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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-57A0135 Original Issue: February 07, 1975 Revision 4: September 26, 2012 ATA System: 5742 SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And Adjustment Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 1989 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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 Boeing liveries 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. BOEING is a trademark of Boeing Management Company.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 1 of 37
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 2 of 37 BOEING SERVICE BULLETIN 727-57A0135
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 8 E. Compliance .............................................. 1 8 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1
1. Existing Data: ......................................... 2 1
2. Data Supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 2 M. Software Accomplishment Summary ................................ 2 2
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary for Each Airplane ................................. 2 3
1. Kits/Parts ............................................ 2 3
2. Parts and Materials Supplied by the Operator ........................ 2 4
3. Parts Modified and Reidentified ................................ 2 4
4. Parts Removed and Not Replaced .............................. 2 4 D. Parts Necessary to Change Spares ................................. 2 4 E. Special Tooling - Price and Availability ............................... 2 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 8 FIGURE 1: INSPECTION .......................................... 3 0 FIGURE 2: CHECK FOR CLEARANCE / INTERFERENCE ....................... 3 2 FIGURE 3: REWORK OF LUG ASSEMBLY ................................ 3 4 FIGURE 4: CARRIAGE FITTING INSTALLATION FOR OUTBOARD FORE FLAP WBL 348 - DEVIATION FROM OVERHAUL MANUAL ................................. 3 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 3 of 37 BOEING SERVICE BULLETIN 727-57A0135
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 4 of 37 BOEING SERVICE BULLETIN 727-57A0135
ALERTALERT
BLANK PAGE
Commercial Airplanes 727 Service Bulletin ALERT Revision Transmittal SheetNumber: 727-57A0135Original Issue: February 07, 1975 Revision 4: September 26, 2012 ATA System: 5742 SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And Adjustment This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplanes changed in accordance with Revision 3 of this service bulletin. For the outboard foreflap, replace the production carriage attach fittings with the new improved carriage attach fittings at the time given in Paragraph 1.E., Compliance. Continue to inspect the carriage attach fittings at the interval given in Paragraph 1.E., Compliance. Do general visual inspections and functionality check of the outboard foreflap installation for damage and incorrect operation at the interval given in Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 is related to this service bulletin.
REASON FOR REVISION This revision is sent to increase the frequency of the repeat High Frequency Eddy Current (HFEC) inspection of production outboard foreflap carriage attach fittings, make compulsory the installation of the improved outboard foreflap carriage attach fittings, make incorporation of the concurrent service bulletins compulsory, add a general visual inspection and functionality check of the outboard foreflap and to require repeat inspections of the improved outboard foreflap carriage attach fittings.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections are changed:
1. Summary Background - Reference to a new Boeing Service Related Problem (SRP) and new service history is added. A Summary Evaluation table is added.
2. The Summary Action is updated.
3. Summary Compliance - Reference to FAA AD 2005-14-07 is added.
4. Paragraph 1.C., Reason - Reference to a new Boeing SRP is added.
5. Paragraph 1.A.1., Airplanes - A Group Configuration Table is added.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 5 of 37
6. Paragraph 1.C., Reason - Reference to a new Boeing Service Related Problem (SRP) and new service history is added. A Summary Evaluation table is added.
7. Paragraph 1.D., Description - Affected maintenance zones are added.
8. Paragraph 1.E., Compliance - Reference to FAA AD 2005-14-07 is added and the compliance information is updated.
9. Paragraph 1.F., Approval - The approval statement is updated.
10. Paragraph 1.G., Manpower - Manpower information for general visual inspection and functionality check is added.
11. Paragraph 1.J.1., Existing Data - References to FAA AD 2005-14-07, a new SRP and Service Bulletin Index are added.
12. Paragraph 1.K., Publications Affected - A Damage Tolerance Inspection (DTI) statement is added.
13. Paragraph 1.M., Software Accomplishment Summary - Section is added.
14. Paragraph 3.A., Accomplishment Instructions - General Note 1 regarding the sequencing of steps is deleted. A caution and 8 general notes are added.
15. Paragraph 3.B., Work Instructions - Instructions to do a general visual inspection and functionality check are added.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY February 07, 1975Original Issue:
August 29, 1975Revision 1:
October 29, 1998Revision 2:
June 27, 2002Revision 3:
September 26, 2012Revision 4:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 6 of 37 BOEING SERVICE BULLETIN 727-57A0135
ALERTALERT
Commercial Airplanes 727 Service Bulletin ALERT SummaryNumber: 727-57A0135Original Issue: February 07, 1975 Revision 4: September 26, 2012 ATA System: 5742 SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And Adjustment
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 Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND This service bulletin gives instructions to inspect the carriage attach fitting of the inboard and outboard foreflaps for any crack or damage. Fleet service information and analysis show that repeat inspections or replacement of the carriage attach fitting decrease the risk of partial or complete foreflap loss caused by fatigue. Inspection and adjustment, if necessary, of the gap between the foreflap carriage attach fitting and the carriage lug on the inboard and outboard foreflap assemblies will decrease the possibility of fatigue failure of the carriage attach fitting from excessive clamp-up. The fatigue life of the new replacement fitting increased with the design of thicker flanges, and a material change to Corrosion Resistant Steel. If the work in this service bulletin is not done, breakage of the carriage attach fitting could result in the loss of the foreflap and damage to adjacent structures which could lead to loss of controllability of the airplane during take-off and landing.
Sixteen operators sent reports of twenty-eight damaged or failed outboard Foreflaps with the carriage attach fitting of the Foreflap Sequencing Carriage cracked or failed. Recent Boeing examination of a failed fitting indicates fatigue breakage of the fitting is possible as a result of high fit-up stress combined with airloads.
Revision 3 changes this service bulletin to Alert status. It also provides specific inspection intervals for the carriage attach fitting.
Since the release of Revision 3, one operator has reported that during a scheduled inspection per Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 , both inboard and outboard Foreflap Carriage Fittings were found broken. The event occurred at 47,125 Flight Cycles. Metallurgical analysis determined that the cause of the broken fittings is a suspected static overload condition.
Boeing Service Related Problem (SRP) 727-SRP-57-0128 and 727-SRP-57-0243 are related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 7 of 37
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedYesSpares Affected Paragraph 1.E., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedYesAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 23907, PRR 24826-R) Do a detailed and High Frequency Eddy Current (HFEC) inspection of the foreflap carriage attach fittings for any crack or damage. If any crack or damage is found, replace the carriage attach fitting. If no crack or damage is found, do the repeat inspections at the interval given in Paragraph 1.E., Compliance .
Incorporate the service bulletins listed in Paragraph 1.B., Concurrent Requirements .
– For the inboard foreflap, installation of the improved carriage attach fittings and incorporation of the service bulletins listed in Paragraph 1.B., Concurrent Requirements terminates the repeat inspections.
– For the outboard foreflap, installation of the improved carriage attach fittings and incorporation of the service bulletins listed in Paragraph 1.B., Concurrent Requirements decreases the frequency of the repeat inspections.
Do a one-time clearance/interference check of the carriage attach fitting. Shim if required. If interference is found, rework the carriage attach lug.
On airplanes with the production carriage attach fitting, replace the production carriage attach fitting with the improved carriage attach fitting and incorporate the service bulletins listed in Paragraph 1.B., Concurrent Requirements . For the outboard foreflap the installation of the improved carriage attach fittings and the incorporation of the service bulletins listed in Paragraph 1.B., Concurrent Requirements , is not a terminating action.
For the outboard foreflap, do general visual inspections and functionality check of the outboard foreflap installation for damage and incorrect operation.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 8 of 37 BOEING SERVICE BULLETIN 727-57A0135
ALERTALERT
EFFECTIVITY All 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 Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-14-07 is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 9 of 37 BOEING SERVICE BULLETIN 727-57A0135
ALERTALERT
BOEING SERVICE BULLETIN 727-57A0135
ALERT ALERT
FOREFLAP
FOREFLAP SEQUENCING
CARRIAGE CARRIAGE
ATTACH FITTING SEE Q
MIDFLAP
FLAP TRACK FLAP CARRIAGE
FOREFLAP SEQUENCING
TOGGLE FWDS
OUTBOARD TRAILING EDGE FLAP INSTALLATION (TYPICAL FOR INBOARD AND OUTBOARD FOREFLAP)
TYPICAL Original Issue: February 07, 1975 Revision 4: September 26, 2012
CARRIAGE
ATTACH LUG CARRIAGE ATTACH FITTING:
INSPECT FOR ANY CRACK OR DAMAGE (TWO PLACES ON EACH FORFLAP) PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 727-57A0135 Work - See page 1 for details. 10 of 37
Commercial Airplanes 727 Service Bulletin ALERT Number: 727-57A0135 Original Issue: February 07, 1975 Revision 4: September 26, 2012 ATA System: 5742 SUBJECT: ATTACH FITTINGS Flight Control - Foreflap Carriage Attachment Inspection And Adjustment
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 D6-9825 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 727, 727-100, 100C, 200, 200F, 727C airplanes line numbers 1 thru 1832.
-1 Airplane Models:
727, 727-100, 727-100C, 727-200, 727-200F, 727C GroupVariable Number 1E0001 - E0042 1E0101 - E0140 1E0201 - E0216 1E0301 - E0351 1E0401 - E0423 1E3001 - E3006 1E3011 - E3014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 11 of 37
GroupVariable Number 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 1E5001 - E5011 1E5031 - E5068 1E5101 - E5116 1E5141 - E5143 1E5161 - E5164 1E5201 - E5203 1E5221 - E5245 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 1975 727-57A0135Revision 4: September 26, 2012 12 of 37 BOEING SERVICE BULLETIN 727-57A0135