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Commercial Airplanes 727 Service Bulletin
SPECIAL ATTENTION Number: 727-57-0187 Original Issue: March 08, 2012 ATA System: 5714 SUBJECT: WINGS - Wing Center Box - Upper Skin and Rear Spar Upper Chord Inspection 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 2012 727-57-0187 1 of 49
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 2012 727-57-0187 2 of 49 BOEING SERVICE BULLETIN 727-57-0187
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 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2
1. Existing Data .......................................... 2 2
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 3 L. Interchangeability and Intermixability of Parts ........................... 2 3
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 5
1. Kits/Parts ............................................ 2 5
2. Parts and Materials Supplied by the Operator ........................ 2 5
3. Parts Modified and Reidentified ................................ 2 5
4. Parts Removed and Not Replaced .............................. 2 5 D. Parts Necessary to Change Spares ................................. 2 5 E. Special Tooling - Price and Availability ............................... 2 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 7 FIGURE 1: WINGS - WING CENTER BOX - INTERNAL FUEL TANK INSPECTION OF THE REAR SPAR UPPER CHORD HORIZONTAL FLANGE .......................... 3 2 FIGURE 2: WINGS - WING CENTER BOX - INTERNAL FUEL TANK INSPECTION OF THE REAR SPAR UPPER CHORD RADIUS [Group 1] .............................. 3 5 FIGURE 3: WINGS - WING CENTER BOX - INTERNAL FUEL TANK INSPECTION OF THE REAR SPAR UPPER CHORD RADIUS REQUIRING SEALANT REMOVAL [Group 2] .......... 3 8 FIGURE 4: WINGS - WING CENTER BOX - INTERNAL FUEL TANK INSPECTION OF THE REAR SPAR UPPER CHORD RADIUS WITHOUT SEALANT REMOVAL ................ 4 1 FIGURE 5: WINGS - WING CENTER BOX - EXTERNAL FUEL TANK INSPECTION OF THE UPPER SKIN AND PRESSURE SEAL AT STA 870 ............................. 4 4 FIGURE 6: WINGS - WING CENTER SECTION - REAR SPAR UPPER CHORD - INTERNAL FUEL TANK SEALANT APPLICATION ................................... 4 7
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Commercial Airplanes 727 Service Bulletin
SPECIAL ATTENTION SummaryNumber: 727-57-0187Original Issue: March 08, 2012 ATA System: 5714 SUBJECT: WINGS - Wing Center Box - Upper Skin and Rear Spar Upper Chord Inspection BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions to inspect the upper skin and the rear spar upper chord of the wing center box, at Body Station (STA) 870 for cracking or corrosion. The upper skin and the rear spar upper chord of the wing center box are classified as principal structural elements. If the work in this service bulletin is not done, undetected cracking or corrosion in this area could severely limit the load carrying capabilities of the structure which could result in the inability of the remaining structure to carry limit load which would preclude the continued safe flight of the airplane.
Several operators have reported spanwise cracks and corrosion in the upper skin and rear spar upper chord between Left Buttock Line (LBL) 70.50 and Right Buttock Line (RBL) 70.50, at STA 870. The crack sizes ranged from 0.125 inches to 12 inches. The airplanes had accumulated between 31, 679 and 61,359 total flight hours and between 17,754 and 58,796 total flight cycles. Analysis has shown that the cracks are a result of stress corrosion which is a common problem in the 7178-T651 and 7178-T6511 aluminum from which the wing center box upper skin and some rear spar upper chords are manufactured. All 727-100/-200 airplanes were delivered with 7178-T651 aluminum plate upper skin panels and therefore all these airplanes are affected.
Corrosion occurrences in the wing center section are known issues. Boeing Service Bulletin 727-57-0170 was issued for inspections and application of a corrosion inhibitor for external portions of the wing center section.
Additionally, multiple Structural Item Interim Advisories (SIIA) were issued for corrosion incidences to wing center section stiffeners, webs, upper skins and chords at the rear spar. However, none of these documents resolves the issue of cracking or corrosion at the wing center box upper skin and rear spar. Accomplishment of this service bulletin will make sure that cracking or corrosion at the upper skin and the rear spar upper chord at the wing center box, STA 870 are detected.
Boeing Service Related Problem (SRP) 727-SRP-52-0228 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 727 FTD 57-08003 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
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Original Issue: March 08, 2012 727-57-0187 5 of 49
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., ComplianceNoAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/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 Defuel all tanks. Get access to the lower surface of the wing center box upper skin near the aft rear spar through the center fuel tank. Between LBL 70.50 and RBL 70.50, at STA 870, do the following inspections: Do a High Frequency Eddy Current (HFEC) inspection or a detailed inspection for cracking around the forward fastener row in the rear spar upper chord horizontal flange. Do a Low Frequency Eddy Current (LFEC) inspection around the aft fastener row in the rear spar upper chord horizontal flange for cracking in the upper skin and the rear spar upper chord horizontal flange. Do a HFEC inspection or a detailed inspection for cracking in the rear spar upper chord radius. If any crack is found, contact Boeing for repair instructions and do the repair. If no cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E., Compliance.
Get access to the upper surface of the wing center box upper skin near the rear spar by removing floor panels at the wing center box. Between LBL 70.50 and RBL 70.50, at STA 870, do the following inspections: Do a detailed inspection or a HFEC inspection for cracking in the upper skin around the forward fastener row common to the rear spar upper chord horizontal flange. Do a detailed inspection for any damage, cracking or corrosion in the pressure seal. If any damage, cracking or corrosion is found, contact Boeing for repair instructions and do the repair. If no cracking is found, do the repeat inspections at the intervals given in Paragraph 1.E., Compliance.
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 Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection procedures given in this service bulletin.
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MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: March 08, 2012 727-57-0187 7 of 49 BOEING SERVICE BULLETIN 727-57-0187
BOEING SERVICE BULLETIN 727-57-0187 EXTERNAL FUEL TANK INSPECTION:
INSPECT THE UPPER SKIN FOR CRACKING AND
INSPECT THE PRESSURE SEAL FOR DAMAGE, CRACKING AND CORROSION. IF ANY DAMAGE,
CRACKING OR CORROSION IS FOUND, CONTACT
BOEING FOR REPAIR INSTRUCTIONS AND DO THE REPAIR INSTRUCTED BY BOEING.
STA 870 STA 740 RBL
70.50 LBL
70.50
INSPECTION AREA
UPPER PRESSURE
SKIN SEAL INTERNAL FUEL TANK INSPECTION:
INSPECT THE UPPER SKIN, THE
REAR SPAR UPPER CHORD
HORIZONTAL FLANGE AND THE
REAR SPAR UPPER CHORD RADIUS FOR CRACKING. IF ANY REAR SPAR
CRACK IS FOUND, CONTACT UPPER CHORD
BOEING FOR REPAIR
INSTRUCTIONS AND DO THE REPAIR INSTRUCTED BY BOEING.
A-A - REAR SPAR WEB 2121797 Original Issue: March 08, 2012 BOEING PROPRIETARY - 727-57-0187 Copyright © Unpublished Work - See page 1 for details. 8 of 49
Commercial Airplanes 727 Service Bulletin
SPECIAL ATTENTION Number: 727-57-0187 Original Issue: March 08, 2012 ATA System: 5714 SUBJECT: WINGS - Wing Center Box - Upper Skin and Rear Spar Upper Chord Inspection BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes
DESCRIPTIONCONFIGURATIONGROUP 727, 727C, 727-100, 727-100C, and 727-200 airplanes with bladder fuel cells at the wing center section.
-1 727, 727-100 and 727-200, 727-200F airplanes with an integral fuel tank at the wing center section.
-2 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 1E3021 - E3040 1E3059
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GroupVariable Number 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 - E3522 2E3523 1E3551 - E3553 1E3571 - E3578 1E3601 - E3604 1E3621 - E3622 1E3651 - E3655 1E3677 1E3681 - E3682 2E3683 - E3684 1E3701 - E3704 1E3751 - E3755 1E3781 - E3784 1E5001 - E5011 1E5031 - E5068 1E5101 - E5116 1E5141 - E5143 1E5161 - E5164 1E5201 - E5203 1E5221 - E5245
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GroupVariable Number 1E5251 - E5252 1E5271 - E5281 1E5301 - E5306 1E5351 - E5353 1E5381 - E5382 1E5401 - E5424 1E5426 - E5429 1E5433 1E5435 1E5451 - E5455 1E5481 - E5483 1E5501 - E5502 1QA001 - QA021 2QA022 - QA023 1QA024 - QA025 2QA026 - QA046 1QA051 - QA058 2QA059 - QA099 1QA101 - QA141 2QA142 - QA199 1QA201 - QA225 1QA301 - QA316 2QA317 - QA324 1QA325 - QA329 2QA330 - QA349 1QA351 - QA368 2QA369 - QA376 2QA378 1QA401 - QA428 2QA429 - QA499 1QA501 - QA532 2QA533 - QA537 1QA551 - QA567
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GroupVariable Number 2QA568 - QA573 1QA574 - QA575 2QA576 1QA577 - QA578 2QA579 2QA581 - QA585 1QA601 - QA626 2QA627 - QA688 1QA701 - QA724 2QA725 - QA753 1QA801 - QA805 1QA851 - QA853 2QA854 - QA899 1QA901 - QA906 2QA907 - QA946 2QA949 1QB001 - QB002 1QB031 - QB033 2QB034 - QB049 2QB051 - QB068 1QB101 - QB102 2QB103 - QB110 2QB114 - QB119 2QB121 - QB149 2QB151 - QB158 2QB201 - QB220 2QB301 - QB316 2QB351 - QB352 2QB401 - QB407 2QB451 - QB458 2QB501 - QB575 2QB601 - QB629 2QB651
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