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Commercial Airplanes 727 Service Bulletin
SPECIAL ATTENTION Number: 727-53-0232 Original Issue: September 23, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Station (STA) 1183 - Aft Pressure Bulkhead Web Inspection, Repair and Preventive Modification.
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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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: September 23, 2009 727-53-0232 1 of 111
5.0
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 1 8 G. Manpower .............................................. 1 9 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
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 3
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 7 FIGURE 1: INSPECTION OF THE AREA AROUND THE HYDRAULIC LINE SUPPORT BRACKET [Group 1, Configuration 1; Group 2] .................................. 3 1 FIGURE 2: INSPECTION OF THE AREA WITHOUT THE HYDRAULIC LINE SUPPORT BRACKET [Group 1, Configuration 2] ....................................... 3 4 FIGURE 3: TRIM OUT CRACKS LESS THAN OR EQUAL TO 4 INCHES AT THE UPPER FASTENER LOCATION OF THE HYDRAULIC LINE SUPPORT BRACKET [Group 1, Configuration 1; Group 2 ] ................................................ 3 7 FIGURE 4: TRIM OUT CRACKS LESS THAN OR EQUAL TO 4 INCHES AT THE LOWER FASTENER LOCATION OF THE HYDRAULIC LINE SUPPORT BRACKET [Group 1, Configuration 1; Group 2 ] ................................................ 4 0 FIGURE 5: TRIM OUT CRACKS LESS THAN OR EQUAL TO 10 INCHES LONG AT THE HYDRAULIC LINE SUPPORT BRACKET LOCATION [Group 1, Configuration 1; Group 2] ....... 4 3
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FIGURE 6: FABRICATION OF PARTS FOR TYPICAL REPAIR FOR UPPER 4 INCH CRACK CUTOUT [Group 1, Configuration 1; Group 2] .............................. 4 6 FIGURE 7: TYPICAL REPAIR INSTALLATION FOR UPPER 4 INCH CRACK CUTOUT [Group 1, Configuration 1; Group 2] ................................... 5 3 FIGURE 8: FABRICATION OF PARTS FOR TYPICAL REPAIR FOR LOWER 4 INCH CRACK CUTOUT [Group 1, Configuration 1; Group 2] .............................. 5 9 FIGURE 9: TYPICAL REPAIR INSTALLATION FOR LOWER 4 INCH CRACK CUTOUT [Group 1, Configuration 1; Group 2] ................................... 6 6 FIGURE 10: FABRICATION OF PARTS FOR TYPICAL REPAIR FOR 10 INCH CRACK CUTOUT [Group 1, Configuration 1; Group 2] ................................... 7 2 FIGURE 11: TYPICAL REPAIR INSTALLATION FOR 10 INCH CRACK CUTOUT [Group 1, Configuration 1; Group 2] ........................................... 7 9 FIGURE 12: PREPARATION FOR INSTALLATION OF PREVENTIVE MODIFICATION DOUBLER [Group 1, Configuration 1; Group 2] .................................. 8 5 FIGURE 13: INSTALLATION OF PREVENTIVE MODIFICATION DOUBLER [Group 1, Configuration 1; Group 2 ] ................................................ 9 1 FIGURE 14: BULKHEAD WEB INSPECTION WITH UPPER 4 INCH CUTOUT REPAIR DOUBLER INSTALLED [Group 1, Configuration 1; Group 2] ....................... 9 6 FIGURE 15: BULKHEAD WEB INSPECTION WITH LOWER 4 INCH CUTOUT REPAIR DOUBLER INSTALLED [Group 1, Configuration 1; Group 2] ...................... 1 0 0 FIGURE 16: BULKHEAD WEB INSPECTION WITH 10 INCH CUTOUT REPAIR DOUBLER INSTALLED [Group 1, Configuration 1; Group 2] ............................. 1 0 4 FIGURE 17: BULKHEAD WEB INSPECTION WITH PREVENTIVE MODIFICATION DOUBLER INSTALLED [Group 1, Configuration 1; Group 2] ............................. 1 0 8
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Original Issue: September 23, 2009 727-53-0232 4 of 111 BOEING SERVICE BULLETIN 727-53-0232
Commercial Airplanes 727 Service Bulletin
SPECIAL ATTENTION SummaryNumber: 727-53-0232Original Issue: September 23, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Station (STA) 1183 - Aft Pressure Bulkhead Web Inspection, Repair and Preventive Modification.
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of this service bulletin will detect cracks if present in the aft pressure bulkhead web. A cracked aft pressure bulkhead web may result in difficulty in achieving or maintaining cabin pressurization, or result in rapid decompression.
Boeing received 13 reports of cracks in the aft pressure bulkhead web ranging from 0.75 inches to 11.8 inches in length at Left Buttock Line (LBL) 61, between Water Line (WL) 220 and WL 228. The cracks originated at the hydraulic line support brackets which were installed in production after airplane Line Number 1336, or in accordance with Service Bulletin 727-29-0057. The cracks were found on airplanes which had accumulated flight hours ranging from 14,939 to 39,369 and flight cycles ranging from 10,685 to 29,357. The cracks are attributed to fatigue of the aft pressure bulkhead web due to vibrations from the number 1 engine hydraulic pump line in addition to normal pressurization cycles. Material analysis revealed multiple crack initiation sites and no evidence of corrosion.
This service bulletin gives instructions for initial and repeat inspections of the aft pressure bulkhead web for any crack and to install a preventive modification if no crack is found or to install a repair if any crack is found.
Accomplishment of this service bulletin will make sure that cracks in the aft pressure bulkhead web are prevented or detected and repaired before the structural integrity of the aft pressure bulkhead is degraded.
Boeing Service Related Problem 727-SRP-53-0314 is related to this service bulletin.
ACTION Group 1, Configuration 1; Group 2:
Get access to the aft pressure bulkhead web. Do a detailed inspection for any crack in the aft pressure bulkhead web around the hydraulic line support bracket area. If no crack is found, either repeat the inspection in accordance with Paragraph 1.E., Compliance or accomplish the preventive modification in accordance with this service bulletin. If any crack is found, accomplish the repair in accordance with this service bulletin. If any crack is found to exceed the trim out limits given in this service bulletin contact Boeing for repair instructions and do the repair.
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Original Issue: September 23, 2009 727-53-0232 5 of 111
Group 1, Configuration 2:
Get access to the aft pressure bulkhead web. Do a detailed inspection for any crack in the aft pressure bulkhead web between WL 217 and WL 230, and LBL 48 and LBL 66. If no crack is found, repeat the detailed inspection at intervals given in Paragraph 1.E., Compliance. If any crack is found, contact Boeing for repair instructions and do the repair.
EFFECTIVITY All 727 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.
Federal Aviation Administration Airworthiness Directive FAA AD 98-11-03 R1 is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, repair and/or preventive modification procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials. Refer to Paragraph 2.C.2., Parts and Materials Supplied by the Operator.
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Original Issue: September 23, 2009 727-53-0232 6 of 111 BOEING SERVICE BULLETIN 727-53-0232
BOEING SERVICE BULLETIN 727-53-0232 STA 1183 AFT PRESSURE
BULKHEAD WEB
INSPECT THE AREA AROUND
THE HYDRAULIC LINE SUPPORT BRACKET FOR ANY CRACK. IF
ANY CRACK IS FOUND ACCOMPLISH THE REPAIR. IF
NO CRACK IS FOUND
ACCOMPLISH THE PREVENTIVE MODIFICATION. 1548918 STA 1183 AFT PRESSURE BULKHEAD Original Issue: September 23, 2009 727-53-0232
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Commercial Airplanes 727 Service Bulletin
SPECIAL ATTENTION Number: 727-53-0232 Original Issue: September 23, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Station (STA) 1183 - Aft Pressure Bulkhead Web Inspection, Repair and Preventive Modification.
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
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 Airplanes Line Number 1-1336 that did not have the 65-17944-84 support bracket installed in production.
-1 Airplanes that have incorporated Service Bulletin 727-29-0057.1 Airplanes that have not incorporated Service Bulletin 727-29-0057.2 727 Airplanes Line Number 1337-1832 that had the 65-17944-84 support bracket installed in production.
-2 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 1E5001 - E5011 1E5031 - E5068 1E5101 - E5116
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GroupVariable Number 1E5141 - E5143 1E5161 - E5164 1E5201 - E5203 1E5221 - E5245 1E5251 - E5252 1E5271 - E5281 1E5301 - E5306 1E5351 - E5353 1E5381 - E5382 1E5401 - E5424 1E5426 - E5429 1E5433 1E5435 1E5451 - E5455 1E5481 - E5483 1E5501 - E5502 1QA001 - QA045 2QA046 1QA051 - QA099 1QA101 - QA174 2QA175 - QA199 1QA201 - QA225 1QA301 - QA321 2QA322 1QA323 - QA344 2QA345 - QA349 1QA351 - QA371 2QA372 - QA376 2QA378 1QA401 - QA440 2QA441 - QA499 1QA501 - QA537 1QA551 - QA579
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GroupVariable Number 1QA581 - QA584 2QA585 1QA601 - QA654 2QA655 - QA688 1QA701 - QA743 2QA744 - QA753 1QA801 - QA805 1QA851 - QA898 2QA899 1QA901 - QA928 2QA929 - QA946 2QA949 1QB001 - QB002 1QB031 - QB042 2QB043 - QB049 2QB051 - QB068 1QB101 - QB110 1QB114 - QB119 1QB121 - QB149 2QB151 - QB158 1QB201 - QB203 2QB204 - QB220 1QB301 - QB310 2QB311 - QB316 1QB351 - QB352 1QB401 - QB407 1QB451 - QB453 2QB454 - QB458 1QB501 - QB539 2QB540 - QB575 2QB601 - QB629 2QB651 2QB701 - QB705
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