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Commercial Airplanes 727 Requirements Bulletin ALERT Number: 727-57A0190 RB Original Issue: September 13, 2021 ATA System: 5714 SUBJECT: WINGS - Center Wing Box - Lower Skin and Rear Spar Lower Chord Inspection 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:
Copyright © 2021 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Unpublished Work.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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, 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.
Original Issue: September 13, 2021 727-57A0190 RB 1 of 23
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
1 . E F F E C T I V I T Y5
A . A i r p l a n e s5
B . S p a r e s A f f e c t e d7
2. CONCURRENT REQUIREMENTS7
3 . C O M P L I A N C E7
4. APPROVAL ................................................ 1 0
5. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 1 A. General Information ......................................... 1 1 B. Work Instructions ........................................... 1 2 FIGURE 2: CENTER WING BOX - LOWER SKIN AND REAR SPAR LOWER CHORD BETWEEN LBBL
34.7 AND RBBL 34.7 - DETAILED INSPECTION [Group 2-3] ................ 1 6 FIGURE 3: CENTER WING BOX - LOWER SKIN AND REAR SPAR LOWER CHORD BETWEEN LBBL
34.7 AND RBBL 34.7 - SEALANT APPLICATION [Group 2-3] ................ 2 0 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 727 Requirements Bulletin ALERT Number: 727-57A0190 RB Original Issue: September 13, 2021 ATA System: 5714 SUBJECT: WINGS - Center Wing Box - Lower Skin and Rear Spar Lower Chord Inspection
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING
PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1. Effectivity A. Airplanes This bulletin is applicable to 727, 727-100, 727-100C, 727-200, 727-200F, 727C Airplane(s), line number(s) 1-1832 in 3 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
This service bulletin is applicable to 727, 727-100/-100C/-200/-200F, 727C Airplanes. The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 727 Airplanes beyond the Limit of Validaty (LOV).-1 727/727-100/727-200 Airplanes.-2 Airplanes with bladder fuel cells in the wing center section.1 Airplanes with an integral fuel tank in the wing center section.2 727C/727-100C/727-200F Airplanes.-3 Airplanes with bladder fuel cells in the wing center section.1 Airplanes with an integral fuel tank in the wing center section.2 Airplane Models:
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Original Issue: September 13, 2021 727-57A0190 RB 5 of 23
727, 727-100, 727-100C, 727-200, 727-200F, 727C GroupVariable Number 1E0001 - E0018 2E0019 - E0042 1E0101 - E0112 2E0113 - E0140 1E0201 - E0205 2E0206 - E0216 1E0301 - E0308 2E0309 - E0351 1E0401 - E0404 2E0405 - E0423 2E3001 - E3006 2E3011 - E3014 2E3021 - E3040 2E3059 2E3061 - E3077 2E3101 - E3103 2E3111 - E3118 2E3141 - E3152 2E3171 - E3177 2E3201 - E3206 2E3221 - E3224 2E3241 - E3290 2E3341 - E3350 2E3401 - E3421 2E3451 - E3452 2E3471 - E3474 2E3501 - E3513 2E3516 - E3523 2E3551 - E3553 2E3571 - E3578 2E3601 - E3604 GroupVariable Number 2E3621 - E3622 2E3651 - E3655 2E3677 2E3681 - E3684 2E3701 - E3704 2E3751 - E3755 2E3781 - E3784 3E5001 - E5011 3E5031 - E5068 3E5101 - E5116 3E5141 - E5143 3E5161 - E5164 3E5201 - E5203 3E5221 - E5245 3E5251 - E5252 3E5271 - E5281 3E5301 - E5306 3E5351 - E5353 3E5381 - E5382 3E5401 - E5424 3E5426 - E5429 3E5433 3E5435 3E5451 - E5455 3E5481 - E5483 3E5501 - E5502 2QA001 - QA046 2QA051 - QA099 2QA101 - QA199 2QA201 - QA225 2QA301 - QA349 GroupVariable Number 2QA351 - QA376 2QA378 2QA401 - QA499 2QA501 - QA537 2QA551 - QA579 2QA581 - QA585 2QA601 - QA688 2QA701 - QA753 2QA801 - QA805 2QA851 - QA899 2QA901 - QA946 2QA949 2QB001 - QB002 2QB031 - QB049 2QB051 - QB068 2QB101 - QB110 2QB114 - QB119 2QB121 - QB149 2QB151 - QB158 2QB201 - QB220 2QB301 - QB316 2QB351 - QB352 2QB401 - QB407 2QB451 - QB458 2QB501 - QB575 2QB601 - QB629 2QB651 2QB701 - QB705 2QB801 - QB810 2QB901 - QB904 2QD001 - QD012 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 2QD031 - QD046 2QD085 - QD088 2QD101 - QD105 2QD121 - QD127 2QD141 - QD149 2QD161 - QD164 2QD191 - QD192 2QD201 - QD239 2QD281 - QD284 2QD301 - QD305 2QD321 - QD330 2QD351 2QD401 - QD403 2QD407 2QD410 2QD421 - QD427 GroupVariable Number 2QD441 - QD453 2QD471 - QD475 2QD501 - QD518 2QD551 - QD558 2QD571 - QD572 2QD581 - QD583 2QD601 - QD607 2QD621 - QD624 2QD641 2QD661 - QD663 2QD681 - QD685 2QD691 - QD692 2QD701 - QD702 2QD711 - QD717 2QD741 2QD761 - QD769 GroupVariable Number 2QD781 - QD782 2QD791 2QD801 - QD804 2QD821 - QD828 2QD901 - QD910 2QD931 - QD932 2QD951 - QD954 2QD971 - QD973 2QD991 - QD992 2QE001 - QE002 2QL001 - QL008 2QL031 - QL032 2QL081 3QL501 - QL515 -- -- B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 727-57A0190 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 727-57A0190 RB mandatory.
Group 1:
Boeing endorses the FAA rules related to Limit of Validity (LOV) and recommends immediate and permanent removal from service of any airplanes upon reaching the LOV, whether or not it is operated under FAA jurisdiction. As such, Boeing no longer provides maintenance instructions for airplanes that have accumulated flight cycles beyond the LOV. Airplanes in Group 1 (line numbers 1-47) have accumulated flight cycles beyond the LOV of the maintenance program. 14 CFR 121.1115 and 129.115 prohibit operation of an airplane beyond its LOV.
Group 2:
Accomplish the required action(s), based on the applicable condition(s) in Table 1, in accordance with Accomplishment Instructions.
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Group 3:
Accomplish the required action(s), based on the applicable condition(s) in Table 2, in accordance with Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Group 2:
Table 1: Wing - Center Wing Box, Lower Skin and Rear Spar Lower Chord between LBBL 34.7 and RBBL
34.7 - Detailed Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,800 flight cycles after the Original Issue date of Requirements Bulletin 727- 57A0190 RB.
Before 55,000 Total Flight Cycles.
Do an internal Detailed Inspection of the center wing box, lower skin and rear spar lower chord between LBBL 34.7 and RBBL 34.7 for any crack.
All airplanes.
-Before further flight.CONDITION 1 (ACTION 1):CONDITION 1: NO CRACK FOUND Apply sealant to the lower skin and lower chord inspection area.
10,000 Flight Cycles.
-CONDITION 1 (ACTION 2):
Repeat internal Detailed Inspection of the center wing box, lower skin and rear spar lower chord between LBBL 34.7 and RBBL 34.7 for any crack. (a) -Before further flight.CONDITION 2 (ACTION 1):CONDITION 2: ANY CRACK FOUND Contact the Boeing Company for repair instructions and do the repair.
-Before further flight.CONDITION 2 (ACTION 2):
Apply sealant to the lower skin and lower chord inspection area.
10,000 Flight Cycles.
-CONDITION 2 (ACTION 3):
Repeat internal Detailed Inspection of the center wing box, lower skin and rear spar lower chord between LBBL 34.7 and RBBL 34.7 for any crack at unrepaired areas. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Group 2:
Table 1: Wing - Center Wing Box, Lower Skin and Rear Spar Lower Chord between LBBL 34.7 and RBBL
34.7 - Detailed Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition
(a) It is not required to do the inspection in areas where a repair covers the affected inspection area if the repair meets the conditions that follow:
1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 727- 57A0190 RB and installed after the original issue date of Requirements Bulletin 727-57A0190 RB.
2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
Group 3:
Table 2: Wing - Center Wing Box, Lower Skin and Rear Spar Lower Chord between LBBL 34.7 and RBBL
34.7 - Detailed Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,800 flight cycles after the Original Issue date of Requirements Bulletin 727- 57A0190 RB.
Before 46,000 Total Flight Cycles.
Do an internal Detailed Inspection of the center wing box, lower skin and rear spar lower chord between LBBL 34.7 and RBBL 34.7 for any crack.
All airplanes.
-Before further flight.CONDITION 3 (ACTION 1):CONDITION 3: NO CRACK FOUND Apply sealant to the lower skin and lower chord inspection area.
10,000 Flight Cycles.
-CONDITION 3 (ACTION 2):
Repeat internal Detailed Inspection of the center wing box, lower skin and rear spar lower chord between LBBL 34.7 and RBBL 34.7 for any crack. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Group 3:
Table 2: Wing - Center Wing Box, Lower Skin and Rear Spar Lower Chord between LBBL 34.7 and RBBL
34.7 - Detailed Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 4 (ACTION 1):CONDITION 4: ANY CRACK FOUND Contact the Boeing Company for repair instructions and do the repair.
-Before further flight.CONDITION 4 (ACTION 2):
Apply sealant to the lower skin and lower chord inspection area.
10,000 Flight Cycles.
-CONDITION 4 (ACTION 3):
Repeat internal Detailed Inspection of the center wing box, lower skin and rear spar lower chord between LBBL 34.7 and RBBL 34.7 for any crack at unrepaired areas. (a)
(a) It is not required to do the inspection in areas where a repair covers the affected inspection area if the repair meets the conditions that follow:
1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 727- 57A0190 RB and installed after the original issue date of Requirements Bulletin 727-57A0190 RB.
2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
4. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document comply with the applicable regulations and are FAA approved, as well as European Union Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in this Requirements Bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
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Original Issue: September 13, 2021 727-57A0190 RB 10 of 23 REQUIREMENTS BULLETIN 727-57A0190
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5. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION NOTE: 1. This is an Enhanced Required for Compliance document. There will be a separate Service Bulletin (SB) and a separate Requirements Bulletin (RB). If an RB is mandated by an Airworthiness Directive (AD), then all applicable requirements specified in the RB must be done. For the related SB, some locations are marked RC Start and RC End to identify the requirements that are restated from the RB. For the related SB, the areas between RC Start and RC End, including sub-steps and any figures identified between RC Start and RC End, must be done to comply with the AD.
Therefore, an Alternative Method of Compliance (AMOC) is required for any deviations to steps between RC Start and RC End, including substeps and identified figures.
For the related SB, the steps not between RC Start and RC End may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC; this is provided that the steps between RC Start and RC End, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition.
Figures not required for compliance are omitted from the RB.
2. This is an Enhanced Required for Compliance document. The Boeing processes used to create the Service Bulletin (SB) and the Requirements Bulletin (RB) ensure that the information between "RC Start" and "RC End" in the SB are identical to the information in the same sections (Compliance, Work Instructions...) of the RB which the SB refers to as the related document.
3. The compliance times for the actions in WORK INSTRUCTIONS are in Compliance.
4. Boeing Service Letter 727-SL-51-041, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided.
5. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values:
— Values for structural fasteners are given in 727 Structural Repair Manual, Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 727 Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 727 Aircraft Maintenance Manual (AMM).
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— Non-standard torque values for maintenance tasks are included in the applicable installation step.
6. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.
7. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part.
8. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed.
9. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.
10. A Detailed Inspection is defined as: An intensive examination of a specific item, installation or assembly to detect damage, failure or irregularity. This could include tactile assessment in which a component or assembly can be checked for tightness/security. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors and magnifying lenses may be necessary. Surface cleaning and elaborate access procedures may be required.
11. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
B. WORK INSTRUCTIONS Actions Required for Compliance:
1. Requirements Group 1:
Boeing endorses the FAA rules related to Limit of Validity (LOV) and recommends immediate and permanent removal from service of any airplanes upon reaching the LOV, whether or not it is operated under FAA jurisdiction. As such, Boeing no longer provides maintenance instructions for airplanes that have accumulated flight cycles beyond the LOV. Airplanes in Group 1 (line numbers 1-47) have accumulated flight cycles beyond the LOV of the maintenance program. 14 CFR
121.1115 and 129.115 prohibit operation of an airplane beyond its LOV.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 13, 2021 727-57A0190 RB 12 of 23 REQUIREMENTS BULLETIN 727-57A0190