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Commercial Airplane Group 747 Service Bulletin ALERT Number: 747-51A2060 Date: October 30, 2008 ATA System: 5100 5331 5500 5730 SUBJECT: STRUCTURES - Structures - Wing Side of Body Joint, Horizontal Stabilizer Side of Body Joint, and Fuselage Circumferential Splice Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P .O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 1 of 196
5.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 2 of 196 BOEING SERVICE BULLETIN 747-51A2060
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Table of Contents
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 2 0 B. Concurrent Requirements ...................................... 2 0 C. Reason ................................................ 2 0 D. Description .............................................. 2 1 E. Compliance .............................................. 2 3 F . Approval ............................................... 2 8 G. Manpower .............................................. 2 8 H. Weight and Balance Changes .................................... 3 0 I. Electrical Load Data ......................................... 3 0 J. References .............................................. 3 0
1. Existing Data: .......................................... 3 0
2. Data supplied with this Service Bulletin: ........................... 3 1
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 1 K. Publications Affected ......................................... 3 3 L. Interchangeability and Intermixability of Parts ........................... 3 3
2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 B. Industry Support Information .................................... 3 5 C. Parts Necessary For Each Airplane ................................. 3 5
1. Kits/Parts: ............................................ 3 5
2. Parts and Materials Supplied by the Operator: ........................ 3 5
3. Parts Modified and Reidentified: ................................ 3 5
4. Parts Removed and Not Replaced: .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 5 F . Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 9 FIGURE 1: DETAILED INSPECTION OF WING SOB JOINT UPPER SURFACE - LEFT SIDE .... 4 8 FIGURE 2: DETAILED INSPECTION OF WING SOB JOINT UPPER SURFACE - RIGHT SIDE .... 5 1 FIGURE 3: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (AFT) UPPER SURFACE - LEFT SIDE .............................................. 5 4 FIGURE 4: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (AFT) UPPER SURFACE - RIGHT SIDE .............................................. 5 8 FIGURE 5: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (MIDDLE) UPPER SURFACE - LEFT SIDE .............................................. 6 2 FIGURE 6: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (MIDDLE) UPPER SURFACE - RIGHT SIDE .............................................. 6 5 FIGURE 7: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (FORWARD) UPPER SURFACE - LEFT SIDE ........................................... 6 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 3 of 196 BOEING SERVICE BULLETIN 747-51A2060
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FIGURE 8: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (FORWARD) UPPER SURFACE - RIGHT SIDE .......................................... 7 1 FIGURE 9: DETAILED INSPECTION OF WING SOB JOINT LOWER SURFACE - LEFT SIDE .... 7 4 FIGURE 10: DETAILED INSPECTION OF WING SOB JOINT LOWER SURFACE - RIGHT SIDE . . . 78 FIGURE 11: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (AFT) LOWER SURFACE - LEFT SIDE .............................................. 8 2 FIGURE 12: OPEN-HOLE INSPECTION OF WING SOB JOINT (AFT) LOWER SURFACE - RIGHT SIDE .................................................. 8 5 FIGURE 13: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (MIDDLE) LOWER SURFACE - LEFT SIDE .............................................. 8 8 FIGURE 14: OPEN-HOLE HFEC INSPECTION OF WING SOB JOINT (MIDDLE) LOWER SURFACE - RIGHT SIDE .......................................... 9 1 FIGURE 15: DETAILED INSPECTION OF HORIZONTAL STABILIZER SOB JOINT - LEFT SIDE . . . 94 FIGURE 16: DETAILED INSPECTION OF HORIZONTAL STABILIZER SOB JOINT - RIGHT SIDE . . 102 FIGURE 17: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT UPPER HINGE FITTING - LEFT SIDE .................................... 1 1 0 FIGURE 18: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT UPPER HINGE FITTING - RIGHT SIDE .................................... 1 1 3 FIGURE 19: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT LOWER HINGE FITTING - LEFT SIDE .................................... 1 1 6 FIGURE 20: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT LOWER HINGE FITTING - RIGHT SIDE .................................... 1 1 9 FIGURE 21: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR UPPER CHORD AND TERMINAL FITTING - LEFT SIDE ................. 1 2 2 FIGURE 22: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR UPPER CHORD AND TERMINAL FITTING - RIGHT SIDE ................ 1 2 6 FIGURE 23: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR LOWER CHORD AND TERMINAL FITTING - LEFT SIDE ................. 1 3 0 FIGURE 24: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR LOWER CHORD AND TERMINAL FITTING - RIGHT SIDE ................ 1 3 3 FIGURE 25: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR UPPER CHORD AND OUTBOARD SKIN - LEFT SIDE .................. 1 3 6 FIGURE 26: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR UPPER CHORD AND OUTBOARD SKIN - RIGHT SIDE .................. 1 3 9 FIGURE 27: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR UPPER CHORD AND CENTER SECTION SKIN - LEFT SIDE .............. 1 4 2 FIGURE 28: OPEN-HOLE HFEC INSPECTION OF HORIZONTAL STABILIZER SOB JOINT REAR SPAR UPPER CHORD AND CENTER SECTION SKIN - RIGHT SIDE .............. 1 4 5 FIGURE 29: DETAILED INSPECTION OF THE FUSELAGE SKIN, STRINGERS, AND STRINGER SPLICE FITTINGS (NON-SUD AIRPLANES). [Group 1, 5] ..................... 1 4 8 FIGURE 30: DETAILED INSPECTION OF THE FUSELAGE SKIN, STRINGERS, AND STRINGER SPLICE FITTINGS (SP AIRPLANES). [Group 2] ........................... 1 5 6 FIGURE 31: DETAILED INSPECTION OF THE FUSELAGE SKIN, STRINGERS, AND STRINGER SPLICE FITTINGS (SUD AIRPLANES). [Group 3-4] ......................... 1 6 4 FIGURE 32: OPEN-HOLE HFEC INSPECTION OF FUSELAGE CIRCUMFERENTIAL SPLICES (NON-SUD AIRPLANES). [Group 1, 5] .................................. 1 7 1 FIGURE 33: OPEN-HOLE HFEC INSPECTION OF FUSELAGE CIRCUMFERENTIAL SPLICES (SP AIRPLANES). [Group 2] ................................... 1 7 5 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 4 of 196 BOEING SERVICE BULLETIN 747-51A2060
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FIGURE 34: OPEN-HOLE HFEC INSPECTION OF FUSELAGE CIRCUMFERENTIAL SPLICES (SUD AIRPLANES). [Group 3-4] .................................. 1 7 9 FIGURE 35: SURFACE HFEC INSPECTION OF FUSELAGE SKIN (NON-SUD AIRPLANES). [Group 1, 5] ................................................. 1 8 3 FIGURE 36: SURFACE HFEC INSPECTION OF FUSELAGE SKIN (SP AIRPLANES). [Group 2] . . . 188 FIGURE 37: SURFACE HFEC INSPECTION OF FUSELAGE SKIN (SUD AIRPLANES). [Group 3-4] . 193 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 5 of 196 BOEING SERVICE BULLETIN 747-51A2060
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 6 of 196 BOEING SERVICE BULLETIN 747-51A2060
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Commercial Airplane Group 747 Service Bulletin ALERT SummaryNumber: 747-51A2060Date: October 30, 2008 ATA System: 5100 5331 5500 5730 SUBJECT: STRUCTURES - Structures - Wing Side of Body Joint, Horizontal Stabilizer Side of Body Joint, and Fuselage Circumferential Splice Inspection
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY . IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None
BACKGROUND Accomplishment of the inspections in this service bulletin will find fatigue cracks in the wing side-of-body (SOB) joint upper and lower surfaces, horizontal stabilizer SOB joint upper and lower surfaces, and the fuselage skin and circumferential splices. The cracks could occur at multiple adjacent locations in the inspection areas and join together to form large cracks. The cracks that are not found and repaired could compromise the structural integrity and lead to loss of controllability and a rapid decompression of the airplane.
Boeing’s analysis shows that the 747 wing SOB joint splices, horizontal stabilizer SOB joint splices, fuselage skin and circumferential splices are susceptible to fatigue cracks. The fatigue cracks are due to high cyclic loads on the airplane.
The accomplishment instructions in this service bulletin provide additional structural maintenance recommendations to support operation of airplanes and preclude possible fatigue cracks in the inspection areas up to the Initial Operational Limit (IOL). The current IOL is 35,000 total flight cycles or 135,000 total flight hours (165,000 total flight hours for the 747-400, 747-400D, and 747-400F airplanes).
The inspections in this service bulletin will make sure that fatigue cracks are found and repaired in the wing SOB joint upper and lower surfaces, horizontal stabilizer SOB joint upper and lower surfaces, and the fuselage skin and circumferential splices. Evaluation of the inspection reports will allow Boeing to determine if additional inspections are necessary. The area of the inspection may change with the inspection findings reported to Boeing.
Boeing Service Related Problem (SRP) 747-SRP-51-0014 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 7 of 196
ACTION As the inspections given in this service bulletin are developed to find fatigue cracking of airplanes that are near the IOL, Boeing recommends that the inspections not be done earlier than the times given in Paragraph 1.E., Compliance.
Do the following as given in Paragraph 1.E., Compliance:
— Wing SOB Joint — Do a Detailed Inspection of the wing SOB joint upper and lower surfaces for any crack.
— Do an Open-Hole High Frequency Eddy Current (HFEC) Inspection of the wing SOB joint upper and lower surfaces for any crack.
— Horizontal Stabilizer SOB Joint — Do a Detailed Inspection of the horizontal stabilizer SOB joint surfaces for any crack.
— Do Surface and Open-Hole HFEC Inspections of the horizontal stabilizer SOB joint upper and lower surfaces for any crack.
— Fuselage Skin and Circumferential Splices — Do a Detailed Inspection of the fuselage skin, stringers, and stringer splice fittings for any crack. Do a repetitive Detailed Inspection of the circumferential skin, stringers, and stringer splice fittings for any crack.
— Do Surface and Open-Hole HFEC Inspections of the fuselage skin and circumferential splices for any crack.
Contact Boeing with any crack finding for repair instructions. Repair any crack found as given by Boeing.
EFFECTIVITY All 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F , 747-300, 747-400, 747-400D, 747-400F , 747SP , and 747SR airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Federal Aviation Administration (FAA) Airworthiness Directives FAA AD 2004-07-22 R1, FAA AD 2004-03-09, and FAA AD 2006-10-16 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures given in this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 8 of 196 BOEING SERVICE BULLETIN 747-51A2060
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MANPOWER Elapsed HoursTotal Task HoursAirplanes
520.752658All
MATERIAL INFORMATION None.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 9 of 196 BOEING SERVICE BULLETIN 747-51A2060
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BOEING SERVICE BULLETIN 747-51A2060
ALERT ALERT STA 1961 STA 1350 STA 1000
DO A DETAILED, SURFACE HFEC, AND
OPEN HOLE HFEC INSPECTIONS OF
THE WING SIDE OF BODY JOINT,
HORIZONTAL STABILIZER SIDE OF BODY
JOINT, AND FUSELAGE SKIN AND
CIRCUMFERENTIAL SPLICES FOR ANY CRACK. IF ANY CRACK IS FOUND, CONTACT BOEING FOR REPAIR INSTRUCTIONS. REPAIR ANY CRACK FOUND AS GIVEN BY BOEING.
1572773 October 30, 2008 747-51A2060 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 196
Commercial Airplane Group 747 Service Bulletin ALERT Number: 747-51A2060 Date: October 30, 2008 ATA System: 5100 5331 5500 5730 SUBJECT: STRUCTURES - Structures - Wing Side of Body Joint, Horizontal Stabilizer Side of Body Joint, and Fuselage Circumferential Splice Inspection
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY . IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
NOTE: 747-8 and 747-8F series airplanes are not affected by this service bulletin.
NOTE: This Service Bulletin is for the airplanes identified below. The Effectivity list shown below is complete for airplanes through line number 1419. Airplanes after line number 1419 are also affected by this service bulletin, and are in Group(s): 1,2,3,4,5
DESCRIPTIONCONFIGURATIONGROUP 747-100/100B/200B/200C/200F/SR airplanes (Non-SUD).-1 747-SP airplanes.-2 747-100B SUD/300 and 747-100/200B Boeing-Modified Streched Upper Deck Modification airplanes.
-3 747-400/400D airplanes (SUD).-4 747-400F airplanes (Non-SUD).-5 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 11 of 196
DESCRIPTIONCONFIGURATIONGROUP 747-400LCF airplanes.-6 Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F , 747-300, 747-400, 747-400D, 747-400F , 747SP , 747SR GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA266 1RA301 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA418 1RA501 - RA502 1RA521 - RA528 1RA532 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 - RA635 1RA651 - RA652 1RA671 - RA677 1RA701 - RA702 1RA721 - RA731 1RA741 - RA745 1RA749 - RA750 1RA761 - RA762 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 30, 2008 747-51A2060 12 of 196 BOEING SERVICE BULLETIN 747-51A2060