Service Bulletin - Regulations.gov

CommercialAirplaneGroup

727Service Bulletin

Number: 727-57-0112 Revision Transmittal SheetDate: September 2, 1970Revision 5: July 31, 1997ATA System: 5712

SUBJECT: WINGS - RIB UPPER CHORD AT BL 70.5 - INSPECTION, MODIFICATION, AND REPAIR

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed by Revision 4 of this service bulletin.

More work is necessary on Group 1 airplanes changed by Revisions 2 or 3, Part V of the AccomplishmentInstructions of this service bulletin. On Group 1 Airplanes with the Major Repair/Preventive Modificationinstalled, it is necessary to make an inspection at BL 70.5 for a repair strap. If a strap is not installed, it isnecessary to make an inspection of the frame for cracks.

SUMMARY

This revision is sent to tell operators that new kits are available for Group 1 and 2 Airplanes. The drawingsused to install the kits are sent with this revision (the drawings have been revised since the release of Noticeof Status Change 3). The format used to show the removal of parts and installation of the kits has changed.Also repairs, that operators have requested, are included, and the compliance information has been clarified.

This revision is sent to tell the 727 airplane operators that this service bulletin has been identified by the 727Structures Working Group (SWG), and the structural change and inspection given in this service bulletin arerecommended to be included on applicable 727 airplanes. The change and inspection given in this servicebulletin must be included at the times given in the Description and Accomplishment Instructions.

As a result of the Aging Fleet Conference held by the FAA, the 727 SWG was made and included 727 airlineoperators from a large part of the high time 727 fleet, persons from the Boeing Company, and monitors fromthe FAA. The SWG examined the structural changes and inspections given in applicable Boeing servicebulletins. A selection of these service bulletins was made that contain structural changes and inspectionsthat are important to the continued structural airworthiness of 727 airplanes. The structural changes given inthese service bulletins are recommended to be included, and the inspections are recommended to be a partof the regularly scheduled maintenance on applicable 727 airplanes.

The data given in Notice of Status Change 727-57-0112 NSC 1, 2 and 3 are included in this revision.

Paragraph I.A., Effectivity, shows changes of airplane operators. Each operator should examine theEffectivity paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph I.A., Effectivity, to show the locationof important changes. Pages with a revision number and date, but no vertical lines, have no importantchanges.

REVISION HISTORY

Initial Release: September 2, 1970 Revision 1: April 23, 1976 Revision 2: May 19,1988Revision 3: December 21, 1989 Revision 4: October 29, 1992 Revision 5: July 31, 1997

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207


727Service Bulletin

Number: 727-57-0112 SummaryDate: September 2, 1970Revision 5: July 31, 1997ATA System: 5712


BACKGROUND

The Structures Working Group (SWG) hasexamined the structural change and inspection inthis service bulletin, and recommends that thechange and inspection be included on 727airplanes.

During a 727 primary fatigue test at Boeing, twocracks were found in the upper vertical flange of thewing-to-body rib upper chord at Body Station 760.One crack in the rib upper chord was between thetwo aft fastener holes of the frame at Body Station760.95. The other crack in the rib upper chord wasimmediately aft of the lower fastener hole in theframe.

To increase the fatigue life of the rib chord and toreduce the risk of repair and maintenance notscheduled, make the change given in this servicebulletin.

ACTION (PRR 24791-R and PRR 24803-R)

As recommended by the 727 SWG, make thePreventive Modification or Large Repair structuralchange given in the Accomplishment Instructions ator before the airplane collects a total of 60,000flights, and make the inspection given in theAccomplishment Instructions, Part II.A.1, Inspection,at or before the airplane collects a total of 14,000flights, or within 3,000 flights, whichever occurslater.

If no cracks are found, increase the hole diameter,cold work the hole, and install a new fastener in sixplaces. Continue the inspection at regularlyscheduled times as given in the AccomplishmentInstructions, Part II.A.2, or B.1, Inspection. Theapproved time between one inspection and thesubsequent inspection must not be more than14,000 flights. To stop the inspection given in thisservice bulletin, do the preventive modification orlarge repair.

If cracks are found, make a change to the rib upperchord as given in this service bulletin.

EFFECTIVITY

All 727 airplanes, divided into 2 groups.

MANPOWER

See Service Bulletin

MATERIAL INFORMATION

Boeing supplied kits and Operator supplied Parts.Refer to Paragraph I.G., Material - Price andAvailability.

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207 Summary Page 1 of 2

BOEING SERVICE BULLETIN 727-57-0112

STA

660

760.95

STA

STA

870

970

STA

MODIFICATION OR REPAIR

INSTALL PREVENTIVE

RIB UPPER CHORD

INSPECT 6 FASTENER

HOLES IN WING−TO−BODY

R44683

Sep 2/70REV 5: Jul 31/97 Summary Page 2 of 2


727Service Bulletin

Number: 727-57-0112Date: September 2, 1970Revision 5: July 31, 1997ATA System: 5712


I. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-9825, Part 3 for Airplane Variable Number, LineNumber, and Serial Number data.

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

A.J. WALTER AVIATION LTD (AJW)1 E0210 E3343

ACES (ACE)1 E3781 E3783 QA633 QB619 QD031 QD5042 QD904

ADC AIRLINES (ADN)1 QA517 QA521

AECA AIRLINES (AED)1 E0341

AERO CONTROLS, INC (AEO)1 QA415 QA418 QA422

AERO COSTA RICA (AOR)1 E0305

AERO PERU (PER)1 E3286-E3288 QA040 QD6072 QD685

AERO REPUBLICA (REU)1 E3146 E3149

AERO UNION (AUC)1 E0328

AEROCAR AVIATION CORPORATION (AAH)1 QA872 QA874 QA917

Sep 2/70 727-57-0112REV 5: Jul 31/97 Page 1 of 163


AEROEJECUTIVO (AEJ)1 E0404 E0423 QA225 QA608 QA611 QA628

QA632 QD001 QD004 QD007-QD012

AEROLINEAS ARGENTINAS (ARG)1 E3222 QD603

AEROLINEAS CARGUERAS S.A. (AEROCAR) (CRQ)1 E3071 E3575

AEROLINEAS INTERNACIONALES (MXC)1 E0325 E0334 QA129

AEROMEXPRESS (MEX)2 QD972

AERON EQUITIES CORP (AAV)1 E3148 QA618 QA622

AEROSUCRE S.A. (SUS)1 E0346 E3221 E3402 QA021

AEROSUR S.A. (REO)1 E0312 E0332 E0345

AGASSI ENTERPRISES (AGA)1 E3420

AIMS LTD (MES)1 E0212

AIR ALFA (ALV)1 QB102

AIR ALGERIE (ALG)1 QA574-QA576 QB451-QB458

AIR ATLANTIC NIGERIA LTD (NGE)1 E0041

AIR COLOMBIA (CLM)1 E3519

AIR DABIA (DBI)1 QA701

AIR FRANCE (AFA)1 QA5622 QD764-QD765

AIR GABON S.A. (GBN)2 QD763

AIR JAMAICA (JAM)2 QD282-QD283

AIR NACOIA LDA (NAO)1 E5114 QA871

Sep 2/70 727-57-0112REV 5: Jul 31/97 2


AIR SLOVAKIA (SLO)1 QB103-QB104

AIR TRANSPORT OFFICE (TOZ)1 QA501

AIR 4000 INC (FTO)1 QA333

AIRCRAFT MANAGEMENT COMPANY LTD (AMI)1 E3509

AL-ANWA EST. (SVE)2 QD407

AL-ATHEER EST (ALN)1 E3410

ALLCANADA EXPRESS LTD. (EXM)1 E36522 QD662-QD663

ALLEGRO AIR (AEG)1 QA675 QA902 QA906

AMERICAN AIRLINES, INC. (AAL)1 QA114 QA119-QA120 QA123-QA124 QA136 QA142-QA149 QA158-QA199

QA854 QA856-QA869 QB801-QB810

AMERICAN INTERNATIONAL AIRWAYS, INC. (CKF)1 E0336 E5050 QA107-QA109 QA111-QA113 QA117 QA132

QA135 QA139 QA155 QA157 QA705

AMERICAN TRANS AIR (AAT)1 QA374-QA376 QA378 QA928 QB066-QB068 QB618 QB620-QB623

QB625-QB628 QD702 QD7912 QD683 QD951-QD952

AMERICANA DE AVIATION S. A. (AMY)1 E3751 QB305

AMERIJET INTERNATIONAL, INC. (AMJ)1 E0344 E3028 E3145 E5161 E5403 QA336

QA727 QA875 QA8862 QD206 QD211-QD212 QD781

AMWAY CORPORATION (AMA)1 E3681

ANGOLA AIR CHARTER (AOH)1 E0333

ANSETT AUSTRALIA (ANS)1 QD034 QD0402 QD043-QD046

Sep 2/70 727-57-0112REV 5: Jul 31/97 3


ARIANA AFGAN AIRLINES CO., LTD (AFG)1 E5410 E54242 QD767-QD768

ARRIVA AIR INTERNATIONAL (ARV)1 QA002

ASIAN EXPRESS AIRLINES (EXZ)2 QL007

ATASCO USA, INC. (ATJ)1 E0032 QB301-QB304

AVENSA (AVN)1 E0034 E0036 E3072 E3244 E3246 E3248

E3511 E3654 QA036 QA039 QA042-QA043 QA853QD121 QD124-QD126 QD444

AVIANCA (AVI)1 QA572 QD553-QD554

AVIATION CAPITAL CORPORATION (ACD)1 E0039

AVIATION LEASING GROUP (ALW)1 E0317

AVIATION PROFESSIONAL CORP (PRP)1 QA630-QA631

AVIOGENEX AIR TRANSPORT (AVG)1 QD191-QD192 QD518

AZERBAIJAN AIRLINES (BAKU) (AHY)1 QA211-QA212

BAHRIAN AMRI FLIGHT (BHR)1 QD451

BAKRIE AVIATION INC. (FES)1 E3346

BELGIAN AIR FORCE (BLG)1 E5351-E5352

BIN MAHFOOZ AVIATION (BMV)1 QA566-QA567

BLENHEIM AVIATION (BLM)1 QD305

BRADLEY AIR SERVICES/FIRST AIR (BRS)1 E3065 E5112 E5141 E5482 QA6142 QD207 QD210

C-S AVIATION SERVICES INC. (CSV)1 E0302-E0303 E0307 E0315 E0320 E0326

Sep 2/70 727-57-0112REV 5: Jul 31/97 4


CAPITAL CARGO AIRLINES (CCA)1 QA371 QD087 QD701

CAPRICORN FLIGHTS (CPR)1 E3075 E3520

CARNIVAL AIR (CVL)1 QA636 QA641 QD3042 QD822-QD823 QD953

CHINESE AIR FORCE (CAF)1 E3506 E3512 E5409 E5435

CIS AIR HOLDINGS, LTD. (CIS)1 QA718 QA721-QA722

CLAY LACY AVIATION, INC. (CYA)1 E3035 E3077

COMPAGNIE AERIENNE BELAIR ILE DE FRANCE (SMH)1 QA573

CONNOR AIRCRAFT (COD)1 QA366

CONSTELLATION INTERNATIONAL AIRLINES (COT)2 QD782

CONTINENTAL AIRLINES, INC. (CAL)1 QA020 QA059-QA061 QA063-QA065 QA067 QA069-QA072 QA331

QA339-QA342 QA345-QA349 QA873 QA882 QA885 QA890-QA896QB034 QB036 QB039-QB040 QB901-QB904 QD501-QD502 QD505QD507-QD510

2 QD905 QD909 QD931-QD932

CONTINENTAL AVIATION SERVICES INC. (CVS)1 E3407

COOK AIRCRAFT LEASING (CKL)1 E3504-E3505

CORP AIR INC. (EKO)1 E5418

CORSAIR (CRA)1 E3011 E3508

CUSTOM AIR SERVICES INC. (CUS)1 E3205 QA343 QA661

CYPRUS TURKISH AIRWAYS (KHT)1 QD321-QD322 QD3242 QD766

D. J. AEROSPACE (DJA)1 E0351

Sep 2/70 727-57-0112REV 5: Jul 31/97 5


DALLAH AVCO (AVO)1 E3038

DALLAS AEROSPACE, INC. (DAA)1 QA358

DAVIS OIL CO. (DOC)1 E3206

DELTA AIR LINES, INC. (DAL)1 QA073-QA079 QA081-QA092 QA096-QA099 QA647 QA649 QA663-QA665

QA907 QA909-QA916 QA919-QA921 QA929-QA933 QA939-QA946 QA949QB501-QB558 QB560-QB575

DHL CORPORATION/WORLDWIDE COURIER EXP. (DHL)1 E0030 E0124 E0342 E3622 E5046-E5047 E5273-E5274

E5281 E5382 E5402 QA552-QA553 QA555-QA556 QA563-QA564QA646

2 QD991-QD992

DHL LATIN AMERICA GROUP AIRLINES (DHA)1 E3073 QB038

DIGEX AERO CARGO (DGX)1 E5481

DOMINICANA AIRLINES (DOM)1 E3755 QD351

EAS EUROPE AIRLINES (EUR)1 QA855

EASTERN AIR LINES, INC. (EAL)1 QA643

ECUATORIANA AIRLINES (ECU)1 QD445 QD604

EMERY WORLDWIDE AIRLINES (EAF)1 E0313-E0314

EUROPEAN AIR TRANSPORT (EPT)1 E3074 E3076 E3701-E3703 QA115 QA137 QA150-QA152

QA156 QB307

EUROPEAN AVIATION AIR CHARTER LTD (EUL)1 E3022

EVERGREEN INTERNATIONAL AIRLINES (EVR)1 E3101 E3151 E3276 E5104-E5105 E5108

EXPRESS ONE INTERNATIONAL, INC. (EOI)1 E0421-E0422 E3117 E3347-E3348 E3350 E3602 QA014

QA062 QA101 QA116 QA121 QA125-QA127 QA138QA140-QA141 QA656 QA713 QB624 QD032 QD441QD453

2 QD821 QD824-QD826

Sep 2/70 727-57-0112REV 5: Jul 31/97 6


FALCON AIR EXPRESS (FAX)1 QA329 QA716

FAMCO AVIATION AND MARITIME SERVICES LTD (FAM)1 E5353

FAUCETT (COMPANIA DE AVIATION S.A. (FCT)1 E3068 QA901 QB042

FEDERAL AVIATION ADMINISTRATION (FAA)1 E5241

FEDERAL EXPRESS (FED)1 E0120 E0122-E0123 E0125-E0129 E0131-E0132 E0134-E0138 E3256-E3261

E3263-E3274 E3277-E3281 E3283 E3290 E5048-E5049 E5052-E5054E5056-E5057 E5063 E5067 E5101-E5102 E5163-E5164 E5221-E5224E5226 E5230 E5233-E5234 E5238-E5240 E5242 E5408E5420 E5454 QA093-QA095 QA644-QA645 QA648 QA650QA653 QA658 QA677 QA679-QA680 QA897-QA899 QA922-QA926QB601-QB617 QD035-QD039 QD041-QD042

2 QD201-QD205 QD208-QD209 QD213-QD239 QD691-QD692 QL501-QL515

FINOVA (GRB)1 QA627

FIRST SECURITY BANK OF UTAH (FSB)1 QA335 QB114

FLY LINHAS AEREAS (FLF)1 QA579 QA585

FORBES, INC. (FRB)1 E3655

FUNAIR (FUN)1 E3419

GE CAPITAL AVIATION SERVICES, INC. (GEH)1 E0038 E0040 E3241 E3245 E3247 E3253

QA206 QA304 QA306 QA310 QA313-QA314 QA325QA328

GENERAL AVIATION PTY LTD (GEL)1 QB316

GEORGETOWN AIRCRAFT SERVICES (GEO)1 E0216

GLENHOLME ENTERPRISES INC. (GLE)1 E3144

GLOBAL AIRCRAFT SALES (GAC)1 QA057 QA851

GM AIRLINES (GMA)1 QB110

Sep 2/70 727-57-0112REV 5: Jul 31/97 7


GOMAIR (GOM)1 E3753

GOVERNMENT OF SENEGAL (SEN)2 QD402

GOVT. OF BURKINA FASO (HTV)1 E3176

GPA GROUP LTD. (GUI)1 QB037 QD571

GRAND HOLDINGS (GRD)1 E3510 QA105 QA122 QA337-QA338

HAPAG LLOYD (HAP)1 E3114

HCL AVIATION, INC. (HCL)1 E0308 E0316 E0324 E0338 QA638 QA671

QD5812 QD902 QD954

HMS AIRWAYS (HSA)1 E30052 QD401

HOLIDAY AIR (HOI)1 QA642

HUNTING CARGO AIRLINES INC. (HCA)1 QA022 QA033 QA037 QA106 QA118 QA131

QA133 QA615 QA888 QD506

IBERIA (LINEAS AEREAS DE ESPANA S.A.) (IBE)1 QB124 QB127 QB129-QB133 QB135-QB145 QB147-QB149 QB151-QB153

QB155-QB158

IDG (CAYMAN) LTD (IDG)1 E3150

IMPERIAL PALACE AIR LTD. (IPA)1 E0213

INTER AIR (ITI)1 E0318-E0319

INTERNATIONAL AIR LEASES (IAL)1 QA673-QA674 QA676 QA918

INTERNATIONAL AIRLINE SUPPORT GROUP (ASG)1 E0202 E0205

INTERNATIONAL PACIFIC TRADING CO. (IPT)1 E3032-E3033 E3069 E3289

Sep 2/70 727-57-0112REV 5: Jul 31/97 8


IRAN AIR (IRN)1 E0204 E3118 E3472-E3473 QD101-QD1042 QD761-QD762

IRAQI AIRWAYS (IRQ)2 QD421-QD426

ISLENA DE AVIACION (ISD)1 E3345 QA704 QB002

ISTANBUL AIRLINES (IST)1 QA557-QA558 QB310-QB314

ITAPEMIRIM TRANSPORTES AEREOS S.A. (ITP)1 E3152 E3344 E5279 E5406 QA678 QD583

JET AVIONICS SYSTEMS INC (JAV)1 QA602

JETAIR TRADING & LEASING INT'L, INC. (JTL)1 QB033

JUGOSLOVENSKI AEROTRANSPORT (JAT)1 QD142-QD149

KABO AIR LIMITED (KAB)1 E0103 E0107 QA019 QA330 QA332 QA334

QA604 QA620

KELOWNA FLIGHTCRAFT AIR CHARTER LTD. (KEL)1 E5001 E5059-E5062 E5201 E5228-E5229 E5428 QA359

QA609-QA610 QA870 QA876 QA879-QA880 QA883-QA884

KITTY HAWK AIR CARGO, INC. (KHC)1 QA110 QA128 QA134 QA153-QA154 QA344 QA372-QA373

QA728-QA7292 QD281 QD284

KIWI INTERNATIONAL AIR LINES (KIW)1 QA629 QA635 QA637 QA639-QA640 QA654-QA655 QA657

QA708-QA709 QA714 QB115

KUWAIT AIRWAYS CORPORATION (KUW)2 QD801

LAKER AIRWAYS (LAK)1 QD085-QD086

LEAR ASTRONICS (LEA)1 QA411

LIBYAN ARAB (LAA)1 QA316 QA318-QA322 QB6512 QA323-QA324

LINEAS AEREAS CANARIAS (LCI)1 QD601-QD602

Sep 2/70 727-57-0112REV 5: Jul 31/97 9


LINEAS AEREAS SURAMERICANAS (LAR)1 E0119 E5451 E5453

LLOYD AERO BOLIVIANO (LAB)1 E3102 E3522 E5421 QD1612 QD162-QD163 QL006

LUFTHANSA CARGO INDIA PRIVATE LTD (LUI)1 QD512-QD513 QD516-QD517

MEXICAN AIR FORCE (MXA)1 E3171-E3172 E3175

MEXICANA (CMA)1 QA041 QB043-QB049 QB051-QB058 QB060-QB064 QD556-QD557 QD605

MEXICARGO (MXO)1 QA616

MIAMI AIR INTERNATIONAL INC. (MIB)1 QA659-QA660 QA662 QA669-QA670 QA6722 QB219

MIBA MINING CO. (MIZ)1 E3275

MID EAST JET INC (SKL)1 E3421

MILLION AIR (MIL)1 E0301 E0322 E0329-E0330

MMG AVIATION (MME)1 E0209

MONGOLIAN AIRLINES MIAT (MNG)1 QA015 QA034-QA035

NATIONAL AIRLINES (NAW)1 QD446

NATIONS AIR EXPRESS (NAX)1 QA504

NATIONWIDE AIR (NWR)1 E3517 E3573

NEW ACS LIMITED (NEC)1 QA355

NIGERIA, GOV OF (NGA)2 QL081

NOMADS, INC. (NOM)2 QD827

NORTHERN AIR CARGO (NAC)1 E0340

Sep 2/70 727-57-0112REV 5: Jul 31/97 10


NORTHWEST AIRLINES, INC. (NWA)1 QA651-QA652 QA667-QA668 QA681-QA684 QA686 QA706 QA725

QA734-QA743 QA745-QA753 QD442 QD447-QD4492 QD711-QD717

OCCIDENTAL PETROLEUM CORP (OCP)1 E3004

OKADA AIR (OKD)1 QA703 QB116 QB308

OLYMPIC AIRWAYS (OLY)1 QA001 QA801-QA805 QB117-QB118 QB309

OMNI AIR EXPRESS (OAX) (OAE)1 E5142 QA427-QA428

ORCA BAY AVIATION (OBA)1 QA066

ORIENT EXPRESS (CAK)1 QA606 QA626 QA889

PACIFIC AIR EXPRESS AUSTRALIA PTY LTD (PAE)1 QA044

PACIFIC INTERNATIONAL AIRLINES, S.A. (PCF)1 E0304 E0310

PANAGRA AIRWAYS (PAG)1 E0349

PANAVIA (PVI)1 E3341

PEGUSUS CAPITAL CORPORATION (PSS)1 QA024 QA702 QA720 QA723 QD088 QD450

QD606

PLM TRANSPORTATION EQUIPMENT CORP. (PLI)1 QA711

PRECISION AIR LTD (PRT)2 QD906

PRESTIGE AIRWAYS (PAR)1 QA505 QA518 QA523 QA581

QATAR AIRWAYS (QTA)1 QB065 QD452 QD5722 QD475

QATAR AMIRI FLIGHT (QAT)2 QD403

QUAKER COAL COMPANY (QCC)1 E3014 QA045-QA046 QA068

Sep 2/70 727-57-0112REV 5: Jul 31/97 11


R. B. HARIRI (RBH)2 QD973 QE002

RATHEON E-SYSTEMS INC (ESM)2 QD908

REEVE ALEUTIAN AIRWAYS, INC. (RVV)1 E5035 E5040

RELIANCE GROUP, INC. (RGI)1 E3285

REPUBLIC OF CAMEROON (CMR)2 QD410

REPUBLIC OF ZAIRE (ZAR)1 E0214

ROTHSCHILD AUSTRALIA AIRCRAFT LEASING (ROI)1 E5501

ROYAL AIR MAROC (RAM)1 QA583-QA584

ROYAL AIRLINES (ROY)1 QB035 QD0332 QD903 QL003 QL008 QL031-QL032

ROYAL NEW ZEALAND AIR FORCE (RNZ)1 E5065 E5068

RYAN INTERNATIONAL AIRLINES (RYN)1 E0418 E0420 E3003 E3201 E3411 E3415-E3418

E5003 E5007-E5011 E5031-E5032 E5039 E5041-E5042 E5058E5381 E5411 E5413 E5415 E5433 E5483E5502 QA416 QA419-QA421 QA423-QA426 QA666

SABRE AIRWAYS (SBE)1 QD005 QD123

SAETA S.A. (SAE)1 E0414 E3576 QA733 QA744 QD302

SAFAIR FREIGHTERS (PTY) LTD. (SFA)1 E0331 QB106 QB108 QB119 QB351-QB3522 QD661 QD971

SAMCO (SMO)1 E3604

SCIBE-AIRLIFT KINSHASA (SAK)1 E0208 E3451

SEAGREEN AIR TRANSPORT (SEG)1 E0104 E0211 E5419

SERVICIOS AEREOS NACIONALES, S.A. (SAN)1 E3684

Sep 2/70 727-57-0112REV 5: Jul 31/97 12


SIGAIR (SIG)1 E0207

SKY TREK (SKY)1 QA717 QB107 QD006

SKYLINE INTERNATIONAL, LTD. (SKT)1 E3006

STARCOM LTD (STK)1 QA369-QA370

STELLAR AVIATION (STL)1 E0347

STERLING EUROPEAN AIRLINES (STR)1 QD4432 QD164 QD427 QD684 QD907 QL001

SUN COUNTRY AIRLINES (SCA)1 QA687-QA688 QA710 QB629 QD303 QD555 QD558

QD5822 QL002 QL004-QL005

SUN PACIFIC INTERNATIONAL (SUI)1 E3452 QA877 QA881 QD5032 QD828

SUNWORLD INTERNATIONAL AIRLINES (SUO)1 QA732

SYRIAN ARAB AIRLINES (SYR)1 QD471-QD4732 QD802-QD804

TAESA (TES)1 E0035 E0311 E0348 E0413 E3024 E3174

E3553 E5455

TATARSTAN FLIGHT LTD. (TAK)1 E3507

THE AGES GROUP (AGJ)1 QB101

THE K. B. A. FOUNDATION (KBA)1 E3574

THE LIMITED, INC. (LII)1 E3704

TOP AIR (TOP)1 QD325 QD330 QD511

TRACINDA CORPORATION (TRD)1 E3284

Sep 2/70 727-57-0112REV 5: Jul 31/97 13


TRANS WORLD AIRLINES, INC. (TWA)1 E0406-E0408 E0412 E0416-E0417 E0419 QA502 QA509-QA515

QA519-QA520 QA522 QA525-QA527 QA529-QA537 QB201-QB2032 QB204-QB218 QB220

TRANSAFRIK (TCL)1 E0335 E0343 E3025 E3242 E3577 E3601

TRANSMERIDIAN AIRLINES (TAL)1 QA730-QA731

TRANSPORTES AEREOS MILITAR EQUATORIANOS (TAM)1 E3513 E3516 E3682 QB105 QB109 QB3152 QD741

TRANSPORTES AEREOS PRESIDENCIALES (MXG)1 E3037

TRANSTEL S.A. (TTL)1 QA508 QD514

TRIANGLE AIRCRAFT SERVICES CORP. (TRI)2 QD910

TRIAX AIRLINES (TIX)1 E3603 QB031

TRITON ENERGY (TRY)1 E0206

TUNISAIR (TUN)1 QA571 QB401-QB405 QB407

TUR EUROPEAN AIRWAYS (TOU)1 QB306

TURKISH AIRLINES (THY)1 QD327-QD329

UNITED AIR LINES, INC. (UAL)1 QA401-QA402 QA404-QA405 QA408 QA429-QA473 QA475-QA499 QB701-QB705

UNITED PARCEL SERVICE (UPS)1 E5002 E5004-E5006 E5033-E5034 E5036 E5038 E5043-E5045

E5051 E5106-E5107 E5109-E5111 E5113 E5115-E5116 E5162E5225 E5227 E5231-E5232 E5235-E5237 E5243-E5245 E5251-E5252E5271 E5275-E5276 E5280 E5301-E5306 E5401 E5405E5417 E5422-E5423 E5426-E5427 E5429 QA927 QA934-QA938QD551-QD552

UNITED STATES AIR FORCE (USF)1 E3061 E3063 E3066-E3067

UNITED STATES MARSHAL'S SERVICE (USV)1 E0215 E3059 QA726

Sep 2/70 727-57-0112REV 5: Jul 31/97 14


USAIR SHUTTLE (TSI)1 QA010-QA012 QA017-QA018 QA617 QA619 QA623 QA625

QA878 QA8872 QD474

USAIR, INC. (USA)1 QA026-QA028 QA030-QA0322 QD681-QD682

USAL, LTD. (ULL)1 E3523

VALLEJO CORPORATION (VAC)1 E3683

VARIG AIRLINES (VAR)1 E3752 E3754 E5272 E5407 E5412

VASP (VSP)1 QB041 QD515

VIASA AIRWAYS (VIA)1 QB123 QB125-QB126 QB128 QB134

VICA - VIACAO CHARTER AEREA LTDA (TCT)1 QA908

WEDGE TRANSPORTATION (WST)2 QE001

WESTFIELD AVIATION LTD. (WEF)1 E0350

WETRAFA AIRLIFT (WET)1 E0140

WILMINGTON TRUST CO. (WTC)1 QA601 QA603 QA605 QA612-QA613 QA624

YEMEN AIRWAYS (YEM)2 QD621-QD624 QD641

Sep 2/70 727-57-0112REV 5: Jul 31/97 15


IDENTIFICATION BY VARIABLE NUMBER

GROUP 1E0001-E0042 E0101-E0140 E0201-E0216 E0301-E0351 E0401-E0423 E3001-E3006E3011-E3014 E3021-E3040 E3059 E3061-E3077 E3101-E3103 E3111-E3118E3141-E3152 E3171-E3177 E3201-E3206 E3221-E3224 E3241-E3290 E3341-E3350E3401-E3421 E3451-E3452 E3471-E3474 E3501-E3513 E3516-E3523 E3551-E3553E3571-E3578 E3601-E3604 E3621-E3622 E3651-E3655 E3677 E3681-E3684E3701-E3704 E3751-E3755 E3781-E3784 E5001-E5011 E5031-E5068 E5101-E5116E5141-E5143 E5161-E5164 E5201-E5203 E5221-E5245 E5251-E5252 E5271-E5281E5301-E5306 E5351-E5353 E5381-E5382 E5401-E5424 E5426-E5429 E5433E5435 E5451-E5455 E5481-E5483 E5501-E5502 QA001-QA046 QA051-QA099QA101-QA199 QA201-QA225 QA301-QA322 QA325-QA349 QA351-QA376 QA378QA401-QA499 QA501-QA537 QA551-QA579 QA581-QA585 QA601-QA688 QA701-QA753QA801-QA805 QA851-QA899 QA901-QA946 QA949 QB001-QB002 QB031-QB049QB051-QB068 QB101-QB110 QB114-QB119 QB121-QB149 QB151-QB158 QB201-QB203QB301-QB316 QB351-QB352 QB401-QB407 QB451-QB458 QB501-QB575 QB601-QB629QB651 QB701-QB705 QB801-QB810 QB901-QB904 QD001-QD012 QD031-QD042QD085-QD088 QD101-QD105 QD121-QD127 QD141-QD149 QD161 QD191-QD192QD301-QD305 QD321-QD330 QD351 QD441-QD453 QD471-QD473 QD501-QD518QD551-QD558 QD571-QD572 QD581-QD583 QD601-QD607 QD701-QD702 QD791

GROUP 2QA323-QA324 QB204-QB220 QD043-QD046 QD162-QD164 QD201-QD239 QD281-QD284QD401-QD403 QD407 QD410 QD421-QD427 QD474-QD475 QD621-QD624QD641 QD661-QD663 QD681-QD685 QD691-QD692 QD711-QD717 QD741QD761-QD769 QD781-QD782 QD801-QD804 QD821-QD828 QD901-QD910 QD931-QD932QD951-QD954 QD971-QD973 QD991-QD992 QE001-QE002 QL001-QL008 QL031-QL032QL081 QL501-QL515

2. Spares

None

Sep 2/70 727-57-0112REV 5: Jul 31/97 16


B. Reason

As a result of the Aging Fleet Conference held by the FAA, the 727 Structures Working Group (SWG)was made and included 727 airline operators from a large part of the high time 727 fleet, personsfrom the Boeing Company, and monitors from the FAA. The SWG examined the structural changesand inspections given in applicable Boeing service bulletins. A selection of these service bulletinswas made that contain structural changes and inspections that are important to the continuedstructural airworthiness of 727 airplanes. The structural change given in this service bulletin isrecommended to be included, and the inspection are recommended to be a part of the regularlyscheduled maintenance on applicable 727 airplanes.

During a 727 primary fatigue test at Boeing, two cracks were found in the upper vertical flange of thewing-to-body rib upper chord at Body Station 760. One crack in the rib upper chord was between thetwo aft fastener holes of the frame at Body Station 760.95. The other crack in the rib upper chordwas immediately aft of the lower fastener hole in the frame.

To increase the fatigue life of the rib upper chord and to reduce the risk of repair and maintenancenot scheduled, make the change given in this service bulletin.

The initial release of this service bulletin recommended that operators cold work six holes in thewing-to-body rib upper chord to extend the chord fatigue life. Cold work the holes at a primaryoverhaul near 30,000 total flight cycles, but before 35,000 total flight cycles.

Revision 1 of this service bulletin decreased the time permitted before the operator should make thechange given in this service bulletin. Also, information was given to repair cracked holes in thevertical flange of the rib upper chord. Since the initial release of this service bulletin, two operatorsreported cracks in these holes on three airplanes. These airplanes had between 19,700 and 24,500flight cycles.

Revision 2 of this service bulletin added new inspection information and repair instructions for the ribupper chord. Since the release of Revision 1 of this service bulletin, seven operators reported longcracks in the rib upper chord and the repair was not given in the service bulletin on six airplanes.These airplanes had between 34,000 and 54,000 flight hours and between 27,000 and 49,000 flightcycles.

Revision 3 of this service bulletin was sent to give the recommendation of the 727 SWG (renamedthe Structures Task Group (STG)).

Revision 4 was sent to tell operators that new kits are available for Group 1 and 2 Airplanes. Thereare separate kits for modifications to airplanes with small cracks or no cracks, and for repairs toairplanes with larger cracks. This revision also gives instructions and figures to show partsinstallation details for the new kits. It is necessary for Group 1 Airplanes with the MajorRepair/Preventive Modification installed to be inspected at BL 70.5 for a repair strap. If a repair strapis not installed, it is necessary to make an inspection of the frame for cracks, see Service Bulletin727-53-0197. Install the repair strap when the repair or preventive modification shown in ServiceBulletin 727-53-0197 is installed, or at a convenient maintenance time. If cracks are found, do therepair shown in Service Bulletin 727-53-0197.

Revision 4 can also be used as a guide to install the Kits 65C33202-1, and -2. See the drawing sentwith Revision 3 of the bulletin for the part numbers, the hole diameters and fastener callout.Revision 4 gives information on the limits the angles in Kits 65C33202-1, and -2 can be trimmed.

If the strap from Service Bulletin 727-53-0197 is installed at Body Station 760.95, or will be installedconcurrent with this service bulletin, use the strap from Service Bulletin 727-53-0197 in place of thestrap shown in this service bulletin.

Sep 2/70 727-57-0112REV 5: Jul 31/97 17


Since the recommendation of the inspection called out in this service bulletin was made by the STGthere have been numerous reports of cracks. It has been necessary to install the PreventiveModification or Large Repair for many of the cracks. Most cracks have been in the forward two holes.

Revision 5 is sent to tell operators that new kits are available to order for Group 1 and 2 Airplanes.The drawings used to install the kits are sent with this revision (the drawings have been revised sincethe release of Notice of Status Change 3). The format used to show the removal of parts andinstallation of the kits has changed. Also the compliance information has been clarified.

Also, for Group 1 airplanes that were changed by Revisions 2 or 3, Part V of the AccomplishmentInstructions of this service bulletin there are changes to the instructions. If the repair strap has notbeen installed, a new repair strap is shown. The new strap is the same as the strap installed in thenew "Large Repair" and new "Preventive Modification " kits.

Revision 5 is also sent to give the inspection recommendation of the 727 STG. Also repairs, thatoperators have requested, are included.

C. Description

The STG has examined the structural change and inspection in this service bulletin, andrecommends that the Preventive Modification or Large Repair structural change given in theAccomplishment Instructions be included at or before the airplane collects a total of 60,000 flights,and to do the inspection given in the Accomplishment Instructions, Part II.A.1, Inspection, at or beforethe airplane collects a total of 14,000 flights, or within 3,000 flights, whichever occurs later.

If no cracks are found, increase the hole diameter, cold work the hole, and install a new fastener insix places. Continue the inspection at regularly scheduled times as given in the AccomplishmentInstructions, Part II.A.2, or B.1, Inspection. The approved time between one inspection and thesubsequent inspection must not be more than 14,000 flights. To stop the inspection given in thisservice bulletin, do the preventive modification or large repair.

If cracks are found, make a change to the rib upper chord as given in this service bulletin.

It is necessary for Group 1 Airplanes with the Major Repair/Preventive Modification installed to beinspected at BL 70.5 for a repair strap at a maintenance check before 3000 flight cycles. If a repairstrap is not installed, it is necessary to make an inspection of the frame for cracks. Continue theinspection of the frame for cracks as given in Service Bulletin 727-53-0197. If cracks are found, dothe repair shown in Service Bulletin 727-53-0197.

The airplane effectivity is divided in two groups. Group 1 airplanes are basic weight and Group 2 arehigh gross weight airplanes.

It is recommended that the changes shown in Service Bulletin 727-53-0197 be done at the same timethat the work for Service Bulletin 727-57-0112 is done.

NOTES:

1. Boeing Document D6-54860, "Aging Airplane Service Bulletin Structural Modification andInspection Program", is applicable to this service bulletin.

Sep 2/70 727-57-0112REV 5: Jul 31/97 18


2. If the damaged area is more than the specified limits, write to Boeing for repair instructions. Tohelp Boeing send a reply, give the limits and location of the damage. When possible, sendsketches and photographs. If the damage includes corrosion, send data on the length, width,and largest depth of clean up.

SEND TO:BOEING COMMERCIAL AIRPLANE GROUPATTENTION: MANAGER, AIRLINE SUPPORT

An evaluation form is attached to this service bulletin. Please use this form to tell us what you thinkof the quality of this service bulletin.

D. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changesspecified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) andare FAA approved. This service bulletin and the FAA approval were based on the airplane in itsoriginal Boeing delivery configuration or as modified by other FAA approved Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system alsoaffected by this service bulletin, the operator is responsible for obtaining appropriate regulatoryagency approval before incorporating this service bulletin.

E. Manpower

The data below shows an estimate of the man-hours necessary to do this change for each wing. Thisestimate is for direct labor only, done by an experienced crew. Adjust the estimate with operatorman-hour data if necessary. The estimate does not include lost time. These are some examples oflost time:

- Time to adjust to the workplace- Time to schedule the work- Time to examine the work- Time to cure the materials- Time to make the parts- Time to find the tools.

Sep 2/70 727-57-0112REV 5: Jul 31/97 19


Small Repair Number of Persons Man-Hours Elapsed Time (Hours)Open Access 4 24 6Inspection 2 6 3Modification 1 24 24Restoration 4 24 6TOTAL FOR EACH WING 72 36Preventive Modification/Large Repair Number of Persons Man-Hours Elapsed Time (Hours)Open Access 4 24 6Inspection 2 6 3Modification 3 246 82Restoration 4 24 6TOTAL FOR EACH WING 300 97Inspection for andInstallation of Repair Strap Number of Persons Man-Hours Elapsed Time (Hours)Open Access 4 24 6Inspection 1 .5 .5Inspection of Strap 1 8 8Restoration 4 24 6TOTAL FOR EACH WING 56.5 20.5

F. Material - Price and Availability

Boeing can supply the kits shown in Paragraph II.A., Parts Necessary For Each Airplane, (andParagraph II.B., Parts Necessary to Change Spares,) as shown below. If there is a limit to thequantity of available kits, a supply sequence is given by Spares. More kits become available asshown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets thepurchase order.

Kit Number Name Date QuantityROLT

(weeks)Unit Price thru

Dec 30/9765-68492-1 (a) Upper Rib Chord Repair - - - -65-68492-2 (a) Upper Rib Chord Repair - - - -65-68492-9 (a) Strap - - - -65-68492-10 (a) Strap - - - -65-68492-11 (a) Upper Rib Chord Repair - - - -65-68492-12 (a) Upper Rib Chord Repair - - - -65-68492-17 (a) Upper Rib Chord Repair - - - -65-68492-18 (a) Upper Rib Chord Repair - - - -65-68492-25 (a) Upper Rib Chord Repair - - - -65-68492-26 (a) Upper Rib Chord Repair - - - -65-68492-33 Upper Rib Chord Repair - - 34 $3,346.0065-68492-34 Upper Rib Chord Repair - - 34 $3,346.0065-68492-35 Upper Rib Chord Repair - - 34 $3,095.0065-68492-36 Upper Rib Chord Repair - - 34 $3,095.0069-78758-1 (a)(b) Strap - - - -

Sep 2/70 727-57-0112REV 5: Jul 31/97 20


(Continued)

Kit Number Name Date QuantityROLT

(weeks)Unit Price thru

Dec 30/9769-78758-2 (a)(b) Strap - - - -69-78758-3 (a)(c) Strap - - - -69-78758-4 (a)(c) Strap - - - -69-78758-5 (b) Strap - - 32 $192.0069-78758-7 (c) Strap - - 32 $192.0065C33202-1 (a) Repair Installation - - - -65C33202-2 (a) Repair Installation - - - -65C33202-19 (a) Large Repair - - - -65C33202-20 (a) Large Repair - - - -65C33202-21 (a) Preventive Modification - - - -65C33202-22 (a) Preventive Modification - - - -65C33202-23 (a) Preventive Modification - - - -65C33202-24 (a) Preventive Modification - - - -65C33202-61 (a) Large Repair - - - -65C33202-62 (a) Large Repair - - - -65C33202-73 (a) Large Repair - - - -65C33202-74 (a) Large Repair - - - -65C33202-79 (a) Preventive Modification - - - -65C33202-80 (a) Preventive Modification - - - -65C33202-91 (a) Large Repair - - - -65C33202-92 (a) Large Repair - - - -65C33202-93 (a) Preventive Modification - - - -65C33202-94 (a) Preventive Modification - - - -65C33202-97 Large Repair - - 38 $12,139.0065C33202-98 Large Repair - - 38 $12,139.0065C33202-99 Preventive Modification - - 38 $11,006.0065C33202-100 Preventive Modification - - 38 $11,006.0065C33202-101 Large Repair - - 38 $12,040.0065C33202-102 Large Repair - - 38 $12,040.0065C33202-103 Preventive Modification - - 38 $10,614.0065C33202-104 Preventive Modification - - 38 $10,614.00(a) Inactive for procurement(b) 727-200 Airplanes(c) 727-100 Airplanes

The kits are subject to the terms and conditions of the Boeing standard purchase orderacknowledgment. After the Unit Price date, new price (and ROLT) data is applicable. Prices are inUnited States Dollars. Terms: Net 30 days.

Send purchase orders and letters about the supply data to the Director of Spares and refer to thisservice bulletin number.

Sep 2/70 727-57-0112REV 5: Jul 31/97 21


G. Special Tools - Price and Availability

The 727 Structural Repair Manual Subject 51-30-10 gives data about cold working tools and sleevesnecessary to do the work given in this service bulletin. These tools are available from industrysources.

Engineering, service, and a kit of cold working tools made for this change are available from FatigueTechnology, Inc. or West Coast Industries, Inc.

Refer To:

FTI Kit Number: FTI-727-57-0112-1Fatigue Technology, Inc.P.O. Box C-88388Seattle, WA 98188Phone Number (206) 246-2010Fax (206) 244-9886

Refer To:

WCI Kit Number: WCI-727-57-0112West Coast Industries, Inc.14900 Whitman Avenue NorthSeattle, WA 98133-6532Phone Number (206) 365-7513Fax (206) 365-7483

H. Weight and Balance

Airplane/EngineChange in Weight

(Pounds)Change in Moment

(Pound-Inches)

Group 1 +(-) +(-)

Small Repair - Part III +3.4 +2,587

Large Repair - Part IV +9.5 +7230

Preventive Modification - Part V +7.7 +5860

Installation of Repair Strap +0.2 +152

Group 2

Small Repair - Part III +2.2 +1674

Large Repair - Part IV

65C33202-101 (left) +11.4 +8675

65C33202-102 (right) +11.2 +8523

Preventive Modification - Part V

65C33202-103 (left) +7.7 +5860

65C33202-104 (right) +7.1 +5403

Sep 2/70 727-57-0112REV 5: Jul 31/97 22


I. References

1. Existing Data:

a Engineering Change Memo PRR 24791-R

b 727 Maintenance Manual Subjects 12-30-2, 25-20-31, 25-20-32, 25-21-1, 25-22-0, 27-81-0,28-10-0, 28-11-0, 28-11-21, 28-12-11, 28-12-1, 28-12-21, 28-12-31, 28-23-0, 51-30-1 and53-20-11

c 727 Structural Repair Manual Subjects 51-10-1, 51-30-8 and 51-30-10

d 727 Nondestructive Test Manual, D6-48875, Part 6, Subject 51-00-00, Figures 1 and 4

e Boeing Document D6-54860 "Aging Airplane Service Bulletin Structural Modification andInspection Program - Model 727"

f Boeing Service Bulletin 727-53-0197, FUSELAGE - MAIN FRAME - FRAMES ANDBULKHEADS - INSPECTION, REPAIR, AND PREVENTIVE MODIFICATION AT BODYSTATION 760.95, 783.95, 825.95, AND 848.95.

g Boeing Standard Overhaul Practices Manual 20-42-10.

2. Data supplied with this service bulletin:

a. Drawings:

Drawing Number Sheet DCN ADCN Title65C36390 PL - 1 "Rib Chord Repair Installation - Fairing

1 - 1 Rework (Kit)"65-68492 PL B - "Uppr Rib Chord Repair - BBL 70.5

4 - - Body Station 760.95 Kit"65C33202 1 F - Rib Chord Repair Installation Upper,

7 B - BBL 70.5, S-16 thru S-218 B -11 A -12 A -

3. Installation Drawings

Boeing Process Specifications referred to on the drawings are not given in this service bulletinsince these procedures are frequently used as standard shop practices.

J. Publications Changed

Publication Chapter-Section727 Structural Repair Manual 57-10

Sep 2/70 727-57-0112REV 5: Jul 31/97 23


II. MATERIAL INFORMATION

A. Parts Necessary For Each Airplane

1. Kits:

To get the kits shown below, refer to Paragraph I.H., Material - Price and Availability.

NOTE: Two top kits and the items shown in Paragraph II.A.2., Parts and Materials Supplied by theOperator, are necessary for each airplane.

65-68492 UPR RIB CHORD REPAIR - BBL 70.5 B. STA 760.95 KIT

-36 -35 -34 -33

Quantity Part Number Name

. . . - 65-68492-33 Top Kit, Upper Rib Chord - Small Repair(Left) - Group 1

. . - . 65-68492-34 Top Kit, Upper Rib Chord - Small Repair(Right) - Group 1

. - . . 65-68492-35 Top Kit, Upper Rib Chord - Small Repair(Left) - Group 2

- . . . 65-68492-36 Top Kit, Upper Rib Chord - Small Repair(Right) - Group 2

. . . 1 65-68492-37 Strap

. . 1 . 65-68492-38 Strap

. . . 1 65-68492-39 Angle

. . 1 . 65-68492-40 Angle

. 1 . 1 65-68492-41 Strap

1 . 1 . 65-68492-42 Strap

. . . 1 65-68492-43 Strap

. . 1 . 65-68492-44 Strap

. . 1 1 65-68492-45 Plate

. . 1 1 65-68492-46 Stock Plate

. . 1 1 65-68492-47 Stock Strap

1 1 . . 65-68492-48 Plate

. 1 . 1 65-68492-49 Stock Angle

1 . 1 . 65-68492-50 Stock Angle

. 1 . . 65-68492-51 Strap

1 . . . 65-68492-52 Strap

. 1 . . 65-68492-53 Angle

1 . . . 65-68492-54 Angle

1 1 . . 65-68492-55 Stock Plate

1 1 . . 65-68492-56 Stock Strap

. 1 . 1 65-68492-57 Tee Clip

1 . 1 . 65-68492-58 Tee Clip

1 1 1 1 65-68492-59 Shim-Laminated

1 1 1 1 65-68492-60 Shim-Laminated

Sep 2/70 727-57-0112REV 5: Jul 31/97 24


(Continued)


-36 -35 -34 -33


1 1 1 1 65-68492-61 Shim-Laminated Stock

1 1 1 1 65-68492-62 Shim-Laminated Stock

. 1 . 1 65C37221-7 Stock Tee Clip

1 . 1 . 65C37221-8 Stock Tee Clip

1 1 1 1 69-78758-5 Stock Strap

. . 1 1 69-78758-7 Stock Strap

2 2 2 2 BACB30MY8K11Y Hi-Lok, 1/32 Oversized

4 4 4 4 BACB30MY8K7Y Hi-Lok, 1/32 Oversized

. . 2 2 BACB30NW8K12Y Hi-Lok, 1/32 Oversized

1 1 . . BACB30NW8K13Y Hi-Lok, 1/32 Oversized

. . 3 3 BACB30NW8K14Y Hi-Lok, 1/32 Oversized

. . 3 3 BACB30NX10K12Y Hi-Lok, 1/32 Oversized

. . 1 1 BACB30NX10K14 Hi-Lok

. . . 1 BACB30NX10K15Y Hi-Lok, 1/32 Oversized


1 1 1 1 BACB30NX10K17 Hi-Lok


. . 1 . BACB30NX10K19Y Hi-Lok, 1/32 Oversized

1 1 . . BACB30NX10K20 Hi-Lok


1 1 . . BACB30NX10K22 Hi-Lok






3 3 . . BACB30NX14K12Y Hi-Lok, 1/32 Oversized












Sep 2/70 727-57-0112REV 5: Jul 31/97 25


(Continued)


-36 -35 -34 -33



. . 5 4 BACB30NY10K12Y Hi-Lok, 1/32 Oversized

. . 1 1 BACB30NY10K14 Hi-Lok, 1/32 Oversized

2 2 2 2 BACB30NY10K17 Hi-Lok, 100 Deg

. . 1 1 BACB30NY10K19 Hi-Lok, 100 Deg

2 2 1 1 BACB30NY10K20 Hi-Lok, 100 Deg

2 2 . . BACB30NY10K22 Hi-Lok, 100 Deg

3 3 . . BACB30NY8K10Y Hi-Lok, 1/32 Oversized



. . 3 3 BACB30NY8K14 Hi-Lok, 100 Deg


4 4 . . BACB30NY8K17 Hi-Lok, 100 Deg



13 13 10 10 BACC30AC8 Collar

7 7 11 11 BACC30R8 Collar

9 9 8 8 BACC30X10 Collar


. . 15 13 HL375-10AW Collar, Self-Align

. . 6 8 HL375-12AW Collar, Self-Align

15 14 . . HL375-14AW Collar, Self-Align

65C33202 - RIB CHORD REPAIR INSTALLATION - UPPER, BBL 70.5, S-16THRU S-21 - GROUP 1

-100 -99 -98 -97


. . . - 65C33202-97 Repair Installation - Left (Large Repair)

. . - . 65C33202-98 Repair Installation - Right (LargeRepair)

. - . . 65C33202-99 Repair Installation - Left (PreventiveModification)

- . . . 65C33202-100 Repair Installation - Right (PreventiveModification)

1 . 1 . 65C33202-10 Filler - Outboard

. 1 . 1 65C33202-105 Angle - Outboard

1 . 1 . 65C33202-106 Angle - Outboard

. 1 . 1 65C33202-107 Angle - Inboard

Sep 2/70 727-57-0112REV 5: Jul 31/97 26


(Continued)


-100 -99 -98 -97


1 . 1 . 65C33202-108 Angle - Inboard

. 1 . 1 65C33202-11 Filler - Tapered

1 1 1 1 65C33202-113 Fitting

. 1 . 1 65C33202-117 Angle - Forward, Inboard

1 . 1 . 65C33202-118 Angle - Forward, Inboard

1 . 1 . 65C33202-12 Filler - Tapered

. 1 . 1 65C33202-15 Spacer

1 . 1 . 65C33202-16 Spacer

. . 1 1 65C33202-67 Filler

. . 1 1 65C33202-85 Shim - Laminated

1 1 . . 65C33202-86 Shim - Laminated

1 . 1 . 65C33202-87 Filler

1 . 1 . 65C33202-88 Shim - Laminated

. 1 . 1 65C33202-89 Filler

. 1 . 1 65C33202-9 Filler - Outboard

1 1 1 1 65C33202-90 Shim - Laminated

4 4 4 4 65C21524-14 Filler - Radius

. 1 . 1 65C21524-19 Angle - Outboard

1 . 1 . 65C21524-20 Angle - Outboard

. 1 . 1 65C21524-21 Angle - Inboard

1 . 1 . 65C21524-22 Angle - Inboard

1 1 1 1 65C37221-1 Tension Tie - Inboard Upper

2 2 2 2 65C37221-10 Filler - Radius

1 1 1 1 65C37221-11 Filler - Radius

2 . 2 . 65C37221-12 Filler - Radius

. 1 . 1 65C37221-13 Filler - Radius

2 . 2 . 65C37221-14 Filler - Radius

. 2 . 2 65C37221-15 Filler - Radius

. 1 . 1 65C37221-16 Filler - Radius

1 1 1 1 65C37221-2 Tension Tie - Inboard Lower

. 1 . 1 65C37221-3 Tension Tie - Outboard

1 . 1 . 65C37221-4 Tension Tie - Outboard

. 1 . 1 65C37221-7 Tee - Frame Attachment

1 . 1 . 65C37221-8 Tee - Frame Attachment

2 2 2 2 65C37221-9 Filler - Radius

15 15 29 29 66-2955-57 Washer - Countersink Repair

1 1 1 1 69-78758-5 Strap

Sep 2/70 727-57-0112REV 5: Jul 31/97 27


(Continued)


-100 -99 -98 -97


1 1 1 1 69-78758-7 Strap

2 2 2 2 BACB30MY8K11Y Bolt - 1/32 Oversized

4 4 4 4 BACB30MY8K7Y Bolt - 1/32 Oversized

2 . 2 . BACB30NW10K15Y Bolt - 1/32 Oversized

1 1 1 1 BACB30NW8K12Y Bolt - 1/32 Oversized





2 2 4 4 BACB30NX10K13Y Bolt - 1/32 Oversized




1 1 1 1 BACB30NX10K23 Bolt - 1/32 Oversized










1 1 1 1 BACB30NX12K20 Bolt

1 . 1 . BACB30NX12K21Y Bolt - 1/32 Oversized

. 1 . 1 BACB30NX12K23Y Bolt - 1/32 Oversized



. . 3 3 BACB30NX8K17Y Bolt - 1/32 Oversized





1 1 1 1 BACB30NY10K23 Bolt


1 1 1 1 BACB30NY8K19Y Bolt - 1/32 Oversized

1 1 1 1 BACB30NY8K20Y Bolt - 1/32 Oversized

Sep 2/70 727-57-0112REV 5: Jul 31/97 28


(Continued)


-100 -99 -98 -97


2 2 2 2 BACB30US6K20 Bolt







2 . 2 . BACC30R10 Collar


10 10 10 10 BACC30X10 Collar


2 2 2 2 BACF3T02L28-11 Filler - Tapered

12 12 12 12 BACN10HR6CD Nut

2 2 2 2 BACN10JC4CD Nut

8 12 8 12 BACR10AK6 Retainer, Nut

1 . 1 . BACR15BA10D22 Rivet

2 2 2 2 BACW10BN42AP Washer

12 12 12 12 BACW10BP6AC Washer

12 12 12 12 BACW10BP6AP Washer

16 24 16 24 MS20427M4C5 Rivet


-104 -103 -102 -101


. . . - 65C33202-101 Repair Installation - Left side (LargeRepair)

. . - . 65C33202-102 Repair Installation - Right side (LargeRepair)

. - . . 65C33202-103 Repair Installation - Left side(Preventive Modifition)

- . . . 65C33202-104 Repair Installation - Right side(Preventive Modifition)

. 1 . 1 65C33202-105 Angle - Outboard

1 . 1 . 65C33202-106 Angle - Outboard

. 1 . 1 65C33202-107 Angle - Inboard

1 . 1 . 65C33202-108 Angle - Inboard

1 1 1 1 65C33202-113 Fitting

Sep 2/70 727-57-0112REV 5: Jul 31/97 29


(Continued)


-104 -103 -102 -101


1 1 1 1 65C33202-115 Radius Filler

. 1 . 1 65C33202-117 Angle - Forward, Inboard

1 . 1 . 65C33202-118 Angle - Forward, Inboard

1 1 1 1 65C33202-44 Angle - Inoard

. 1 . 1 65C33202-45 Angle - Outboard

1 . 1 . 65C33202-46 Angle - Outboard

1 1 1 1 65C33202-47 Spacer

1 1 1 1 65C33202-48 Filler - Tapered

1 1 1 1 65C33202-50 Filler - Outboard

1 1 1 1 65C33202-51 Shim - Laminated

. . 1 1 65C33202-52 Shim - Laminated

1 1 1 1 65C33202-53 Shim - Laminated

1 1 1 1 65C33202-54 Angle - Pressure Retaining

1 . 1 . 65C33202-55 Filler

1 . 1 . 65C33202-56 Shim - Laminated

. 1 . 1 65C33202-59 Shim - Laminated

. 1 . 1 65C33202-60 Filler

4 4 4 4 65C33202-68 Radius Filler

1 1 1 1 65C33202-69 Filler

. . 1 1 65C33202-71 Shim - Circular

. 1 . 1 65C33202-95 Shim - Laminated

1 . 1 . 65C33202-96 Shim - Laminated

1 1 1 1 65C37073-1 Tension Tie

1 . 1 . 65C37073-2 Tension Tie

2 . 2 . 65C37073-3 Radius Filler

2 . 2 . 65C37073-4 Radius Filler

. 1 . 1 65C37083-1 Tension Tie

. 1 . 1 65C37083-2 Radius Filler




. 1 . 1 65C37221-7 Tee Clip

1 . 1 . 65C37221-8 Tee Clip

1 1 1 1 69-78758-5 Strap

2 2 2 2 BACB30MY14K7Y Bolt - 1/32 oversized

. 2 . 2 BACB30MY14K10Y Bolt - 1/32 oversized

Sep 2/70 727-57-0112REV 5: Jul 31/97 30


(Continued)


-104 -103 -102 -101




1 1 . . BACB30MY8K10Y Bolt - 1/32 oversized


. . 2 2 BACB30MY8K12Y Bolt - 1/32 oversized

2 2 . . BACB30MY8K13Y Bolt - 1/32 oversized



2 2 2 2 BACB30NW8K12Y Bolt - 1/32 oversized



. 1 . 1 BACB30NX10K19 Bolt




1 . 1 . BACB30NX10K24 Bolt


3 3 5 6 BACB30NX14K14Y Bolt - 1/32 oversized





. . 8 8 BACB30NX14K19Y Bolt - 1/32 oversized











3 3 3 3 BACB30NY8K18Y Bolt - 1/32 oversized

2 . 2 . BACB30US7K20 Bolt

1 1 1 1 BACB30US7K20Y Bolt - 1/32 oversized


Sep 2/70 727-57-0112REV 5: Jul 31/97 31


(Continued)


-104 -103 -102 -101


. 1 . 1 BACB30US7K25Y Bolt - 1/32 oversized



2 2 2 2 BACF3T02M26-12 Filler - Tapered





16 17 16 17 BACC30X14 Collar


10 10 10 10 BACN10HR7 Nut

1 1 1 1 BACS40R019E036F Shim - Laminated

8 8 8 8 BACR10AK7 Retainer, Nut

2 . 2 . BACW10BP7AC Washer

8 10 8 10 BACW10BP72AC Washer

2 . 2 . BACW10BP7AP Washer

8 10 8 10 BACW10BP72AP Washer

8 8 8 8 MS20427M4C10 Rivet

8 8 8 8 MS20427M4C5 Rivet

Sep 2/70 727-57-0112REV 5: Jul 31/97 32


2. Parts and Materials Supplied by the Operator:

Quantity Part Number (Specification) Name

As Necessary RTV 174 (a), (b) Silicone Rubber Adhesive

As Necessary BMS 5-26, Type II, Class B Integral Fuel Tank Sealant

As Necessary BMS 5-95 Sealant

As Necessary BMS 10-11, Type I Primer

As Necessary BACB30NW10K( ) (c)(k) Bolt

As Necessary BACB30MY10K( ) (c)(l) Bolt

1 65C37221-7 (j) Tee

1 65C37221-8 (j) Tee

1 69-78758-5 (d) (e) Strap (On 727-200 Airplanes)

1 69-78758-7 (d) (e) Strap (On 727-100 Airplanes)

(g) BACC30M8 (d), (e) Collar

6 BACC30M10 (c) Collar

1 BACC30M12 (e) Collar

1 BACB30MK8K16 (e) Fastener

1 BACB30MK8K20 (e) Fastener

3 BACB30MK8K16Y (e) Fastener


(h) BACB30MK8K20Y (d), (e) Fastener


2 BACB30NW8K12Y (d), (e) Fastener





2 BACN10HR6 (e) Nut

As Necessary 2024-T3 Aluminum Alloy (i) Shim

As Necessary 7075-T6 Aluminum Alloy (i) Shim

As Necessary BAC1506-855 x 4 (j) Tee extrusion

As Necessary 7075-T73511 Aluminum (j) Tee

(a) General Electric Co. (V9172)Materials Information Services1285 Boston Ave. Bldg 29EEBridgeport, Connecticut 06602, USA

(b) RTV 102, and DC Q3-7063 are optional to RTV 174. The DC Q3-7063 isavailable from:Dow Corning Corporation (V71984)3901 South Saginaw RoadMidland, Michagan 48641-2721, USA

(c) Necessary to make the change given in Figure 2. On 727-100 Airplanesthe grip lenths can range from -9 to -14. The grip lengths on 727-200Airplanes can range from -12 to -18. Larger diameters can be necessary ifcracks were found in Figure 1.

Sep 2/70 727-57-0112REV 5: Jul 31/97 33


(Continued)

(d) Necessary for the Repair Strap Installation, Left Side (Figure 20).

(e) Necessary for the Repair Strap Installation, Right Side (Figure 21).

(f) Deleted

(g) 9 (left side repair), 15 (right side repair)

(h) 2 (left side repair), 1 (right side repair)

(i) To fill gaps, maximum thickness 0.060 inches, as specified inAccomplishment Instructions, Note 7.

(j) Necessary only if there was not sufficient edge margin on the existing Teeafter removal of cracks found in Figure 1. Can use the Tee 65C37221-7,or -8 Opposite, or make a tee from extrusion BAC1506-855 or Aluminum7075-T73511 as shown in Figure 23.

(k) Optional: BACB30FN10A( ) or BACB30FN10( )

(l) Optional: BACB30FM10A( ) or BACB30FM10( )

B. Parts Necessary to Change Spares

None

C. Special Tools and Equipment

Cold working tools are necessary to do the change given in this service bulletin. To get the coldworking tools, refer to Paragraph I.I., Special Tools - Price and Availability.

D. Existing Parts Accountability

None

Sep 2/70 727-57-0112REV 5: Jul 31/97 34


III. ACCOMPLISHMENT INSTRUCTIONS

NOTES:

1. As recommended by the 727 SWG, make the Preventive Modification or Large Repair structuralchange given in Part IV or Part V at or before the airplane collects a total of 60,000 flights. Makethe inspection given in Part II.A.1, Inspection, at or before the airplane collects a total of 14,000flights, or within 3,000 flights, whichever occurs later. Continue the inspection at regularlyscheduled times as given in Part II.A.2, or B.1, Inspection. The approved time between oneinspection and the subsequent inspection must not be more than 14,000 flights.

2. The paragraphs identified with a letter give the general work instructions and the necessary tests.The instructions identified with numbers on the figures give the recommended sequence of steps.

3. 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 fasteners are given in 727 Structural Repair Manual Chapter 51.- Torque limits to tighten nuts and bolts are given in 727 Structural Repair Manual Chapter 51.

4. Alternative fasteners are given in 727 Structural Repair Manual Chapter 51.

5. Obey all of the warnings and cautions given in the specified manual sections.

6. On Figures 1 and 2 do inspections as shown in the figures. On the remaining figures, make aneddy current inspection of the holes at the locations where the fasteners are replaced. Refer to the727 Nondestructive Test Manual, Part 6, Subject 51-00-00. If fasteners other than those specifiedin the bulletin are removed, do an eddy current inspection of those holes too. If no cracks arefound, oversize the hole by 1/32 inch diameter. Install equivalent or better oversize fasteners asshown in the 727 Structural Repair Manual. If cracks are found contact the Boeing Company forinstructions.

7. The maximum clearance between parts must not be more than 0.005 inches. If the distance ismore than 0.005 inches shim with 2024-T3 or 7075-T6 aluminum alloy to a maximum of 0.060inches.

8. Maintain a 2 diameter (2D) edge margin or greater on all parts unless told differently.

9. Install all fasteners, that touch fuel, wet with Sealant BMS 5-26, type II. Install fluid tight fastenerscommon to the fuel tanks. Install all parts, that touch fuel, with a faying surface Sealant BMS 5-26,type II. Fill all voids with sealant.

10. Install all fasteners, that do not touch fuel, wet with Sealant BMS 5-95. Install all parts, that do nottouch fuel, with a faying surface Sealant BMS 5-95. Fill all voids with sealant.

11. Revision 4 can be used as a guide to install the Kits 65C33202-1, and -2. See the drawing sentwith Revision 3 of the bulletin for the part numbers, the hole diameters and fastener callout.Revision 4 also gives information on the limits that the angles in Kits 65C33202-1, -2, -19, -20,-61, and -62 can be trimmed.

12. Look at the 727 Structural Repair Manual Subject 51-30-8 for the proper size of the countersinkrepair washers called out in the figures or make them from the removed fasteners.

13. Make a 125 microinch finish on all edges.

Sep 2/70 727-57-0112REV 5: Jul 31/97 35


14. Group 1 - The Repair Strap, installed at Body Station 760.95, in the preferred Kit 65C36279-35, or-36 used in Service Bulletin 727-53-0197 Revision 2 is identical to the strap used in this servicebulletin. If a strap from an earlier revision of Service Bulletin 727-53-0197 has been installed, usethe strap shown in this service bulletin.

15. Group 2 - If the Repair Strap 65C36279-14, 65C36279-35, or -36, from Service Bulletin727-53-0197 is installed at Body Station 760.95, or will be installed concurrent with this servicebulletin, use the strap shown in Service Bulletin 727-53-0197.

PART I - ACCESS

A Remove the seats as necessary to get access to the center section upper surface, Body Station 740through 783. Refer to the 727 Maintenance Manual Subject 25-22-0.

B Remove the carpets as necessary to get access to the center section upper surface, Body Station 740through 783. Refer to the 727 Maintenance Manual Subject 25-20-31 for standard passengerairplanes or 25-20-32 for passenger/cargo convertible airplanes.

C Remove the floor panels as necessary to get access to the center section upper surface, Body Station740 through 783. Refer to the 727 Maintenance Manual Subject 53-20-11.

D Remove the interior access panels as necessary to get access to the center section upper surface,Body Station 740 through 783. Refer to the 727 Maintenance Manual Subject 25-21-1.

E Remove the pressure seal and the pressure pan to get access to the chord, Body Station 740 through760. Refer to the 727 Maintenance Manual Subject 51-30-1.

F Remove the wing-to-body fairing as necessary to get access to Body Station 740 through 783. Referto the 727 Maintenance Manual Subject 12-30-2.

PART II - INSPECTION

A Airplanes not changed as given in Figure 2.

1 Make an inspection for cracks as given in Figure 1, at or before the airplane collects a total of14,000 flight cycles, or in 3,000 flights, whichever occurs later.

2 If no cracks are found, cold work the holes as given in Figure 2, install the size and type of fastenershown in Figure 2 and return the airplane to a serviceable condition as given in Part VI. Make theinspection as given in Figure 1 at regularly scheduled times. The time between one inspection andthe subsequent inspection must not be more than 14,000 flight cycles. To stop the inspectionmade necessary by this service bulletin, make the change as given in Part V - PREVENTIVEMODIFICATION.

Sep 2/70 727-57-0112REV 5: Jul 31/97 36


3 If cracks are found:

a That are less than one inch total in length and do not go into the horizontal flange.

NOTE: The length includes the fastener hole diameter, the crack length and the final stop holediameter.

There are four options for repair. Before you start the repair, estimate if a stop drill will benecessary, or if the hole can be oversized sufficiently to remove the damage. Estimate theamount of edge margin between the upper fasteners and the upper flange. Also determine ifthe crack goes through one or more fastener holes.

NOTE: It is easier to estimate the crack length if the Frame Attach Tee is removed. This willgive visual access to the vertical flange of the plus chord from the inboard side.

i Options 1 and 2: A stop drill is not necessary, and there is more than 1.0 diameter edgemargin to the upper flange after the hole has been oversized:

Increase the fastener hole size in 1/64 inch increments to remove the damage. Do a secondinspection for cracks as given in Figure 1. If no cracks are found, increase the hole diameterby 1/32 inch diameter. Cold work and ream the holes as given in Figure 2. After you makethe fastener hole larger, and have coldworked and reamed the hole:

- Option 1: If there is 1.5 diameter edge margin to the upper flange, and a 0.375 inchdiameter or smaller hole, install the size and type of fastener shown in Figure 2. Returnthe airplane to a serviceable condition as given in Part VI - RETURN TO SERVICE. Makethe inspection as given in Figure 1 at regularly scheduled times. The time between oneinspection and the subsequent inspection must not be more than 14,000 flight cycles. Tostop the inspection made necessary by this service bulletin, make the change as given inPart V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR.

NOTE: If the Tee has less than 1.2 diameter edge margin install a new Tee 65C37221-7,-8 Opposite, or make a new Tee as shown in Figure 23.

- Option 2: If the hole diameter is larger than 0.375 inch, or if there is between 1.5 and 1.0diameter edge margin to the upper flange, get alternate repair data and inspection timesfrom Boeing or do Part III- SMALL REPAIR, or Part V - PREVENTIVE MODIFICATION,or PART IV - LARGE REPAIR.

or

ii Option 3: If a stop drill is necessary, or if the crack goes through two fastener holes, or ifthere is less then 1.0 diameter edge margin, do Part III - SMALL REPAIR. Continue theSmall Repair inspections at 3500 flight cycle intervals, as shown in Part III.A. To terminatethe inspections do Part V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR.

or

iii Option 4: If a stop drill is necessary, or if the crack goes through two or more fastener holes,or if there is less then 1.0 diameter edge margin, do Part V - PREVENTIVE MODIFICATION,or PART IV - LARGE REPAIR. This terminates the inspection made necessary by thisservice bulletin.

Sep 2/70 727-57-0112REV 5: Jul 31/97 37


b That are more than one inch total in length, but do not extend aft of B.S. 766 or go into thehorizontal flange, make the change as given in PART V - PREVENTIVE MODIFICATION, orPART IV - LARGE REPAIR. The change given in the PART V - PREVENTIVEMODIFICATION, or PART IV - LARGE REPAIR stops the inspections made necessary by thisservice bulletin.

c That extend aft of B.S. 766, but do not extend aft of B.S. 775.5 or go into the horizontal flange,make the change as given in Part IV - LARGE REPAIR. The change given in the PART IV -LARGE REPAIR stops the inspections made necessary by this service bulletin.

d That go into the horizontal flange, but do not extend aft of B.S. 775.5.

CAUTION: IF THE CRACK GOES INTO THE HORIZONTAL FLANGE, DO NOT DRILL ASTOP HOLE VERTICALLY INTO THE HORIZONTAL FLANGE. THE REPAIRWITH A VERTICAL STOP HOLE TAKES MORE TIME THAN THE REPAIR WITHA HORIZONTAL STOP HOLE.

i. Remove the crack as shown in Figure 22.

ii. After the crack is removed write to Boeing for instructions. Include the information shownbelow:

- The distance (dimension "A") from the upper surface of the inboard horizontal flange tothe deepest point of the blend out.

- A side view that shows where the blendout starts and ends. Indicate the blendout lengthsand widths.

- The blend out lengths forward to aft (dimension "C"), and inboard to outboard (dimension"B").

- If possible, the minimum remaining thickness of the rib chord in the area of the blend out.Measure ultrasonically.

e That extend aft of B.S. 775.5, write to Boeing for instructions.

B Airplanes changed as given in Figure 2. Make the inspection as given in Figure 1 at the next D check(or equivalent major inspection) or before the airplane collects 14,000 more flight cycles, since thechange. Use the time or flight cycles that occurs first.

1 If no cracks are found, install new fasteners. Install the size and type of fastener shown in Figure 2and return the airplane to a serviceable condition as given in Part VI - RETURN TO SERVICE.Make the inspection as given in Figure 1 at regularly scheduled times. The time between oneinspection and the subsequent inspection must not be more than 14,000 flight cycles. To stop theinspection made necessary by this service bulletin, make the change as given in Part V -PREVENTIVE MODIFICATION.

2 If cracks are found:

a That are less than one inch total in length, and do not go into the horizontal flange.

NOTE: The length includes the fastener hole diameter, the crack length and the final stop holediameter.

Sep 2/70 727-57-0112REV 5: Jul 31/97 38


There are four options for repair. Before you start the repair, estimate if a stop drill will benecessary, or if the hole can be oversized sufficiently to remove the damage. Estimate theamount of edge margin between the upper fasteners and the upper flange. Also determine ifthe crack goes through one or more fastener holes.

NOTE: It is easier to estimate the crack length if the Frame Attach Tee is removed. This willgive visual access to the vertical flange of the plus chord from the inboard side.

i Options 1 and 2: A stop drill is not necessary, and there is more than 1.0 diameter edgemargin to the upper flange after the hole has been oversized:

Increase the fastener hole size in 1/64 inch increments to remove the damage. Do a secondinspection for cracks as given in Figure 1. If no cracks are found, increase the hole diameterby 1/32 inch diameter. Cold work and ream the holes as given in Figure 2. After you makethe fastener hole larger, and have coldworked and reamed the hole:

- Option 1: If there is 1.5 diameter edge margin to the upper flange, and a 0.375 inchdiameter or smaller hole, install the size and type of fastener shown in Figure 2. Returnthe airplane to a serviceable condition as given in Part VI - RETURN TO SERVICE. Makethe inspection as given in Figure 1 at regularly scheduled times. The time between oneinspection and the subsequent inspection must not be more than 14,000 flight cycles. Tostop the inspection made necessary by this service bulletin, make the change as given inPart V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR.

NOTE: If the Tee has less than 1.2 diameter edge margin install a new Tee 65C37221-7,-8 Opposite, or make a new Tee as shown in Figure 23.

- Option 2: If the hole diameter is larger than 0.375 inch, or if there is between 1.5 and 1.0diameter edge margin to the upper flange, get alternate repair data and inspection timesfrom Boeing or do Part III- SMALL REPAIR, or Part V - PREVENTIVE MODIFICATION,or PART IV - LARGE REPAIR.

or

ii Option 3: If a stop drill is necessary, or if the crack goes through two fastener holes, or ifthere is less then 1.0 diameter edge margin, do Part III - SMALL REPAIR. Continue theSmall Repair inspections at 3500 flight cycle intervals, as shown in Part III.A. To terminatethe inspections do Part V - PREVENTIVE MODIFICATION, or PART IV - LARGE REPAIR.

or

iii Option 4: If a stop drill is necessary, or if the crack goes through two or more fastener holes,or if there is less then 1.0 diameter edge margin, do Part V - PREVENTIVE MODIFICATION,or PART IV - LARGE REPAIR. This terminates the inspection made necessary by thisservice bulletin.

b That are more than one inch in length, but do not extend aft of B.S. 766 or go into the horizontalflange, make the change as given in PART V - PREVENTIVE MODIFICATION, or PART IV -LARGE REPAIR. The change given in the PART V - PREVENTIVE MODIFICATION, or PARTIV - LARGE REPAIR stops the inspections made necessary by this service bulletin.

c That extend aft of B.S. 766, but do not extend aft of B.S. 775.5 or go into the horizontal flange,make the change as given in Part IV - LARGE REPAIR. The change given in the PART IV -LARGE REPAIR stops the inspections made necessary by this service bulletin.

d That go into the horizontal flange, but do not extend aft of B.S. 775.5.

Sep 2/70 727-57-0112REV 5: Jul 31/97 39


CAUTION: IF THE CRACK GOES INTO THE HORIZONTAL FLANGE, DO NOT DRILL ASTOP HOLE VERTICALLY INTO THE HORIZONTAL FLANGE. THE REPAIRWITH A VERTICAL STOP HOLE TAKES MORE TIME THAN THE REPAIR WITHA HORIZONTAL STOP HOLE.

i. Remove the crack as shown in Figure 22.

ii. After the crack is removed write to Boeing for instructions. Include the information shownbelow:

- The distance (dimension "A") from the upper surface of the inboard horizontal flange tothe deepest point of the blend out.

- A side view that shows where the blendout starts and ends. Indicate the blendout lengthsand widths.

- The blend out lengths forward to aft (dimension "C"), and inboard to outboard(dimension "B").

- If possible, the minimum remaining thickness of the rib chord in the area of the blend out.Measure ultrasonically.

e That extend aft of B.S. 775.5, write to Boeing for instructions.

C On Group 1 Airplanes that had the Major Repair/ Preventive Modification (65C33202-1, -2 Opposite)done as shown in Revision 2, or 3, a repair strap was omitted from the drawings and kits for Revision2, and 3. It is necessary for Group 1 Airplanes that have the Major Repair/Preventive Modificationinstalled, as shown in Revision 2 or 3, to make an inspection at BL 70.5 for the repair strap as follows:

NOTE: Some operators have installed the strap used in Service Bulletin 727-53-0197, or anoperator-furnished strap

1. Make an inspection for the repair strap at a maintenance check before the airplane collects a totalof 3,000 more flight cycles, see Figure 19.

2. If the strap was not installed, refer to Service Bulletin 727-53-0197 for the inspection of the BS760.95 frame. Install the repair strap when the repair or preventive modification shown in ServiceBulletin 727-53-0197 is installed, or at a convenient maintenance time, as shown below.

a. Left Side:

1. Make the changes to the left side as shown in Figure 20.

2. Return the airplane to serviceable condition as given in Part VI.

b. Right Side:

1. Gain access to the wing upper surface and the wing fuel cell. Use the appropriate accessinstructions given in Part IV - LARGE REPAIR. A - Access.

2. Make the changes to the right side as shown in Figure 21.

3. Close access to the wing upper surface and the wing fuel cell. Use the appropriate accessinstructions given in Part IV - LARGE REPAIR. E - Restoration.

3. If the strap was not installed, and there are cracks, do Service Bulletin 727-53-0197.

Sep 2/70 727-57-0112REV 5: Jul 31/97 40


PART III - SMALL REPAIR -

A Make the repair, refer to Drawing 65-68492 and install 65-68492-33 and/or 65-68492-34 opposite(Group 1 Airplanes) or install 65-68492-35 and/or 65-68492-36 opposite (Group 2 Airplanes).

NOTE:

1. Do not cold work the hole where the crack started. Enlarge the diameter of the hole, inthe rib chord only, where the crack started. Enlarge the hole by 1/64 to 1/32 inch diameterlarger than the repair fastener.

2. Airplanes that have been repaired by previous kits (65-68492-1, -2, -11, -12, -17, -18, -25,and -26) are structurally satisfactory.

Return the airplane to a serviceable condition as given in Part Vl - RETURN TO SERVICE.

Make the inspection as given in the 727 Nondestructive Test Manual, D6-48875, Part 6, Subject51-00-00, Figure 4 (or operators equal procedure) at regularly scheduled times. The time betweenone inspection and the subsequent inspection must not be more than 3,500 flight cycles.

NOTES:

1. It is not necessary to remove the repair or the fasteners to do the subsequent inspections.

2. Do the inspection of the vertical flange of the rib chord from the inboard side.

3. Carefully inspect the radius of the rib chord below the inboard repair plate, and the area of therib chord near the forward and aft sides of the inboard repair plate.

To stop the inspection given in this service bulletin, make the change as given in Part V -PREVENTIVE MODIFICATION, or Part IV - LARGE REPAIR.

or

B Do Part V - PREVENTIVE MODIFICATION.

Sep 2/70 727-57-0112REV 5: Jul 31/97 41


PART IV - LARGE REPAIR

A. Access

1 Provide System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

2 Fully extend the leading edge slats. Refer to the 727 Maintenance Manual Subject 27-81-0.

3 Remove System B hydraulic power. Refer to the 727 Maintenance Manual Subject 27-81-0.

4 Defuel the left wing tank, right wing tank, and center section tank. Refer to the 727 MaintenanceManual Subject 28-23-0.

5 Purge the center section fuel cells and the necessary wing fuel tank(s). Refer to the 727Maintenance Manual Subject 28-10-0.

6 Remove and keep the center section access panel. Refer to the 727 Maintenance Manual Subject28-11-21.

7 Remove and keep the center section fuel cell access panel. Refer to the 727 Maintenance ManualSubject 28-12-11.

8 If fuel cell bladders are installed and the Number 1 fuel cell bladder is not installed remove theintercell access panel. Refer to the 727 Maintenance Manual Subject 28-12-31.

9 Remove and keep the intercell baffle plate(s). Refer to the 727 Maintenance Manual Subject28-12-21.

10 If fuel cell bladders are installed remove and keep the fuel cell bladder. Refer to the 727Maintenance Manual Subject 28-12-1.

11 Remove and keep the fuel tank access panel in the wing front spar. Refer to the 727 MaintenanceManual Subject 28-11-21.

12 Remove and keep the forward retainer strip used to hold the fairing to the body.

B. Cracks

1. Drill a stop hole at the end of the cracks that do not terminate in a fastener hole (use the 727Structural Repair Manual Subject 51-10-1). If the hole will be farther than 1 inch aft of thereference holes, shown in Figure 1, increase the stop hole diameter to 0.625 inch. Deburr theholes and make a 32 microinch finish in the holes.

2. Oversize all of the fastener holes, in the chord only, that are cracked. Increase the diameter ofthese holes an additional 1/64 to 1/32 inch larger than final hole size shown in Figures 4, 6, 8, 10.Only increase the hole size in the chord, not the hole size in the body skin or the structures to beadded in this bulletin. The oversized holes in the chord are oversized more than the diameter ofthe fasteners installed through these holes. This is done so that no load is transferred from thefastener to the chord, at the crack locations.

C. Change (Group 1 Airplanes):

1 Left Chord: Make the changes shown in Figures 3 and 4.

2 Right Chord: Make the changes shown in Figures 5 and 6.

Sep 2/70 727-57-0112REV 5: Jul 31/97 42


D. Change (Group 2 Airplanes):



E. Restoration

1 Install the access panels on the vent stringers, use the fasteners kept and Sealant BMS 5-26,type II.

2 Install the fuel tank access panel in the wing front spar. Refer to the 727 Maintenance ManualSubject 28-11-21.

3 Install the fuel cell bladders if they were removed. Refer to the 727 Maintenance Manual Subject28-12-1.

4 Install the intercell baffle plate(s). Refer to the 727 Maintenance Manual Subject 28-12-21.

5 If the fuel cell bladders were installed and the Number 1 fuel cell bladder was not installed installthe intercell access panel. Refer to the 727 Maintenance Manual Subject 28-12-31.

6 Install the center section fuel cell access panel. Refer to the 727 Maintenance Manual Subject28-12-11.

7 Install the center section access panel. Refer to the 727 Maintenance Manual Subject 28-11-21.

8 Fuel the left wing tank, right wing tank, and center section tank and check for leaks. Refer to the727 Maintenance Manual Subject 28-11-0.


10 Fully retract the leading edge slats. Refer to the 727 Maintenance Manual Subject 27-81-0.


12 Return the airplane to serviceable condition as given in Part VI.

Sep 2/70 727-57-0112REV 5: Jul 31/97 43


PART V - PREVENTIVE MODIFICATION

A Access


2 Fully extend the leading edge slats. Refer to the 727 Maintenance Manual Subject 27-81-0.


4 Defuel the left wing tank, right wing tank, and center section tank. Refer to the 727 MaintenanceManual Subject 28-23-0.

5 Purge the center section fuel cells and the necessary wing fuel tank(s). Refer to t.0he 7270..0Maintenance Manual Subject 28-10-0.

6 Remove and keep the center section access panel. Refer to the 727 Maintenance Manual Subject28-11-21.

7 Remove and keep the center section fuel cell access panel. Refer to the 727 Maintenance ManualSubject 28-12-11.

8 If fuel cell bladders are installed and the Number 1 fuel cell bladder is not installed remove theintercell access panel. Refer to the 727 Maintenance Manual Subject 28-12-31.

9 Remove and keep the intercell baffle plate(s). Refer to the 727 Maintenance Manual Subject28-12-21.

10 If fuel cell bladders are installed remove and keep the fuel cell bladder. Refer to the 727Maintenance Manual Subject 28-12-1.

11 Remove and keep the fuel tank access panel in the wing front spar. Refer to the 727 MaintenanceManual Subject 28-11-21.

12 Remove and keep the forward retainer strip used to hold the fairing to the body.

B Cracks

1. Drill a stop hole at the end of the cracks that do not terminate in a fastener hole (use 727 StructuralRepair Manual Subject 51-10-1). If the hole will be farther than 1 inch aft of the reference holes,shown in Figure 1, increase the stop hole diameter to 0.625 inch. Deburr the holes and make a 32microinch finish in the holes.

2. Oversize all of the fastener holes, in the chord only, that are cracked. Increase the diameter ofthese holes an additional 1/64 to 1/32 inch larger than final hole size shown in Figures 12, 14, 16,18. Only increase the hole size in the chord, not the hole size in the body skin or the structures tobe added in this bulletin. The oversized holes in the chord are oversized more than the diameter ofthe fasteners installed through these holes. This is done so that no load is transferred from thefastener to the chord, at the crack locations.

C Change (Group 1 Airplanes):



Sep 2/70 727-57-0112REV 5: Jul 31/97 44


D Change (Group 2 Airplanes):



E Restoration

1 Install the access panels on the vent stringers, use the fasteners kept and Sealant BMS 5-26,type II.

2 Install the fuel tank access panel in the wing front spar. Refer to the 727 Maintenance ManualSubject 28-11-21.

3 Install the fuel cell bladders if they were removed. Refer to the 727 Maintenance Manual Subject28-12-1.

4 Install the intercell baffle plate(s). Refer to the 727 Maintenance Manual Subject 28-12-21.

5 If the fuel cell bladders were installed and the Number 1 fuel cell bladder was not installed installthe intercell access panel. Refer to the 727 Maintenance Manual Subject 28-12-31.

6 Install the center section fuel cell access panel. Refer to the 727 Maintenance Manual Subject28-12-11.

7 Install the center section access panel. Refer to the 727 Maintenance Manual Subject 28-11-21.

8 Fuel the left wing tank, right wing tank, and center section tank and check for leaks. Refer to the727 Maintenance Manual Subject 28-11-0.


10 Fully retract the leading edge slats. Refer to the 727 Maintenance Manual Subject 27-81-0.


12 Return the airplane to serviceable condition as given in Part VI.

PART VI - RETURN TO SERVICE

A Install the pressure seal and the pressure pan removed to get access to the chord, Body Station 740through 760. Refer to the 727 Maintenance Manual Subject 51-30-1.

B Install the interior access panels removed to get access to the center section upper surface, BodyStation 740 through 783. Refer to the 727 Maintenance Manual Subject 25-21-1.

C Install the floor panels removed to get access to the center section upper surface, Body Station 740through 783. Refer to the 727 Maintenance Manual Subject 53-20-11.

D Install the carpets removed to get access to the center section upper surface, Body Station 740through 783. Refer to the 727 Maintenance Manual Subject 25-20-31 for standard passengerairplanes or 25-20-32 for passenger/cargo convertible airplanes.

E Install the seats removed to get access to the center section upper surface, Body Station 740 through783. Refer to the 727 Maintenance Manual Subject 25-22-0.

F Install the forward retainer strip and the wing-to body fairing. If changes are necessary use Drawing65C36390 Rib Chord Repair Installation - Fairing Rework.

Sep 2/70 727-57-0112REV 5: Jul 31/97 45


FIGURE TABLE OF CONTENTS

Title Page

FIGURE 1. INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

FIGURE 2. COLD WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIGURE 3. GROUP 1, LARGE REPAIR, LEFT SIDE, REMOVAL . . . . . . . . . . . . . . . . . . 52

FIGURE 4. GROUP 1, LARGE REPAIR, LEFT SIDE, INSTALLATION . . . . . . . . . . . . . . 58

FIGURE 5. GROUP 1, LARGE REPAIR, RIGHT SIDE, REMOVAL. . . . . . . . . . . . . . . . . 64

FIGURE 6. GROUP 1, LARGE REPAIR, RIGHT SIDE, INSTALLATION. . . . . . . . . . . . . 70

FIGURE 7. GROUP 2, LARGE REPAIR, LEFT SIDE, REMOVAL . . . . . . . . . . . . . . . . . . 76

FIGURE 8. GROUP 2, LARGE REPAIR, LEFT SIDE, INSTALLATION . . . . . . . . . . . . . . 82

FIGURE 9. GROUP 2, LARGE REPAIR, RIGHT SIDE, REMOVAL. . . . . . . . . . . . . . . . . 89

FIGURE 10. GROUP 2, LARGE REPAIR, RIGHT SIDE, INSTALLATION. . . . . . . . . . . . 95

FIGURE 11. GROUP 1, PREVENTIVE MODIFICATION, LEFT SIDE, REMOVAL. . . . . . 102

FIGURE 12. GROUP 1, PREVENTIVE MODIFICATION, LEFT SIDE,INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

FIGURE 13. GROUP 1, PREVENTIVE MODIFICATION, RIGHT SIDE, REMOVAL . . . . 114

FIGURE 14. GROUP 1, PREVENTIVE MODIFICATION, RIGHT SIDE,INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

FIGURE 15. GROUP 2, PREVENTIVE MODIFICATION, LEFT SIDE, REMOVAL. . . . . . 126

FIGURE 16. GROUP 2, PREVENTIVE MODIFICATION, LEFT SIDE,INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

FIGURE 17. GROUP 2, PREVENTIVE MODIFICATION, RIGHT SIDE, REMOVAL . . . . 139

FIGURE 18. GROUP 2, PREVENTIVE MODIFICATION, RIGHT SIDE,INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

FIGURE 19. INSPECTION FOR THE REPAIR STRAP AT BS 760.95 FRAME. . . . . . . . 151

FIGURE 20. INSTALLATION OF THE REPAIR STRAP AT BS 760.95 FRAME -LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

FIGURE 21. INSTALLATION OF THE REPAIR STRAP AT BS 760.95 FRAME -RIGHT SIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

FIGURE 22. CRACK REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

FIGURE 23. MAKE NEW FRAME ATTACH TEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Sep 2/70 727-57-0112REV 5: Jul 31/97 46


FWD

DETAIL I

6 PLACES1 2

SEE DETAIL I

BODY SKIN

VERTICAL FLANGE

RIB CHORD UPPER

REINFORCING ANGLE

A

A

BODY FRAME

REFERENCE HOLES

STA

970

STA

870

760.95

STA

STA

660

STA

760.95

R48142

FIGURE 1. INSPECTION

Sep 2/70 SHEET 1 OF 2 727-57-0112REV 5: Jul 31/97 47


3

1 2

70.5

BBL

INBD

RIB CHORD

WING UPPER SKIN

FILLER

REINFORCING ANGLE

BODY SKIN

SECTION A−A

R44700

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PROCEDURE REFERENCES NOTES

1 Remove Fastener - -

2 Examine Hole High Freqency EddyCurrent

727 NDT, D6-48875,Part 6, 51-00-00,Figures 1 and 4

3 Examine Radius Close Visual - Examine the radius ofthe upper rib chordfor cracks

FIGURE 1. INSPECTION



FWD

BODY SKIN

RIB CHORD UPPER

VERTICAL FLANGE

REINFORCING ANGLE

6 PLACES (TYPICAL)21

BODY FRAME

A

A

STA

760.95

B

A

B

AA

B

SEE DETAIL I

970

STA

870

STA

STA

760.95

660

STA

DETAIL I

R44705

FIGURE 2. COLD WORKING



INBD

SECTION A−A

RIB CHORD

1 2

BODY SKIN

REINFORCING ANGLE

FILLER

WING UPPER SKIN

BBL

70.5

R44708


STEP TASK NAME PART NUMBER QTY NOTES

1 Cold Work Hole - 6 (a)

2 Install Fastener - 6

(a) Low interference cold work the hole. Refer to the SRM 51-30-10 for the start hole diameter and thefinal hole diameter. If the final edge margin is less then 1.5D (except the Frame Attach Tee), write toBoeing for instructions.




The codes given below agree with the letter shown in the upper left corner of the fastener symbols in thefigure. A number in the lower right corner gives the grip length of the fastener.

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NW10K( ) (a)(e)

- Increase the countersink diameterof the hole. Refer to SRM51-30-08. Install wet with BMS5-95 Sealant.

Collar BACC30M10 (e)

B Bolt BACB30MY10K( )(b)(e)

- (c)

BACB30NW10K( )(a)(e)

(c), (d)

Collar BACC30M10 (e)

(a) Optional BACB30FN10A( ) or BACB30FN10( ).

(b) Optional BACB30FM10A( ) or BACB30FM10( ).

(c) Install a fastener with a shear protuding head or a shear flush head as necessary to agree with thestructure. Install wet with BMS 5-95 sealant.

(d) If a fastener with a shear flush head is installed, increase the countersink diameter of the hole.

(e) The fastener diameter is a "10" if the hole has not been oversized to remove damage. If the hole hasbeen made larger to remove damage, use an equivalent fastener in a size to agree with the holediameter, after the hole has been coldworked.




INBDFWD

660

STA

STA

970

SEE DETAIL I

WING SKIN

1

52

760.95

BS

1

4

SEE DETAIL IV

SEE DETAIL II

BODY SKIN

BBL

70.5

STA

760.95

870

STA

R44803

FIGURE 3. GROUP 1, LARGE REPAIR, LEFT SIDE, REMOVAL



INBDFWD

DETAIL I

RIB WEB

2 5

2

1 ACCESS PANEL

S−19

S−20

R44815




FWD

INBD

DETAIL II

CENTER SECTION SKIN

BS

760.95

4

BODY SKIN

52

52

DETAIL III

SEE

BBL

70.5

R44817




FWDINBD

DETAIL III

52

1

1

3 4

1

4

BODY SKIN

BBL

70.5

BS

760.95

R44854




FWDINBD

2

RIB WEB

1

PANELS

ACCESS

2 5

CENTER SECTION SKIN

DETAIL IV

S−19C

S−20C

BBL

70.5

R44858




The step numbers shown below agree with the numbers shown in the circle symbols in the figure. Referto Drawing 65C33202, Sheet 7, to the structural changes shown below.


1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3

2 Remove Sealant - -

Fastener - -

3 Cut Strap - 1 See Zone B7, Section 1D8

4 Remove Angle - 2

Filler - 1

Tee - 1

Strap (lower section) - 1

5 Examine Hole - - NDT Subject 51-00-00, Figures1 and 4




FWDINBD

1

1

3

2

SEE DETAIL II

ACCESS PANEL14

ACCESS PANEL

4

CENTER SECTION SKIN

SEE DETAIL IV

SEE DETAIL I

S−20C

BBL

70.5

S−19C

14

R45312

FIGURE 4. GROUP 1, LARGE REPAIR, LEFT SIDE, INSTALLATION



FWD INBD

6

DETAIL I

70.5

BBL

S−20

S−19

5

14PANEL

ACCESS

7

RIB

R45346




INBD

FWD

DETAIL II

SEE DETAIL III

8

8

9

BBL

70.5

BODY SKIN

CENTER SECTION SKIN

BS

760.95

R45370




FWDINBD

DETAIL III

CENTER SECTION SKIN

14

14

10

10

BODY SKIN

760.95

BS

BBL

70.5

R45384




INBDFWD

DETAIL IV

11

13

12

12

BODY SKIN

WING SKIN

BS

760.95

70.5

BBL

R45415





STEP TASK NAME PART NUMBER QTY NOTES1 Install Tension Tie -

Inboard (Upper)65C37221-1 1 See Sheet 7, Zone A7, Section

1D8 and Zone C11, Section 1C7and Flag Note (FL) 79

Tension Tie -Inboard (Lower)

65C37221-2 1

2 Install Radius Filler 65C37221-10 23 Install Radius Filler 65C37221-9 24 Install Angle - Inboard 65C21524-21 1

Radius Filler 65C21524-14 25 Install Tension Tie -

Outboard65C37221-3 1 See Zone C11, Section 1C7 and

Flag note 78Shim 65C33202-89 1 Above the Tension TieRadius Filler 65C37221-16 1 Aft side of Tension TieRadius Filler 65C37221-13 1 Forward side of Tension Tie

6 Install Radius Filler 65C37221-15 2Shim 65C33202-90 1

7 Install Angle - Outboard 65C21524-19 1Radius Filler 65C21524-14 2

8 Install Shim 65C33202-85 1Shim 65C33202-67 1Angle 65C33202-107 1 Trim the contour of part, see FL 93Tapered Filler 65C33202-11 1 Between the Angle and the chord

9 Apply Sealant BMS5-95 - Put the sealant into the hole10 Install Strap (a) 1 (b)

Filler (kept) 65-16325-28 1Tee 65C37221-7 1 Trim the contour of part, see FL 84Angle - Forward,Inboard

65C33202-117 1 Trim the contour of part, see FL 93

11 Install Filler-Outboard 65C33202-9 1Angle - Outboard 65C33202-105 1 Trim the contour of part, see FL 93

12 Install Spacer 65C33202-15 1Filler BACF3T02L28-11 2Fitting 65C33202-113 1 Trim the contour of part, see FL 94Radius Filler 65C37221-11 1 See FL 106

13 Apply Silicon RubberAdhesive

- -

Install Foam Seal (kept) - 1 Trim as nesessary14 Install Access Panel (kept) - 3

Angle (kept) - 3(a) For 727-100 airplanes, use the Strap 69-78758-7. For 727-200 airplanes, use the Strap 69-78758-5(b) Cut the upper area of the strap, if necessary. Remove no more than the upper two fastenerlocations, keep an edge margin of 2D above the new top fastener location and the cut.




FWDINBD

1

WING SKIN

SEE DETAIL ISEE DETAIL IV

BBL

70.5

SEE DETAIL II

2 5 760.95

BS

BODY SKIN

4

STA

970

STA

870

STA

760.95

660

STA

1

R45480

FIGURE 5. GROUP 1, LARGE REPAIR, RIGHT SIDE, REMOVAL



FWDINBD

DETAIL I

RIB WEB

52

WING SKIN

62

ACCESS PANEL1

S−20

S−19

BBL

70.5

R45497




FWD

INBD

DETAIL II

BODY SKIN

CENTER SECTION SKIN

SEE

DETAIL III

BS

760.95

BBL

70.5

2 5

4

R45506




INBDFWD

DETAIL III

1

52

1

4

43

BODY SKIN

1

BBL

70.5

BS

760.95

R45537




INBDFWD

DETAIL IV

CENTER SECTION SKIN

1

ACCESS

PANELS

70.5

BBL

RIB WEB

52

S−20C

S−19C

2

R45540






1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3


Fastener - -

3 Cut Strap - 1 See Zone B7, section 1D8

4 Remove Angle - 2

Filler - 1

Tee - 1



6 Install Rivet - 1 Install aluminum rivet,countersink, and shave smooth




1

3

4

12

14

14

INBDFWD

SEE DETAIL I

70.5

BBL

ACCESS PANEL

SEE DETAIL IV

CENTER SECTION SKIN

SEE DETAIL IIACCESS PANEL

S−20C

S−19C

R45546

FIGURE 6. GROUP 1, LARGE REPAIR, RIGHT SIDE, INSTALLATION



INBD FWD

S−20

14PANEL

ACCESS

S−20

S−19

5

WING SKIN

DETAIL I

BBL

70.57

6

RIB WEB

R45557




FWD

INBD

8

DETAIL II

CENTER SECTION SKIN

BS

760.95

SEE DETAIL III

BBL

70.5

BODY SKIN

9

8

R45559




10

10

INBDFWD

DETAIL III

BODY SKIN

14

14

CENTER SECTION SKIN

70.5

BBL

760.95

BS

R45564




BBL

70.5

FWDINBD

DETAIL IV

BODY SKIN

13

12

11

WING

SKIN

12

R45569









65C37221-2 1



Outboard65C37221-4 1 See Zone D3, Section 1B4, and

Flag Note 78Shim 65C33202-88 1 Above the Tension TieFiller 65C33202-87 1 between the shim and the wing

skinRadius Filler 65C37221-14 2



8 Install Shim 65C33202-85 1Shim 65C33202-67 1Angle 65C33202-108 1 Trim the contour of part, see FL 93Tapered Filler 65C33202-12 1 Between the Angle and the chord





12 Install Spacer 65C33202-16 1Filler BACF3T02L28-11 2Fitting 65C33202-113 1 Trim the contour of part, see FL 94Radius Filler 65C37221-11 1 See FL 106

13 Apply Silicone RubberAdhesive

- -






INBDFWD

SEE DETAIL I

SEE DETAIL IV

660

STA

STA

760.95

870

STA

STA

970

BODY SKIN

SEE

DETAIL II

WING SKIN

1

1

4

760.95

BS

2 5

70.5

BBL

R45581




INBDFWD

S−19

DETAIL I

52

RIB WEB

2

ACCESS PANEL1

S−20

2

R45583




SEE

DETAIL III

BODY SKIN

DETAIL II

FWD

INBD

CENTER SECTION SKIN

70.5

BBL

4

760.95

BS

2 5

R45585




FWDINBD

DETAIL III

CENTER SECTION SKIN

2 5

1

BODY SKIN

43

760.95

BS

4

1

BBL

70.5

1

R45588




FWDINBD

DETAIL IV

PANELS

ACCESS

CENTER SECTION SKIN

1

BBL

70.5

52

RIB WEB

2

S−20C

S−19C

R45597






1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3


Fastener - -

3 Cut Strap - 1 See Zone B7, Section D8

4 Remove Angle - 2

Filler - 1

Tee - 1






BBL

70.5

FWDINBD

ACCESS

PANEL14

ACCESS

PANEL14

SEE DETAIL II

CENTER SECTION SKIN

SEE DETAIL IV

RIB WEB

SEE DETAIL I

S−20C

S−19C

2

1

R45696




FWD INBD

BBL

70.5

S−19

S−20

6

WING SKIN14

ACCESS

PANEL

4

DETAIL I

3

5

RIB

R45731




BODY SKIN

BBL

70.5

760.95

BS

FWD

DETAIL II

INBD

7

SEE

DETAIL III

CENTER SECTION SKIN

7

7

R45744




14

14

9

70.5

BBL

FWDINBD

BS

760.95

DETAIL III

BODY SKIN

CENTER SECTION SKIN

7

8

R45770




INBDFWD

BODY SKIN

WING SKIN

DETAIL IV

BS

760.95

11

10

13

10

11

12

R45777






1 Install Tension Tie -Inboard

65C37073-1 1 See Sheet 11, Zone A7, SectionD8

Shim BACS40R019E036F 1

2 Install Angle - Inboard 65C33202-44 1

Radius Filler 65C33202-68 2

3 Install Tension Tie -Outboard

65C37083-1 1 See Zone B1, Section 1C7 andZone C9, Section D7 and FlagNotes (FL) 44 and 86

Shim 65C33202-59 1 Above the Tension Tie

Filler 65C33202-60 1 Between the Tension Tie and thewing skin

4 Install Radius Filler 65C37083-3 1 Aft side of Tension Tie

Radius Filler 65C37083-5 1 Forward side of Tension Tie



Shim 65C33202-95 1

6 Install Angle - Outboard 65C33202-45 1


7 Install Shim 65C33202-51 1

65C33202-52 1

65C33202-53 1

Pressure RetainingAngle

65C33202-54 1

Angle 65C33202-107 1 Trim the contour of part, see FL 93

Tee 65C37221-7 1 Trim the contour of part, see FL 93

Tapered Filler 65C33202-48 1 Between the Angle and the chord

Filler 65C33202-69 1

8 Install Strap 69-78758-5 1

Filler (kept) 65-16325-80 1

9 Install Angle - Forward,Inboard


10 Install Filler-Outboard 65C33202-50 1

Shim 65C33202-71 1

Angle - Outboard 65C33202-105 1 Trim the contour of part, see FL 93

11 Install Spacer 65C33202-47 1

Filler BACF3T02M26-12 2




(Continued)


12 Install Fitting 65C33202-113 1 Trim the contour of part, see FL 94

Radius Filler 65C33202-115 1 Optional, see FL 106


- -

Install Foam Seal (kept) - 1 Trim as nesessary

14 Install Access Panel (kept) - 3

Angle (kept) - 3




INBD FWD

1

SEE DETAIL I

760.95

52

1

4

BS

970

STA

STA

870

STA

760.95

STA

660

BODY SKIN

WING SKIN

SEE DETAIL II

SEE DETAIL IV

BBL

70.5

R45796




FWDINBD

DETAIL I

RIB WEB

S−19

S−20

ACCESS PANEL1

2

WING SKIN

2 5BBL

70.5

R45801




FWD

INBD

SEE

DETAIL III

4

BODY SKIN

DETAIL II

CENTER SECTION SKIN

2 5

BBL

70.5

BS

760.95

R45870




INBDFWD

DETAIL III

CENTER SECTION SKIN

4

BODY SKIN

BBL

70.5

43

760.95

BS

52

11

1

R45872




INBDFWD

2

CENTER SECTION SKIN

DETAIL IV

RIB WEB

52

S−19C

S−20C

PANELS

ACCESS

1

BBL

70.5

R45874






1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3


Fastener - -


4 Remove Angle - 2

Filler - 1

Tee - 1






INBDFWD

RIB WEB

SEE DETAIL I

SEE DETAIL II

CENTER SECTION SKIN

SEE DETAIL IV1

ACCESS

PANEL

70.5

BBLPANEL

ACCESS

S−20C

S−19C

2

13

13

R45881




FWDINBD

DETAIL I

RIB WEB

WING SKIN

3

S−20

S−19

ACCESS

PANEL

4

4

S−20

70.5

BBL

5

13

R45896




INBD

FWD

DETAIL II

CENTER SECTION SKIN

6

SEE

DETAIL III

BODY SKIN

BBL

70.5

BS

760.95

6

6

R45918




INBDFWD

DETAIL III

CENTER SECTION SKIN

8

7

BODY SKIN

BBL

70.5

6

BS

760.95

13

13

R45923




FWDINBD

BODY SKIN

DETAIL IV

9

9

WING SKIN

10

BS

760.95

10

12

11

R45925












65C37073-2 1 See Zone D2, Section C3 andZone A10, Section D3 and FlagNote (FL) 86

Shim 65C33202-96 Above the Tension Tie


4 Install Radius Filler 65C37073-3 2

Shim 65C33202-56 1 Below the Tension Tie

Filler 65C33202-55 1 Between the shim and the lowerAngle




65C33202-52 1

65C33202-53 1

Pressure RetainingAngle

65C33202-54 1




Filler 65C33202-69 1


Filler (kept) 65-16325-80 1




Shim 65C33202-71 1









(Continued)



- -



Angle (kept) - 3




INBDFWD

WING SKIN

1

4

SEE DETAIL I

1

52

BODY SKIN

SEE DETAIL II

SEE DETAIL IV

760.95

BS

BBL

70.5

660

STA

STA

760.95

STA

970

870

STA

R45952

FIGURE 11. GROUP 1, PREVENTIVE MODIFICATION, LEFT SIDE, REMOVAL



INBDFWD

2

S−20

S−19

ACCESS PANEL1

RIB WEB

DETAIL I

52

R45957




BODY SKIN

INBD

DETAIL II

FWD

DETAIL III

SEE

CENTER SECTION SKIN

BS

760.95

BBL

70.5

4

52

R45962




FWDINBD

DETAIL III

1

43

4

BODY SKIN

1

2 5

1

760.95

BS

70.5

BBL

R45969




FWDINBD

DETAIL IV

RIB WEB

2 5

CENTER SECTION SKIN

2

1

PANELS

ACCESS

S−19C

S−20C

BBL

70.5

R45974






1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3


Fastener - -


4 Remove Angle - 2

Filler - 1

Tee - 1






FWDINBD

1 2

3

1

4

SEE DETAIL I

SEE DETAIL IV

CENTER SECTION SKINSEE DETAIL II

ACCESS PANEL

14

S−20C

BBL

70.5

S−19C

R45984

FIGURE 12. GROUP 1, PREVENTIVE MODIFICATION, LEFT SIDE, INSTALLATION



INBDFWD

DETAIL I

S−20

S−19

PANEL

ACCESS14

5

7

6

70.5

BBLRIB

R45987




9

BODY SKIN

8

FWD

DETAIL II

INBD

CENTER SECTION SKIN

DETAIL III

SEE

70.5

BBL

760.95

BS

8

R46042




10

10

FWDINBD

DETAIL III

CENTER SECTION SKIN

14

14

BODY SKIN

760.95

BS

BBL

70.5

R46084




INBDFWD

12

13

11

70.5

BBL

DETAIL IV

760.95

BS

R46147









65C37221-2 1



Outboard65C37221-3 1 See Zone C7, Section 1D8 and

Zone C11, Section 1C7, and FlagNote 78

Shim 65C33202-89 1 Above the Tension TieRadius Filler 65C37221-16 1 Aft side of Tension TieRadius Filler 65C37221-13 1 Forward side of Tension Tie



8 Install Shim 65C33202-86 1Angle 65C33202-107 1 Trim the contour of part, see FL 93Tapered Filler 65C33202-11 1 Between the Angle and the chord





12 Install Spacer 65C33202-15 1 Delete the reference to FL80Filler BACF3T02L28-11 2Fitting 65C33202-113 1 Trim the contour of part, see FL 94Radius Filler 65C37221-11 1 Optional, see FL 106


- -






FWDINBD

760.95

BS

SEE DETAIL I

70.5

BBL

SEE DETAIL IV

SEE DETAIL II

WING SKIN

BODY SKIN

1

STA

760.95

4

2 5

1

STA

970

STA

870

660

STA

R46150

FIGURE 13. GROUP 1, PREVENTIVE MODIFICATION, RIGHT SIDE, REMOVAL



INBD FWD

6

2

DETAIL I

BBL

70.5

S−20

S−19

WING SKIN

RIB WEB

1 ACCESS PANEL

52

R46152




INBD

FWD

DETAIL II

CENTER SECTION SKIN

BODY SKIN

SEE

DETAIL III

BS

760.95

BBL

70.5

2 5

4

R46174




INBDFWD

DETAIL III

52

BODY SKIN

1

1

4

43

BBL

70.5

BS

760.95

1

R46193




INBDFWD

DETAIL IV

RIB WEB

2 5

CENTER SECTION SKIN

BBL

70.5

PANELS

ACCESS

1

2

S−19C

S−20C

R46204






1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3


Fastener - -


4 Remove Angle - 2

Filler - 1

Tee - 1



6 Install Rivet - 1 Install aluminum rivet,countersink, and shave smooth




INBDFWD

CENTER SECTION SKIN

3

1

1

2

ACCESS PANEL14

70.5

BBL

ACCESS PANEL

14

SEE DETAIL II

SEE DETAIL IV

SEE DETAIL I

4

S−20C

S−19C

R46231

FIGURE 14. GROUP 1, PREVENTIVE MODIFICATION, RIGHT SIDE, INSTALLATION



FWDINBD

DETAIL I

RIB WEB

7

S−20

S−19

5

PANEL

ACCESS14

WING SKIN

6

BBL

70.5

S−20

R46233




FWD

INBD

CENTER SECTION SKIN

DETAIL II

BODY SKIN

9

8

8

SEE DETAIL III

70.5

BBL

760.95

BS

R46250




10

10

INBDFWD

CENTER SECTION SKIN

DETAIL III

14

14

BODY SKIN

BBL

70.5

BS

760.95

R46254




BBL

70.5

FWDINBD

13

12

WING SKIN

BODY SKIN

DETAIL IV

12

11

R46258







2C7 and Flag Note (FL) 79Tension Tie -Inboard (Lower)

65C37221-2 1



Outboard65C37221-4 1 See Zone C11, Section 1C7 and

Zone C4, Section 1B4 and FlagNote 78

Shim 65C33202-88 1 Above the Tension TieFiller 65C33202-87 1 Between the shim and the wing

skinRadius Filler 65C37221-14 2



8 Install Shim 65C33202-86 1Angle 65C33202-108 1 Trim the contour of part, see FL 93Tapered Filler 65C33202-12 1 Between the Angle and the chord





12 Install Spacer 65C33202-16 1Filler BACF3T02L28-11 2Fitting 65C33202-113 1 Trim the contour of part, see FL 94Radius Filler 65C37221-11 1 Optional, see FL 106


- -






FWD INBD

70.5

BBL

4

760.95

BS

2 5

1

1

BODY SKIN

760.95

STA

STA

660

870

STA

STA

970

SEE

DETAIL II

SEE DETAIL IVSEE DETAIL I

WING SKIN

R46340




INBDFWD

DETAIL I

2 5

RIB WEB

2

1 ACCESS PANEL

S−19

S−20

2

R46341




FWD

INBD

DETAIL II

BODY SKIN

CENTER SECTION SKIN

SEE

DETAIL III

4

52

70.5

BBL

760.95

BS

R46359




FWDINBD

DETAIL III

BODY SKIN

BBL

70.5

BS

760.95

4

1

3 4

1

52

1

R46365




FWDINBD

BBL

70.5

DETAIL IV

RIB WEB

CENTER SECTION SKIN

S−20

S−19

PANELS

ACCESS

1

2

52

R46369






1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3


Fastener - -


4 Remove Angle - 2

Filler - 1

Tee - 1






FWDINBD

SEE DETAIL II

PANEL

ACCESS

2

SEE DETAIL I

RIB WEB

SEE DETAIL IV

CENTER SECTION SKIN

ACCESS

PANEL

S−20C

S−19C

1

BBL

70.5

14

14

R46373




INBDFWD

5

3

DETAIL I

4

PANEL

ACCESS14

WING SKIN

6

S−20

S−19

70.5

BBL

RIB

R46374




BBL

70.5

7

BS

760.95

FWD

INBD

DETAIL II

CENTER SECTION SKIN

7

7

BODY SKIN

DETAIL III

SEE

R46377




70.5

BBL

FWDINBD

BS

760.95

DETAIL III

CENTER SECTION SKIN

BODY SKIN

7

8

14

9

14

R46387




INBDFWD

BBL

70.5

WING SKIN

BODY SKIN

DETAIL IV

BS

760.95

11

11

12

10

13

R46391












65C37083-1 1 See Zone B1, Section 1C7 andZone C9, Section D7, and FlagNote (FL) 86

Shim 65C33202-59 1 Above the Tension Tie

Filler 65C33202-60 1 Between the shim and the wingskin





Shim 65C33202-95 1




Shim 65C33202-53 1

Pressure Retainingangle

65C33202-54 1




Filler 65C33202-69 1


Filler (kept) 65-16325-80 1












(Continued)



- -



Angle (kept) - 3




INBD FWD

760.95

BS

1

4

70.5

BBL

SEE DETAIL IVSEE DETAIL I

WING SKIN

1

2 5

DETAIL II

SEE

BODY SKIN

760.95

STA

STA

660

870

STA

STA

970

R46395




FWDINBD

BBL

70.5

DETAIL I

RIB WEB

2 5

2

S−20

S−19

WING SKIN

ACCESS PANEL1

R46396




FWD

INBD

DETAIL II

CENTER SECTION SKIN

2 5

DETAIL III

SEE

70.5

BBL

BS

760.95

BODY SKIN

4

R46398




INBDFWD

DETAIL III

4

BODY SKIN

BBL

70.5

CENTER SECTION SKIN

43

1

52

1

760.95

BS

1

R46400




INBDFWD

DETAIL IV

RIB WEB

CENTER SECTION SKIN

70.5

BBL

1

ACCESS

PANELS

S−19C

S−20C

2

2 5

R46402






1 Removeand Keep

Foam Seal - 1

Nutplate - 2

Access Panel - 3

Filler - 1

Angle - 3


Fastener - -


4 Remove Angle - 2

Filler - 1

Tee - 1






INBDFWD

ACCESS

PANEL

2SEE DETAIL I

RIB WEB

CENTER SECTION SKIN

SEE DETAIL II

PANEL

ACCESS

SEE DETAIL IV

1

S−20C

S−19C

BBL

70.5

13

13

R46406




FWDINBD

DETAIL I

5

RIB WEB

3

S−20

S−19

ACCESS

PANEL

4

4

S−20

70.5

BBL

WING SKIN

13

R46408




INBD

FWD

SEE

DETAIL III

6

DETAIL II

CENTER SECTION SKIN

6

BS

760.95

6

BODY SKIN

BBL

70.5

R46409




INBDFWD

DETAIL III

CENTER SECTION SKIN

8

7

BODY SKIN

760.95

BS

6

70.5

BBL

13

13

R46410




FWDINBD

70.5

BBL

WING SKIN

BODY SKIN

DETAIL IV

9

BS

760.95

10

10

11

12

R46411






Inboard65C37073-1 1 See Sheet 12, Zone A4, Section

D2Shim BACS40R019E036F 1

2 Install Angle - Inboard 65C33202-44 1Radius Filler 65C33202-68 2


65C37073-2 1 See Zone D2, Section C3 andZone A10, section D3 and FlagNote 86

Shim 65C33202-96 1 Above the Tension TieRadius Filler 65C37073-4 2

4 Install Radius Filler 65C37073-3 2Shim 65C33202-56 1 Below the Tension TieFiller 65C33202-55 1 Between the shim and the Angle

65C33202-465 Install Angle - Outboard 65C33202-46 1

Radius Filler 65C33202-68 26 Install Shim 65C33202-51 1

Shim 65C33202-53 1Pressure Retainingangle

65C33202-54 1

Angle 65C33202-108 1 Trim the contour of part, see FL 93Tee 65C37221-8 1 Trim the contour of part, see FL 93Tapered Filler 65C33202-48 1 Between the Angle and the chordFiller 65C33202-69 1

7 Install Strap 69-78758-5 1Filler (kept) 65-16325-80 1




10 Install Spacer 65C33202-47 1Filler BACF3T02M26-12 2

11 Install Fitting 65C33202-113 1 Trim the contour of part, see FL 93Radius Filler 65C33202-115 1 Optional, see FL 106


- -


Angle (kept) - 3




FWDINBD

CENTER SECTION SKIN

BODY SKIN

EXISTING STRAP

A

A

760.95

BS

REPAIR STRAP1BBL

70.5

R46419

FIGURE 19. INSPECTION FOR THE REPAIR STRAP AT BS 760.95 FRAME



INBD

2

1

WL

210

S−17

VIEW A−A

(VIEW LOOKS BACKWARD)

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

R46420





STEP TASK NAME PROCEDURE REFERENCES NOTES

1 Examine Repair Strap Visual - (a)

2 Examine Shaded area Close Visual - (b)

(a) If a repair strap for Service Bulletin 727-53-0197 was installed, or an operator furnished repair strapwas installed, no more work is necessary. If no repair strap is install do Step 2.

(b) If cracks are found, repair the frame as shown in Service Bulletin 727-53-0197.




FWDINBD

CENTER SECTION SKIN

A

BODY SKIN

43

F

41

2

B

DE

1 5

C

51

70.5

BBL

BS

760.95

R46429

FIGURE 20. INSTALLATION OF THE REPAIR STRAP AT BS 760.95 FRAME - LEFT SIDE





1 Removeand Keep

Filler - 1

Angle - 3 If necessary

2 Remove Fastener - 9

3 Put Repair Strap 69-78758-7 1 727-100 Airplanes (a)

Repair Strap 69-78758-5 1 727-200 Airplanes (a)

4 Install Repair Strap - 1

Filler (kept) - 1

Apply Sealant BMS 5-95 -

5 Install Angle (kept) - 3

(a) Temporarily install the Repair Strap, thicker side up, over the existing strap, and drill to match.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.


A Bolt BACB30NW8K12Y - head far side

Collar BACC30M8

B Bolt BACB30NW8K14Y - head far side

Collar BACC30M8

C Bolt BACB30NW8K20Y - head far side

Collar BACC30M8

D Bolt BACB30MY8K20Y - head far side

Collar BACC30M8

E Bolt BACB30NW8K15Y - head far side

Collar BACC30M8

F Bolt BACB30NW8K13Y - head far side

Collar BACC30M8

FIGURE 20. INSTALLATION OF THE REPAIR STRAP AT BS 760.95 FRAME - LEFT SIDE



INBDFWD

CENTER SECTION SKIN

1 6

SEE DETAIL IBODY SKIN

BS

760.95

70.5

BBL

1 6

4A

3

1 5

R46432

FIGURE 21. INSTALLATION OF THE REPAIR STRAP AT BS 760.95 FRAME - RIGHT SIDE



760.95

BS

FWDINBD

DETAIL I

BBL

70.5

BODY SKIN

F

B

M

L

C

D

K

H

G

I

E

J

WING SKIN

52

R46446






1 Removeand Keep

Filler - 1

Angle - 3 As necessary

2 Removeand Keep

Fitting 65C21524-8 1

Bolt - 2 Discard the additional fastenersshown

Washer - 4

Nut - 2

3 Put Repair Strap 69-78758-7 1 727-100 Airplanes (a)

Repair Strap 69-78758-5 1 727-200 Airplanes (a)

4 Install Repair Strap -

Fastener - 1 Install fastener specified in letterStep A.

Apply Sealant BMS 5-95 -

5 Install Fitting (kept) - 1

Filler (kept) - 1

Fastener - 17 Install the remaining fasteners

Apply Sealant BMS 5-26 - Apply on fasteners that touchfuel.

BMS 5-26 - Apply on the remainingfasteners

6 Install Angle (kept) - 3

(a) Temporarily install the Repair Strap, thicker side up, over the existing strap, and drill to match.




The codes given below agree with the letter shown in the upper left corner of the fastener symbols in thefigure. A number in the lower right corner gives the grip length of the fastener.


A Bolt BACB30MY8K16Y - Head far side

Collar BACC30M8

B Bolt BACB30NW8K12Y -

Collar BACC30M8

C Bolt BACB30NW8K14Y -

Collar BACC30M8

D Bolt BACB30NW8K20Y -

Collar BACC30M8

E Bolt BACB30MY8K18Y -

Collar BACC30M8

F Bolt BACB30MY8K16Y -

Collar BACC30M8

G Bolt BACB30MY8K20 -

Collar BACC30M8

H Bolt BACB30MY8K16 -

Collar BACC30M8

I Bolt BACB30MY12K20Y -

Collar BACC30M12

J Bolt BACB30US6K28 - Head near side

Washer BACW10BP6AC Under bolt head

BACW10BP6AP Under nut

Nut BACN10HR6

K Bolt BACB30MY8K20Y -

Collar BACC30M8

L Bolt BACB30NW8K15Y -

Collar BACC30M8

M Bolt BACB30NW8K13Y -

Collar BACC30M8




1

1

"C"

FWD

FRAME ATTACH TEE

5

RIB CHORD UPPER

VERTICAL FLANGE

REINFORCING ANGLE

BODY SKIN

STA

760.95

SEE DETAIL I

970

STA

870

STA

STA

760.95

660

STA

DETAIL I

A

A

S07771

FIGURE 22. CRACK REMOVAL



1

5

5

42

3

6

1

INBD

SECTION A−A

ANGLE

"B"

"A"RIB CHORD

1 TEEBODY SKIN

WING UPPER SKIN

BBL

70.5

FILLER

S07788



1 Remove/Keep

Frame Attach Tee - 1 If necessary to get access to theend of the crack

Reinforcing Angle 1

Filler 1

2 Drill Stop Drill - 1 Drill from the inboard side to theoutboard side. Drill as near tothe horizontal flange aspossible. 727 SRM 51-10-1

3 Blend Crack - - Blend out the crack downward,use a 0.5 inch radius. Use 0.03to 0.05 inch increments. Blendout until the crack is not visable.




(Continued)


4 Examine Rib Chord - - Do a High Frequency EddyCurrent as shown in 727 NDT,D6-48875, Part 6, 51-00-00,Figure 4. If there is a crackindication do the blend stepbelow. If no crack indication goto Step 5.

Blend Crack - - Blend out the crack downward,use a 0.5 inch radius. Use 0.03to 0.05 inch increments.Continue to blend and examinethe hole until there is no crackremaining.

5 Measure "A" - - Measure the distance from theupper surface of the horizontalflange down to the deepestpoint of the blend out,

"B" - - Measure the blend out inboardto outboard.

"C" - - Measure the blend out forwardto aft.

6 Measure Rib Chord - - Determine the minimumremaining thickness in the blendregion. Can be measured witha digital ultrasonic thicknessgauge.




3.41

0.22

1 3

0.50 R

(2 PLACES)

TYPICAL

TYPICAL2

2

3.53

0.25 R

2.21

(4 PLACES)

0.50 R

0.125 R0.160

0.125

S07887


STEP TASK NAME MATERIAL QTY NOTES

1 Make Frame Attach Tee BAC1506-855 x 4 1 7075-T73511 (QQ-A-200/11)

2 Cut Frame Attach Tee - - Trim the tee from 1.5 to 2Diameter edge margin from theexisting holes in the rib chord

3 Apply Alodine - -

Primer BMS 10-11, Type 1 -

FIGURE 23. MAKE NEW FRAME ATTACH TEE



727Service Bulletin

Number: 727-57-0112 Evaluation FormDate: September 2, 1970Revision 5: July 31, 1997ATA System: 5712Prepared By: Jane Beck


Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the datathat you give us to improve the quality of our service bulletins. Please include data about these or otheritems:

- Did this service bulletin meet your estimate of quality?- How easy is this service bulletin to understand?- Are the Planning Information, Material Information and Accomplishment Instructions satisfactory?- Will you do this service bulletin fully? If not, please tell us why.- Is the Manpower estimate satisfactory?

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make thesechanges, please use a Publication Change Request (PCR) form.

Please give us this data:OPERATOR: TODAY'S DATE:

PREPARED BY: TITLE:

ORGANIZATION: TELEX CODE:

TELEPHONE NUMBER: BASE:

COMMENTS:

If you have other comments please use the other side. Thank you for the time you used to complete thisform.

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation formdirectly to this address:

T.J. Taylor, ManagerService Bulletin EngineeringBoeing Commercial Airplane GroupP.O. Box 3707, Mail Stop 20-85Seattle, WA 98124-2207

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207

Service Bulletin - Regulations.gov

Documents

Transcript of Service Bulletin - Regulations.gov