Boeing ASB 747-53A2427: U.S. DOT/FAA - Service Bulletin, text

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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2427 Original Issue: December 17, 1998 Revision 7: July 19, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Tail Section - Body Station 2598 Bulkhead Inner Chord and Web Inspection 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:

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 17, 1998 747-53A2427Revision 7: July 19, 2013 1 of 126

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Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 2 of 126 BOEING SERVICE BULLETIN 747-53A2427

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Table of Contents

Revision Transmittal Sheet5

Summary9

1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3

1. Airplanes ............................................ 1 3

2. Spares Affected ........................................ 2 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 3 D. Description .............................................. 2 3 E. Compliance .............................................. 2 5 F. Approval ............................................... 3 6 G. Manpower .............................................. 3 7 H. Weight and Balance Changes .................................... 3 7 I. Electrical Load Data ......................................... 3 7 J. References .............................................. 3 8

1. Existing Data: ......................................... 3 8

2. Data Supplied with this Service Bulletin: ........................... 3 8

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 8 K. Publications Affected ........................................ 3 9 L. Interchangeability and Intermixability of Parts ........................... 3 9 M. Software Accomplishment Summary ................................ 3 9

2. MATERIAL INFORMATION ........................................ 4 1 A. Material - Price and Availability ................................... 4 1 B. Industry Support Information .................................... 4 1 C. Parts Necessary for Each Airplane ................................. 4 1

1. Kits/Parts: ........................................... 4 1

2. Parts and Materials Supplied by the Operator: ........................ 4 1

3. Parts Modified and Reidentified: ............................... 4 1

4. Parts Removed and Not Replaced: .............................. 4 1 D. Parts Necessary to Change Spares ................................. 4 1 E. Special Tooling - Price and Availability ............................... 4 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 2

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 3 A. GENERAL INFORMATION ..................................... 4 3 B. WORK INSTRUCTIONS ....................................... 4 4 FIGURE 1: DELETED ............................................ 4 9 FIGURE 2: INSPECTION .......................................... 5 0 FIGURE 3: DELETED ............................................ 6 0 FIGURE 4: WEB CRACK REMOVAL ................................... 6 1 FIGURE 5: INSPECTION - POST REPAIR / INTERIM MODIFICATION - REPAIRED/MODIFIED AREA .................................................. 6 4 FIGURE 6: INSPECTION - POST REPAIR / INTERIM MODIFICATION - FORWARD SIDE ...... 7 5 FIGURE 7: WEB REPAIR OR INTERIM MODIFICATION - NO EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 1, Configuration 1] .................... 7 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 3 of 126 BOEING SERVICE BULLETIN 747-53A2427

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FIGURE 8: WEB REPAIR OR INTERIM MODIFICATION - NO EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 2-3, Configuration 1] ................... 9 0 FIGURE 9: UPPER WEB REPAIR - EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 1, Configuration 2] .................................. 1 0 0 FIGURE 10: UPPER WEB REPAIR - EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 2-3, Configuration 2] ................................. 1 1 2 APPENDIX A: SERVICE HISTORY ..................................... 1 2 4 APPENDIX B: PREVIOUS REVISION CHANGE INFORMATION ..................... 1 2 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 4 of 126 BOEING SERVICE BULLETIN 747-53A2427

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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2427Original Issue: December 17, 1998 Revision 7: July 19, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Tail Section - Body Station 2598 Bulkhead Inner Chord and Web Inspection This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with previous releases of this service bulletin;

however, it is not necessary to do this additional work sooner than the compliance time for the next inspection as specified in the previous release of this service bulletin. This revision extends the bulkhead inspection to include additional surface and open hole HFEC inspection for cracks at/near the frame support upper splice fittings and additional open hole HFEC inspection for cracks at/near the frame support lower splice fittings.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-14-07 and FAA Airworthiness Directive AD 2004-07-22 R1 are related to this service bulletin.

REASON FOR REVISION After the release of Revision 6 of this service bulletin, an operator reported a crack found in the web section of the bulkhead frame support where it is sandwiched between the upper splice fitting and the aft inner chord. This crack was found (at 12,302 flight cycles) because the splice fitting was removed to do a repair for a different crack found in the chord section of the frame support. Also, 1.8 inch and 1.6 inch cracks have been found in the frame support upper splice fitting on airplanes with 12,302 and 13,728 flight cycles respectively. These cracks were found in the fillet radius of the splice fitting horizontal flange where it connects to the upper shear deck.

Also, 0.07 inch and 0.50 inch cracks have been found in the RS frame support lower splice fitting on airplanes with 10,409 and 19,203 flight cycles respectively. In response to these crack findings, this revision extends the open hole HFEC inspection for cracks given in this service bulletin to include more fastener holes common to the upper and lower splice fittings on both sides of the bulkhead, plus some additional fastener holes adjacent to the lower splice fitting. Also, this revision extends the surface HFEC inspection for cracks to include the fillet radius area of the upper splice fitting. This expansion of the open hole and surface inspections is necessary to find cracks that could have an effect on the structural integrity of the bulkhead.

Also, this revision is sent to clarify the compliance time for the initial surface HFEC inspection of the upper web for airplanes modified or repaired before the upper web inspection was added with revision 6 to this service bulletin. This revision clarifies that the compliance time for the next post-repair/modification inspection (referenced to the time of the repair/modification) is applicable for the first inspection of the web in such cases.

This revision is also sent to identify/include the modification given in service bulletin 747-53A2837 as an additional terminating action for the inspections given in this service bulletin.

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 5 of 126

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These sections of the service bulletin have been changed:

1. Paragraph 1.D., Description, and Paragraph 3.B., Work Instructions: The modification given in service bulletin 747-53A2837 is identified/added as a terminating action for the inspections given in this service bulletin. Previously, only the modification given in service bulletin 747-53A2473 (or 747-53-2473) was given as a terminating action. In Paragraph 3.B it is also noted that the modification given in service bulletin 747-53A2837 has been approved as an AMOC (an alternative to the modification given in service bulletin 747-53A2473) for AD 2010-14-07.

2. Paragraph 1.E., Compliance: Table 1 is revised to include the inspection areas added with this revision and to include reference to service bulletin 747-53A2837. Revision bars were added to the table for these additions. Other changes were made that rearranged the table to make it more clear/concise;

however, these secondary changes didn't change the actions/times given previously and therefore revision bars were not added to the table for these changes. The secondary changes include the division of actions into upper area actions and lower area actions and also into actions associated with specific revisions to this service bulletin. Also, descriptive details of the actions have been moved into notes to make the information in the table itself more concise.

3. Paragraph 1.E., Compliance: Table 2 is revised to include the inspection areas added with this revision and to include reference to service bulletin 747-53A2837. Revision bars were added to the table for these additions. Other changes were made that rearranged the table to make it more clear/concise;

4. Paragraph 1.E., Compliance: Table 3 is revised to include the inspection areas added with this revision and to include reference to service bulletin 747-53A2837. Also, the time given in row 2 of Compliance Table 3 was changed from: "Within 6,000 flight cycles after accomplishment of the chord and/or web repair" to: "Within 6,000 flight cycles after accomplishment of the chord and/or web repair or Interim Modification". Also, a note (about continued lower area inspection) that previously preceded the table was moved to the Action column header inside the table to better link the note to the information in the table.

5. Paragraph 1.H., Weight and Balance Changes: relocated a misplaced decimal point in the moment change value for Group 1 airplanes (2218.0 in-lb was 22180.0 in-lb in previous revision) and provided moment change values for Group 2, 3 airplanes which were inadvertently omitted from the previous revision of this service bulletin.

6. Paragraph 2.C.2, Parts and Materials Supplied by the Operator: Clarified that specified parts quantities are for one/each side of the airplane.

7. Paragraph 3.B., Work Instructions:

Part 1: Added reference to service bulletin 747-53A2837 as a terminating action for the inspections given in this service bulletin and as an AMOC (to the modification given in service bulletin 747-53A2473) for AD 2010-14-07. Also added reference to 747-400F SRM for inner chord repair and added a Figure number to the 747-SP SRM reference for the inner chord repair.

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 6 of 126 BOEING SERVICE BULLETIN 747-53A2427

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Part 3: The Caution statement previously included in only Part 1 and Part 2 of the work instructions (regarding use of the STA 2598 jack point) was added to Part 3 where it is also applicable. Also added reference to service bulletin 747-53A2837 as a terminating action for the inspections given in this service bulletin and as an AMOC (to the modification given in service bulletin 747-53A2473) for AD 2010-14-07.

8. Figure 2: Expanded inspection work to include additional surface and open hole inspection areas/locations and associated fastener replacement data.

9. Figure 5: Expanded post-repair/modification inspection work to include additional open hole inspection locations and associated fastener replacement data.

10. Figure 6: Expanded post-repair/modification inspection work to include surface HFEC inspection in the fillet radius area of the upper splice fitting.

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 December 17, 1998Original Issue:

October 28, 1999Revision 1:

October 05, 2000Revision 2:

September 27, 2001Revision 3:

March 06, 2008Revision 4:

October 01, 2009Revision 5:

July 14, 2011Revision 6:

July 19, 2013Revision 7:

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 7 of 126 BOEING SERVICE BULLETIN 747-53A2427

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Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 8 of 126 BOEING SERVICE BULLETIN 747-53A2427

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2427Original Issue: December 17, 1998 Revision 7: July 19, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Tail Section - Body Station 2598 Bulkhead Inner Chord and Web 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 given in this service bulletin will make sure that cracks in the frame supports, upper and lower splice fittings, floor supports, forward and aft inner chords, and upper and lower web panels of the Body Station (STA) 2598 bulkhead are found and repaired before the crack damage can have an effect on flight safety. The horizontal stabilizer hinge fittings are attached to the STA 2598 bulkhead. Cracks in the bulkhead splice fittings, frame supports, web, or inner chords that are not found and repaired could extend with continued use of the airplane and adversely affect the structural integrity of the bulkhead and the horizontal stabilizer support structure.

Eleven operators have told Boeing about cracks that were found in the aft inner chord of the STA 2598 bulkhead on 14 airplanes. In addition, three operators have also told Boeing about cracks that were found in the forward inner chord of the STA 2598 bulkhead on three airplanes. These cracks were all found near the upper corners of the cutout for the horizontal stabilizer rear spar. Refer to Appendix A for more information about service history.

NOTE: Refer to Appendix A for service history data for the period between the original issue and Revision 6 of this service bulletin. Refer to Appendix B for Revision 1-6 change information previously described in this Service Bulletin.

After the release of Revision 6 of this service bulletin, operators reported cracks found in the frame support (one airplane) and the upper and lower frame support splice fittings (four airplanes). These cracks were found between 10,409 to 19,203 flight cycles. The surface and open hole HFEC inspections given in this service bulletin have been expanded in response to these findings.

Boeing Structural Item Interim Advisory (SIIA) 747-167 is related to this Service Bulletin.

Boeing Service Related Problem (SRP) 747/747OP-SRP-53-0106, 747/747OP-SRP-53-0316, 747-SRP-53-0343, and 747-SRP-53-0427 are related to this service bulletin.

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 9 of 126

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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 ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Do open hole and surface high frequency eddy current (HFEC) inspections for cracks in the left and right side frame supports, splice fittings, forward and aft inner chords and floor supports. In addition, do open hole and surface HFEC inspections for cracks in the bulkhead upper and lower web near the aft inner chord to shear deck connection.

If no crack(s) are found, repeat the open hole and surface HFEC inspections, or alternatively, accomplish a modification in accordance with Service Bulletin 747-53A2473 or 747-53A2837 . No further action is required by this service bulletin after modification in accordance with Service Bulletin 747-53A2473 or 747-53A2837 .

If a crack is found in the aft inner chord only, accomplish the inner chord repair given in this service bulletin, or alternatively, accomplish a modification in accordance with Service Bulletin 747-53A2473 or 747-53A2837 .

If a crack is found in a splice fitting, frame support, forward inner chord, or floor support, contact Boeing for repair data and do the repair.

If a crack is found in the bulkhead upper web, accomplish the upper web repair given in this Service Bulletin, or alternatively, accomplish a modification in accordance with Service Bulletin 747-53A2473 or 747-53A2837 .

If a crack is found in the bulkhead lower web, accomplish a modification in accordance with Service Bulletin 747-53A2473 or 747-53A2837 or contact Boeing for repair data and do the repair.

For Group 1 and group 2 airplanes, an interim modification is to be accomplished in accordance with this service bulletin by the time given in Paragraph 1.E., Compliance if the modification given in Service Bulletin 747-53A2473 or 747-53A2837 is not accomplished by that time.

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 10 of 126 BOEING SERVICE BULLETIN 747-53A2427

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After accomplishment of an inner chord repair, upper web repair, or interim modification, do post-repair/modification inspections in accordance with this service bulletin.

EFFECTIVITY 747-100/-100B/-100B SUD/-200B/-200C/-200F/-300/-400/-400D/-400F/SP/SR Airplanes. Refer to Paragraph

1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-14-07 and FAA Airworthiness Directive AD 2004-07-22 R1 are related to this service bulletin.

The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

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.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION None.

Original Issue: December 17, 1998 747-53A2427Revision 7: July 19, 2013 11 of 126 BOEING SERVICE BULLETIN 747-53A2427

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BOEING SERVICE BULLETIN 747-53A2427

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STA IN THE UPPER AND LOWER 2598 INSPECTION AREAS:

ACCOMPLISH OPEN HOLE AND SURFACE

HFEC INSPECTIONS FOR CRACKS IN

THE FORWARD AND AFT INNER CHORDS,

FRAME SUPPORT, SPLICE FITTING AND WEB PANELS.

ACCOMPLISH REPAIRS AS NECESSARY STA 2598 AND REGULAR REPEAT INSPECTIONS,

OR ALTERNATIVELY, ACCOMPLISH A

BULKHEAD (SUPPORT FRAME) MODIFICATION.

UPPER

INSPECTION AREA

HORIZONTAL

STABILIZER LOWER

INSPECTION AREA S64511 Original Issue: December 17, 1998 Revision 7: July 19, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2427 Work - See page 1 for details. 12 of 126

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