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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2367 Original Issue: December 18, 1991 Revision 5: July 08, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Body Skin Lap Joint Inspections Based On Fatigue Test Results Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 1991 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 1 of 171
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 2 of 171 BOEING SERVICE BULLETIN 747-53A2367
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 9 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 2 0 E. Compliance .............................................. 2 5 F. Approval ............................................... 3 2 G. Manpower .............................................. 3 6 H. Weight and Balance Changes .................................... 4 0 I. Electrical Load Data ......................................... 4 0 J. References .............................................. 4 0
1. Existing Data: ......................................... 4 0
2. Data Supplied with this Service Bulletin: ........................... 4 1
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 2 K. Publications Affected ........................................ 4 3 L. Interchangeability and Intermixability of Parts ........................... 4 3 M. Software Accomplishment Summary ................................ 4 3
2. MATERIAL INFORMATION ........................................ 4 5 A. Material - Price and Availability ................................... 4 5 B. Industry Support Information .................................... 4 6 C. Parts Necessary for Each Airplane ................................. 4 6
1. Kits/Parts: ........................................... 4 6
2. Parts and Materials Supplied by the Operator: ........................ 6 2
3. Parts Modified and Reidentified: ............................... 6 2
4. Parts Removed and Not Replaced: .............................. 6 2 D. Parts Necessary to Change Spares ................................. 6 2 E. Special Tooling - Price and Availability ............................... 6 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 3 A. GENERAL INFORMATION ..................................... 6 3 B. WORK INSTRUCTIONS ....................................... 6 7 FIGURE 1: THIS FIGURE IS DELETED .................................. 7 6 FIGURE 2: THIS FIGURE IS DELETED .................................. 7 7 FIGURE 3: THIS FIGURE IS DELETED .................................. 7 8 FIGURE 4: THIS FIGURE IS DELETED .................................. 7 9 FIGURE 5: THIS FIGURE IS DELETED .................................. 8 0 FIGURE 6: THIS FIGURE IS DELETED .................................. 8 1 FIGURE 7: THIS FIGURE IS DELETED .................................. 8 2 FIGURE 8: THIS FIGURE IS DELETED .................................. 8 3 FIGURE 9: SECTION 41 - LAP JOINT INSPECTION [Group 1, 3, 7] .................. 8 4 FIGURE 10: SECTION 41 - LAP JOINT INSPECTION [Group 2, 4, 8-9] ................. 8 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 3 of 171 BOEING SERVICE BULLETIN 747-53A2367
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FIGURE 11: SECTION 41 - LAP JOINT INSPECTION [Group 5-6, 10-13] ................ 9 2 FIGURE 12: SECTION 42 - LAP JOINT INSPECTION [Group 1-2, 4-5, 7-9, 11-13] ........... 9 6 FIGURE 13: SECTION 42 - LAP JOINT INSPECTION [Group 10] .................... 1 0 0 FIGURE 14: SECTION 46 - LAP JOINT INSPECTION [Group 1-2, 4-5, 12] ............... 1 0 4 FIGURE 15: SECTION 41, STRINGER 6 - LAP JOINT MODIFICATION ................ 1 0 7 FIGURE 16: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION ................ 1 0 9 FIGURE 17: SECTION 42 - LAP JOINT INSPECTION [Group 3, 6] ................... 1 1 2 FIGURE 18: SECTION 41, STRINGER 44 - LAP JOINT MODIFICATION ................ 1 1 7 FIGURE 19: SECTION 42, STRINGER 44 - LAP JOINT MODIFICATION ................ 1 1 9 FIGURE 20: SECTION 46 - LAP JOINT INSPECTION [Group 7-9, 11, 13] ............... 1 2 1 FIGURE 21: SECTION 46 - LAP JOINT INSPECTION [Group 10] .................... 1 2 7 FIGURE 22: SECTION 46 - LAP JOINT INSPECTION [Group 3, 6] ................... 1 3 0 FIGURE 23: SECTION 44 - LAP JOINT INSPECTION [Group 3, 6] ................... 1 3 3 FIGURE 24: SECTION 41, STRINGER 6 - LAP JOINT POST-MODIFICATION INSPECTION ..... 1 3 6 FIGURE 25: SECTION 41, STRINGER 23 - LAP JOINT POST-MODIFICATION INSPECTION .... 1 4 2 FIGURE 26: SECTION 41, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION .... 1 4 6 FIGURE 27: SECTION 42, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION .... 1 4 9 FIGURE 28: SECTION 41, STRINGER 6, STA 340 TO STA 400 - LAP JOINT POST-MODIFICATION
INSPECTION - LEFT SIDE - AIRPLANES WITH EXTERNAL DOUBLERS INSTALLED AS GIVEN IN SB 747-53-2272 BETWEEN STA 340 AND STA 400 [Group 4-6, 9-11] .... 1 5 2 FIGURE 29: SECTION 41, STRINGER 6, STA 340 TO STA 400 - LAP JOINT POST-MODIFICATION
INSPECTION - RIGHT SIDE - AIRPLANES WITH EXTERNAL DOUBLERS INSTALLED AS GIVEN IN SB 747-53-2272 BETWEEN STA 340 AND STA 400 [Group 4-6, 9-11] .... 1 5 8 Appendix A: REDUCED EDGE MARGIN PROCEDURES ........................ 1 6 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 4 of 171 BOEING SERVICE BULLETIN 747-53A2367
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2367Original Issue: December 18, 1991 Revision 5: July 08, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Body Skin Lap Joint Inspections Based On Fatigue Test Results This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes that have had lap joint modifications accomplished as given in previous revisions of this service bulletin before 20,000 total flight cycles. Post-modification inspections will be required within 15,000 flight cycles after modification in order to allow continued operation to the Limit of Validity (LOV) of 35,000 total flight cycles.
In addition, more work is necessary on airplane line numbers 604 - 685 that had external doublers installed as given in Service Bulletin 747-53-2272 at Stringer 6 from Station 340 to Station 400. Post-modification inspection at Stringer 6 from Station 340 to Station 400 is now required.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-10-05 is related to this service bulletin.
REASON FOR REVISION This revision is sent to add post-modification inspections for all airplanes, and to give instructions for modification of 747SP airplanes rather than requiring operators to contact Boeing for modification instructions. Other changes have also been made.
These sections were changed:
1. In the Summary: Added Widespread Fatigue Damage (WFD) statement. Added new SRP and FTD references. Added planning data table. Updated the Action section, related Airworthiness Directives, and summary illustration.
2. In paragraph 1.A., Effectivity: Revised some group descriptions in the Group/Configuration table. Added Group 12 for 747-200B and -300 airplanes, line numbers 688 through 750, that do not have a side cargo door (these airplanes were previously in Group 5). Added Group 13 for 747-200B and -300 airplanes, line numbers 686 through 810, that do have a side cargo door (these airplanes were previously in Group 11). Group 12 and 13 airplanes have unique inspection requirements due to a thicker skin at the Stringer 6 lap joint from Station 340 to 400.
3. In Paragraph 1.C., Reason: Added reason for Revision 5, added WFD statement, and added new SRP and FTD references.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 5 of 171
4. In Paragraph 1.D., Description: Added description of post-modification inspection requirements, and added "More work" statements for Revision 5. Added reference to 747 SRM 53-30-03, Figure 19.
5. In Paragraph 1.E., Compliance: Updated related AD information. Added information for post-repair inspection requirements. Updated compliance Tables 1 and 2 so that existing compliance times are based from the effective dates of related Airworthiness Directives where applicable. In compliance Table 1, revised footnote "(f)" (previously footnote "(g)") to be applicable to new Group 13 and added footnote "(h)" which was previously a general information note in the Accomplishment Instructions.
Removed post-modification actions from Compliance Table 2. Added new Compliance Tables 3, 4, 5, and 6 for post-modification inspection requirements.
6. In Paragraph 1.F., Approval: Updated Alternative Method of Compliance (AMOC) statements to reflect new compliance tables. Added new AMOC statements for AD 2012-10-03 and AD 2013-16-24.
7. In Paragraph 1.G., Manpower: Added manpower information for post-modification inspections.
8. In Paragraph 3.A., General Information: Updated some existing notes and added new notes 27 through
33. Added reference to 747 SRM 53-30-03, Figure 19.
9. In Paragraph 3.B., Work Instructions: Added information for post-repair inspection requirements. Revised PART 3 to make modification instructions applicable for Group 3 and 6 airplanes, and removed the instruction for operators to contact Boeing for modification of Group 3 and 6 airplanes (no vertical revision lines shown for deleted steps). Added PART 4, PART 5, and PART 6 for post-modification inspection requirements.
10. In Figure 11: Revised footnote (c) to also reference Service Bulletin 747-53-2253.
11. In Figure 15: Revised notes related to previous modifications at Stringer 6.
12. Figures 24, 25, 26, and 27: These new figures have been added for post-modification inspections of areas where modification doublers have been installed as given in this service bulletin.
13. Figures 28 and 29: These new figures have been added for post-modification inspections at Stringer 6 from Station 340 to Station 400 on applicable line numbers 604 - 685 with external doublers installed as given in Service Bulletin 747-53-2272 or as given in Service Bulletin 747-53-2253.
14. Revised "cracks found" and "no cracks found" conditions to "any crack found" and "no crack found", respectively, throughout the service bulletin.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY December 18, 1991Original Issue:
January 27, 1994Revision 1:
October 30, 2008Revision 2:
January 15, 2009Revision 3:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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January 13, 2011Revision 4:
July 08, 2014Revision 5:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 7 of 171 BOEING SERVICE BULLETIN 747-53A2367
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 8 of 171 BOEING SERVICE BULLETIN 747-53A2367
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2367Original Issue: December 18, 1991 Revision 5: July 08, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Body Skin Lap Joint Inspections Based On Fatigue Test Results
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 Based on a structural review of the 747 airplane, incorporation of the inspection shown in this service bulletin is recommended on the 747 airplanes shown in this service bulletin. This service bulletin gives data for the inspection and repair of certain 747 airplane body skin longitudinal lap joints. These inspections and repairs are necessary for safe operation of 747 airplanes past the design goal for economic usage.
Boeing has completed extended pressure fatigue tests on two 747 fuselage test articles. These tests have identified areas of the body lap joints where fatigue cracks can occur. Inspection and repair of these areas is necessary for safe operation of 747 airplanes past the design goal for economic usage.
The inspections in this service bulletin will make sure that fatigue cracks in the body lap joints shown are found and repaired before they become critical. 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.
Revision 2: Subsequent to the release of Revision 1 of this service bulletin, a review of all lap joints was accomplished for the affected airplanes. It was determined that all lap joints with upper skin thickness of 0.090 inches or less should be inspected at the times given in Paragraph 1.E., Compliance. In addition, a review of all bulletins which recommend repeat inspections was performed to determine if the inspections were appropriate on aging airplanes. This review indicated that certain lap joints where the skin thickness is less than or equal to
0.071 inches should be modified at the times given in Paragraph 1.E., Compliance on airplane line numbers 201 through 810.
The skin lap joints affected by this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to 747-SL-53-088.
Boeing Service Related Problem (SRP) 747-SRP-53-0278 and 747-SRP-53-0437 are related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 9 of 171
Boeing Fleet Team Digest (FTD) article 747 FTD 53-13003 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-88RS) Lap joint inspection:
– Do external eddy current inspections of certain lap joints for cracks. These lap joints are in Section 41, Section 42, Section 44 and Section 46. If no crack is found, do the inspection again at the time shown in this service bulletin. If any crack is found, remove the fastener in the cracked hole and sufficient adjacent fasteners and do open hole HFEC inspections to find the crack length. Repair as shown in the structural repair manual before any more flights.
Lap joint modification:
– Do eddy current inspections of the lap joints in sections 41 and 42 that will be modified. If any crack is found, repair the crack and contact Boeing for lap joint modification instructions. For areas where no crack is found,do the lap joint modifications.
Lap joint post-modification inspection:
– Do detailed and eddy current inspections for cracks in the skin and/or doubler structure at certain lap joint areas where external modification doublers were installed. If any crack is found, contact Boeing for repair instructions and do the repair.
EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747SP, and 747SR airplanes. Refer to Paragraph
1.A., Effectivity for the list of affected airplanes.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 10 of 171 BOEING SERVICE BULLETIN 747-53A2367
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COMPLIANCE Refer to Service Bulletin Paragraph 1.E., Compliance for Compliance information.
Federal Aviation Administration (FAA) Airworthiness Directives AD 90-06-06, AD 2004-07-22 R1, AD 2005-08-01, AD 2006-20-02, AD 2006-22-09, AD 2006-24-02, AD 2006-24-05, AD 2007-15-07, AD 2008-16-14, AD 2009-04-16, AD 2010-10-05, AD 2012-10-03 , and AD 2013-16-24 are related to this service bulletin.
INDUSTRY SUPPORT INFORMATION This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether you ever filed a warranty claim with Boeing on this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 1991 747-53A2367Revision 5: July 08, 2014 11 of 171 BOEING SERVICE BULLETIN 747-53A2367
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BOEING SERVICE BULLETIN 747-53A2367
ALERT ALERT S-39
FORWARD WING-TO-BODY FAIRING S-45
LAP JOINT (TYPICAL)
RIGHT SIDE SHOWN
LEFT SIDE SIMILAR AFT S-40 WING-TO-BODY
FAIRING S-46 STA SECTION 46 2360 SECTION 44 -12 DO EDDY CURRENT INSPECTIONS OF STA 1480
SKIN LAP JOINTS FOR CRACKS IN LAP JOINT UPPER FASTENER ROWS. (TYPICAL)
DO A STRUCTURAL MODIFICATION ON
SPECIFIED LAP JOINTS AT STRINGERS 6, 23 AND 44 S-19
DO POST MODIFICATION INSPECTIONS FOR CRACKS.
STA 1000 CRACK UPPER SKIN PROTRUDING S-19
HEAD FASTENER
• (TYPICAL) STA 520 S-23
FLUSH HEAD STA UPPER -. ROW FASTENER (TYPICAL) SECTIONS 41 AND 42 140 NOTE: INSPECTION AREAS VARY DEPENDING ON CONFIGURATION.
SECTION 42, SECTION 41 44 AND 46 1479023
STRINGER STRINGER (TYPICAL) (TYPICAL) Original Issue: December 18, 1991 Revision 5: July 08, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2367 Work - See page 1 for details. 12 of 171