To install the decals across lap joint steps or repairs, investigation into maintenance practices has shown that decals have been cut in place, using some form of knife, to allow the decal to lie flush to the skin at these stepped locations. This operation results in scribe lines at the decal cut location. Based on service reports, sharp tools have also been used for close trimming of the decal's outline. This type of decal trimming has also left scribe lines on the fuselage skin.
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The above maintenance operations can each lead to the same type of scribe line damage and subsequent premature fatigue cracks.
Boeing Service Related Problem (SRP) 727-SRP-53-0248 is related to this service bulletin.
ACTION At or before the scribe line inspection thresholds shown in this service bulletin, remove paint and sealant at the applicable locations. Do a detailed inspection of the fuselage skin at applicable lap joints, external approved repairs, decals, fairings, and external features for any scribe line or any crack. Also, do a detailed inspection of splice plate at certain butt joints for any scribe line or any crack. If any crack is found, contact Boeing for repair instructions and do the repair.
When scribe lines are found, they shall be repaired before further flight. As an alternative to immediate repair, for a scribe line that qualifies, the provided Limited Return To Service (LRTS) program may be used to allow airplanes to return to revenue flight for a limited period before scribe lines are repaired. This service bulletin contains a LRTS program.
NOTE: Further Boeing approval is not required to begin a LRTS program.
The LRTS program consists of repeat inspections to detect any crack where scribe lines were found. Total airplane flight cycles, location, and extent of scribe line must meet specific criteria in order for a scribe line to qualify for a LRTS program. Inspections at each affected structural location within a LRTS program will be terminated with a repair.
Since a scribe line can occur at any time during the service life of an airplane and at many locations, this program uses both total flight cycles and structural criticality of location to determine the inspection requirements.
Criticality of location allows this service bulletin to address the most critical areas first and to provide less critical areas with appropriately reduced compliance requirements. Criticality of location determines the inspection thresholds for each location. This service bulletin uses figures and compliance times to address all of the critical locations and ranges of inspection thresholds. Each critical piece of structure susceptible to a scribe line is assigned to a figure. The affected structure for each group of airplanes is identified in individual figures in this service bulletin.
EFFECTIVITY 727, 727-100, 727-100C, 727-200, 727-200F, 727C Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections or repair procedures given in this service bulletin.
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Original Issue: February 19, 2010 727-53A0233 6 of 192 BOEING SERVICE BULLETIN 727-53A0233
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MANPOWER Elapsed HoursTotal Task HoursAirplanes
62.0300.0727, 727-100, 727C, and 727-100C
72.0320.0727-200 and 727-200F
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 727-53A0233
ALERT ALERT ...
D
DO A DETAILED INSPECTION FOR ANY SCRIBE LINE ALONG SKIN
LAP JOINTS, SKIN BUTT JOINTS EXTERNAL FEATURES, EXTERNAL APPROVED REPAIRS, DECALS, AND FAIRINGS. IF A
SCRIBE LINE IS FOUND DO A NON-DESTRUCTIVE TESTING INSPECTION FOR ANY CRACK.
1895741 Original Issue: February 19, 2010 727-53A0233
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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-53A0233 Original Issue: February 19, 2010 ATA System: 5330 SUBJECT: FUSELAGE - Fuselage Skin - Inspection of the Fuselage Skin for Scribe Lines
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-9825 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP 727 and 727-100 Airplanes-1 727C and 727-100C Airplanes-2 727-200 Airplanes-3 727-200F Airplanes-4 Airplane Models:
727, 727-100, 727-100C, 727-200, 727-200F, 727C GroupVariable Number 1E0001 - E0042 1E0101 - E0140 1E0201 - E0216
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GroupVariable Number 1E0301 - E0351 1E0401 - E0423 1E3001 - E3006 1E3011 - E3014 1E3021 - E3040 1E3059 1E3061 - E3077 1E3101 - E3103 1E3111 - E3118 1E3141 - E3152 1E3171 - E3177 1E3201 - E3206 1E3221 - E3224 1E3241 - E3290 1E3341 - E3350 1E3401 - E3421 1E3451 - E3452 1E3471 - E3474 1E3501 - E3513 1E3516 - E3523 1E3551 - E3553 1E3571 - E3578 1E3601 - E3604 1E3621 - E3622 1E3651 - E3655 1E3677 1E3681 - E3684 1E3701 - E3704 1E3751 - E3755 1E3781 - E3784 2E5001 - E5011 2E5031 - E5068 2E5101 - E5116
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GroupVariable Number 2E5141 - E5143 2E5161 - E5164 2E5201 - E5203 2E5221 - E5245 2E5251 - E5252 2E5271 - E5281 2E5301 - E5306 2E5351 - E5353 2E5381 - E5382 2E5401 - E5424 2E5426 - E5429 2E5433 2E5435 2E5451 - E5455 2E5481 - E5483 2E5501 1E5502 3QA001 - QA046 3QA051 - QA099 3QA101 - QA199 3QA201 - QA225 3QA301 - QA349 3QA351 - QA376 3QA378 3QA401 - QA499 3QA501 - QA537 3QA551 - QA579 3QA581 - QA585 3QA601 - QA688 3QA701 - QA753 3QA801 - QA805 3QA851 - QA899 3QA901 - QA946
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GroupVariable Number 3QA949 3QB001 - QB002 3QB031 - QB049 3QB051 - QB068 3QB101 - QB110 3QB114 - QB119 3QB121 - QB149 3QB151 - QB158 3QB201 - QB220 3QB301 - QB316 3QB351 - QB352 3QB401 - QB407 3QB451 - QB458 3QB501 - QB575 3QB601 - QB629 3QB651 3QB701 - QB705 3QB801 - QB810 3QB901 - QB904 3QD001 - QD012 3QD031 - QD046 3QD085 - QD088 3QD101 - QD105 3QD121 - QD127 3QD141 - QD149 3QD161 - QD164 3QD191 - QD192 3QD201 - QD239 3QD281 - QD284 3QD301 - QD305 3QD321 - QD330 3QD351 3QD401 - QD403
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