Boeing ASB 747-53A2303: U.S. DOT/FAA - Service Bulletin, text

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Commercial Airplane Group 747 Service Bulletin Number: 747-53A2303 Date: June 02, 1988 Revision 2: October 01, 2009 ATA System: 5310 5311 SUBJECT: FUSELAGE - Nose Section - Station 400 to 520 Stringer Lap Splice Inspection, Repair and Modification

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1989 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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BLANK PAGE

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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 36

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 36

4. Process Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 36

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 40

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 40

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FIGURE 1: THIS FIGURE IS DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 FIGURE 2: INITIAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 3: INTERNAL ACCESS AND RESTORATION. . . . . . . . . . . . . . . . . . . . . . . . . 54 FIGURE 4: THIS FIGURE IS DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FIGURE 5: TOP ROW PROTRUDING HEAD FASTENER MODIFICATION INSPECTION . . . . . . 57 FIGURE 6: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND REPAIR DOUBLER INSTALLED BY SERVICE BULLETIN 747-53A2321 - INSPECTION . . . . . . . . . . . . . . . . . 64 FIGURE 7: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND SKIN REPLACEMENT MODIFICATION BY SERVICE BULLETIN 747-53A2321 - INSPECTION . . . . . . . . 66 FIGURE 8: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND REPAIR DOUBLER INSTALLED

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BY SERVICE BULLETIN 747-53A2321 - ALTERNATIVE INSPECTION . . . . . . . . . 68 FIGURE 9: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND SKIN REPLACEMENT MODIFICATION BY SERVICE BULLETIN 747-53A2321 - ALTERNATIVE INSPECTION 70 APPENDIX A: DISCREPANT STRUCTURE REPORT . . . . . . . . . . . . . . . . . . . . . . . . . 72 APPENDIX B: ALTERNATIVE LAP SPLICE TRIM INSTRUCTIONS . . . . . . . . . . . . . . . . . . 75 APPENDIX C: EXTENSION OF THE 141U2100 MODIFICATION DOUBLERS WHEN AN SRM REPAIR IS PRESENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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Commercial Airplanes 747 Service Bulletin Number: 747-53A2303 Revision Transmittal Sheet Original Issue: June 02, 1988 Revision 2: October 01, 2009 ATA System: 5310 5311 SUBJECT: FUSELAGE - Nose Section - Station 400 to 520 Stringer Lap Splice Inspection, Repair and Modification This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes on which the Flight Safety inspections are being accomplished. The repeat inspection interval has been reduced from 5,000 flight-cycles to 3,000 flight-cycles since the last Flight Safety inspection was accomplished, or within 1,000 flight-cycles after the date on Revision 2, whichever occurs later.

More work is also necessary on airplanes modified as shown in the initial release and/or Revision 1 of this service bulletin. Airplanes that have accomplished a protruding head fastener modification or a modification as given in certain Structural Repair Manual (SRM) repairs will be required to accomplish the doubler modification as given in Paragraph 1.E., Compliance. In addition, airplanes that have had a structural modification accomplished as given in the SRM or other Boeing service bulletins will be required to accomplish post modification inspections as given in Paragraph 1.E., Compliance.

REASON FOR REVISION This revision is sent to update inspection requirements and to update the post modification inspection requirements for airplanes that have accomplished a modification as shown in the initial release and/or Revision 1 of this service bulletin. This revision is also sent to remove the optional top row protruding head fastener modification, as well as modifications per certain SRM repairs.

Changes to this service bulletin include:

– Airworthiness Directive (AD) 90-21-17 supersedes AD 89-05-03.

– Specific repair figures in SRM 53-30-03 are referenced as an acceptable modification.

– Compliance information is added to Paragraph 1.E., Compliance. Existing compliance information to accomplish the Flight Safety Inspection Program, the Economics Based Inspection Program and the modification has been moved from the logic diagrams in Figure 1 to Tables 1 and 2 of Paragraph 1.E., Compliance. Compliance information for the repeat post modification inspections is included in Table 3 of Paragraph 1.E., Compliance. New compliance information for the inspection and modification of airplanes with certain SRM repairs or the optional top row protruding head fastener modification that was shown in the original release and Revision 1 of this service bulletin is added to Tables 4 and 5.

– The 747 Non-Destructive Test manual, Boeing service bulletins, a Service Related Problem, a Boeing Document, an AD and SRM references are added to Paragraph 1.J., References.

– Primer and Sealant are added to the Parts and Materials Supplied by the Operator.

– Paragraph 3.B., Work Instructions have been extensively rewritten.

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– Figure 1 is deleted. The information previously in the logic diagrams has been moved to the tables in Paragraph 1.E., Compliance.

– The NDT procedures referenced in Figure 2 have been changed.

– Figure 4 is deleted to remove the top row protruding head fastener modification.

– Figure 5 is added to inspect the top row protruding head fastener modification accomplished by previous releases of this service bulletin for cracks.

– Figure 6 is added to provide inspections for airplanes with doublers installed by this service bulletin and doublers installed by service bulletin 747-53A2321 for cracks.

– Figure 7 is added to provide inspections for airplanes with doublers installed by this service bulletin and the skin replacement modification by service bulletin 747-53A2321 for cracks.

– Figure 8 is added to provide alternative inspections to the Figure 6 inspections for cracks.

– Figure 9 is added to provide alternative inspections to the Figure 7 inspections for cracks.

– Appendix B is added to provide alternative lap splice trim instructions.

– Appendix C is added to show how the Drawing 141U2100 modification doublers should be changed when an SRM repair is present in the modification area.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY Original Issue: June 02, 1988 Revision 1: March 29, 1990 Revision 2: October 1, 2009

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Commercial Airplanes 747 Service Bulletin Number: 747-53A2303 Summary Original Issue: June 02, 1988 Revision 2: October 01, 2009 ATA System: 5310 5311 SUBJECT: FUSELAGE - Nose Section - Station 400 to 520 Stringer Lap Splice Inspection, Repair and Modification

CONCURRENT REQUIREMENTS None.

BACKGROUND Based on a structural review of the 747 airplane, incorporation of a modification per Revision 2 of this service bulletin is recommended on aging airplanes.

Accomplishment of the intent of this service bulletin will ensure the structural integrity of the fuselage skin lap splice along stringer 6 left and stringer 6 right from Station (STA) 400 to 520 throughout the operational life of the airplane.

One operator reported fuselage skin cracks of 0.16 inch long at 10 rivet locations in the upper fastener row of the left stringer 6 skin lap splice between STA 400 and 420 on one airplane. This airplane had accumulated 29,439 flight hours and 22,248 reduced pressure cycles (approximately 19,000 equivalent full pressure cycles).

Investigation revealed the cracks were initiated in the fastener countersinks and were propagated by cabin pressurization cyclic loading.

A structural reassessment of the 747 airplane was made under the requirements of Federal Aviation Administration (FAA) Advisory Circular 91-56, in accordance with Federal Aviation Regulation (FAR) 25.571 as amended in 1978, to ensure the safe operation of 747 airplanes throughout their operational life. As a result of this reassessment, the stringer lap splice, left and right sides, between STA 400 and 520 have been determined to be structurally significant and critical to the structural integrity of the airplane.

Skin cracks not detected prior to reaching critical crack length may result in in-flight depressurization of the airplane and the inability to withstand current regulatory fail-safe loads.

Therefore, a flight safety inspection program is defined in this bulletin which will continue throughout the operational life of the airplane.

This service bulletin is the subject of Federal Aviation Administration (FAA) Airworthiness Directives (AD) 90-21-17 and 90-06-06. AD 90-21-17 supersedes AD 89-05-03.

Boeing Service Related Problem (SRP) 747OP-SRP-53-0292 is related to this service bulletin.

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ACTION (PRR 82284R) As recommended by the 747 Aging Fleet Structures Working Group, accomplish a modification per the accomplishment instructions at or before the accumulation of 23,000 flight-cycles. Airplanes on which a protruding head fastener modification or a modification as given in certain SRM repairs are required to accomplish the external doubler modification given in this service bulletin at the time given in Paragraph 1.E., Compliance, Table 5.

This bulletin details a flight safety inspection program, an economics based inspection program, structural modifications to improve the resistance to cracking along the affected skin lap splice, and an after-modification inspection program.

The flight safety inspection program is defined as follows:

On unmodified airplanes initiate a detailed and High Frequency Eddy Current (HFEC) inspection at the time given in Paragraph 1.E., Compliance, Table 1. If a crack is not indicated, reinspect as given in Paragraph 1.E., Compliance, Table 1. As an alternative, install a modification which will consist of the installation of an external doubler. If cracks are indicated during the initial inspection, modify the skin lap splice per the accomplishment instructions of this service bulletin before further flight. On any area left unmodified, repeat the initial inspection as given in Paragraph 1.E., Compliance, Table 1.

At modified areas initiate the post modification internal and external inspections at the time given in Paragraph

1.E., Compliance, Table 3. If no cracks are found, repeat these inspections as given in Paragraph 1.E., Compliance, Table 3. If cracks are found, repair per 747 Structural Repair Manual or contact Boeing. If the Service Bulletin 747-53-2272 Zone 2 modification has previously been accomplished, the after modification inspections per this service bulletin may be performed using external methods only, and with a repeat interval as given in Paragraph 1.E., Compliance, Table 3.

The Economic Based Inspection Program has a lower initial threshold than the Flight Safety Inspection Program. The repeat inspection interval, inspection methods, and options are the same for both inspection programs.

EFFECTIVITY 747-100, 747-100B, 747-200B, 747-200C, 747-200F, 747-300, 747SR and 747SP series airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release another 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 90-21-17 and 90-06-06 are related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin.

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MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

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STA 520 STA 400 STA 400 STA 520

UPPER SKIN PANEL

INSPECT FOR

CRACKS IN TOP ROW 3 ROW SPLICE SHOWN 4 ROW SPLICE SIMILAR STRINGER NO.6

LEFT SIDE SHOWN

RIGHT SIDE SIMILAR

LOWER SKIN PANEL

AND ACCOMPLISH A

STRUCTURAL MODIFICATION J76126

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Commercial Airplanes 747 Service Bulletin Number: 747-53A2303 Original Issue: June 02, 1988 Revision 2: October 01, 2009 ATA System: 5310 5311 SUBJECT: FUSELAGE - Nose Section - Station 400 to 520 Stringer Lap Splice Inspection, Repair and Modification

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. Refer to PRR 82284R for data about this change.

Airplane models:

GROUP CONFIGURATION DESCRIPTION 1 - 747-100, -200B and -200F airplanes, line number 1 through 200 with standard upper deck configuration of one right side crew entry door.

2 - 747-100 and -200B airplanes, line number 1 through 200 with right and left side upper deck crew entry doors.

3 - 747-100, -100B, -200B, -200C, -200F, 747SP and 747SR airplanes, line number 201 through 628 with standard upper deck configuration of one right side crew entry door.

4 - 747-100, -100B, -200B, -200C, -200F, 747SP and 747SR airplanes, line number 201 through 628 with right and left side upper deck crew entry doors.

5 - 747-200 and -300 airplanes, line number 201 through 628 with a 208 inch Stretched Upper Deck (SUD) configuration, including airplanes modified to SUD per Master Change 42360-( )

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747-100 747-100B 747-200B 747-200C 747-200F 747-300 747SP 747SR

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AAR AIRCRAFT SALES & LEASING (AFD) 4 RB681–RB682 RB691

AERO CONTROLS (AEO) 2 RA722–RA723

AEROLINEAS ARGENTINAS (ARG) 3 RD122–RD127

AEROSUR (REO) 5R S 2 3 5 AFRICA UNITED HOLDING CO. (UHD) 3R B 0 1 0 4 RD513

AFX (AXL) 3 RD201

AGES AIRCRAFT SALES & LEASING (AGJ) 1R B 0 0 4

AIR ATLANTA ICELANDIC (AID) 3 RD414 RR204 4 RD141–RD142 RD144 RD647–RD648 RD771 5 RS211 RS233 RS237

Boeing ASB 747-53A2303: U.S. DOT/FAA - Service Bulletin