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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2427 Original Issue: December 17, 1998 Revision 6: July 14, 2011 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 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1998 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, KC-10, KDC-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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 1 of 118
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 2 of 118 BOEING SERVICE BULLETIN 747-53A2427
ALERTALERT
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 ........................................ 2 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 3 D. Description .............................................. 2 3 E. Compliance .............................................. 2 4 F. Approval ............................................... 3 5 G. Manpower .............................................. 3 5 H. Weight and Balance Changes .................................... 3 6 I. Electrical Load Data ......................................... 3 6 J. References .............................................. 3 6
1. Existing Data: ......................................... 3 6
2. Data supplied with this Service Bulletin: ........................... 3 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 7 K. Publications Affected ........................................ 3 7 L. Interchangeability and Intermixability of Parts ........................... 3 8
2. MATERIAL INFORMATION ........................................ 3 9 A. Material - Price and Availability ................................... 3 9 B. Industry Support Information .................................... 3 9 C. Parts Necessary For Each Airplane ................................. 3 9
1. Kits/Parts: ........................................... 3 9
2. Parts and Materials Supplied by the Operator: ........................ 3 9
3. Parts Modified and Reidentified: ............................... 3 9
4. Parts Removed and Not Replaced: .............................. 3 9 D. Parts Necessary to Change Spares ................................. 3 9 E. Special Tooling - Price and Availability ............................... 3 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 1 A. GENERAL INFORMATION ..................................... 4 1 B. WORK INSTRUCTIONS ....................................... 4 2 FIGURE 1: DELETED ............................................ 4 7 FIGURE 2: INSPECTION .......................................... 4 8 FIGURE 3: DELETED ............................................ 5 5 FIGURE 4: WEB CRACK REMOVAL ................................... 5 6 FIGURE 5: INSPECTION - POST REPAIR / INTERIM MODIFICATION - REPAIRED/MODIFIED AREA .................................................. 5 9 FIGURE 6: INSPECTION - POST REPAIR / INTERIM MODIFICATION - FORWARD SIDE ...... 6 8 FIGURE 7: WEB REPAIR OR INTERIM MODIFICATION - NO EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 1, Configuration 1] .................... 7 2 FIGURE 8: WEB REPAIR OR INTERIM MODIFICATION - NO EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 2-3, Configuration 1] ................... 8 2
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Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 3 of 118 BOEING SERVICE BULLETIN 747-53A2427
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FIGURE 9: UPPER WEB REPAIR - EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 1, Configuration 2] ................................... 9 2 FIGURE 10: UPPER WEB REPAIR - EXISTING INNER CHORD REPAIR OR INTERIM MODIFICATION [Group 2-3, Configuration 2] ................................. 1 0 4 APPENDIX A: SERVICE HISTORY ..................................... 1 1 6 APPENDIX B: PREVIOUS REVISION CHANGE INFORMATION ..................... 1 1 8
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 4 of 118 BOEING SERVICE BULLETIN 747-53A2427
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2427Original Issue: December 17, 1998 Revision 6: July 14, 2011 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 the original issue and Revisions 1 thru 5 of this service bulletin. Open hole and surface high-frequency eddy current (HFEC) inspections for cracks in the bulkhead upper and lower web panels are to be accomplished in accordance with this revision.
The effectivity groups are changed with this revision. Airplanes with line numbers 1-1241 (group 1 airplanes before this revision) are now divided into group 1 (line number 1-695 airplanes) and group 2 (line number 696-1241 airplanes). The group 1 airplanes have a bonded doubler on the bulkhead web which has an affect on the web repair added with this revision. Airplanes with line numbers 1242-1307 (group 2 airplanes before this revision) are now group 3 airplanes. The interim modification given in this service bulletin is applicable to group 1 and group 2 airplanes only.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-14-07 is related to this service bulletin.
AD 2010-14-07 supersedes AD 2006-05-06 which superseded AD 2001-15-03.
REASON FOR REVISION After the release of Revision 5 of this service bulletin, several operators found cracks in the bulkhead upper and lower web panels near the inner chord to shear deck connection. Open hole and surface HFEC inspections for such cracks (plus web repairs and post-repair inspections) have been added with this revision as a result of these crack findings.
These sections of the service bulletin have been changed:
1. Summary: updated the Background, Action and Manpower paragraphs and graphic to address added web inspections.
2. Planning Information
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Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 5 of 118
a. Paragraph 1.A.1., Group Configuration table: revised airplane groups to account for differences in the bulkhead web configurations.
b. Paragraph 1.C., Reason and Paragraph 1.D., Description: added information about bulkhead web cracks and associated inspections/repairs.
c. Paragraph 1.E., Compliance: revised compliance tables to give new web inspection and repair data.
Moved the interim modification data into Table 1 and moved the post-repair/modification data to Table
3.
d. Paragraph 1.G., Manpower: revised manpower data to account for added web inspection.
3. Accomplishment Instructions:
Part 1: added instruction for web inspections and repairs and changed to a table format to give the inspection/repair/modification alternatives.
Part 3: created new Part 3 to give the post-repair/modification work.
Part 4: created new Part 4 to give upper web repair work.
4. Figure 2: added upper and lower web inspection.
5. Figure 4: changed this figure to give the web crack removal work and removed the interim repair instruction which now appears in figures 7 and 8.
6. Figure 5: added post-repair/modification inspection of the upper web and added new post-repair configuration for the upper web repair.
7. Figure 7, 8: added these figures to give upper web repair for group 1 and group 2,3 airplanes respectively.
These figures also give the instruction for the interim modification which is changed in configuration to be equivalent to the upper web repair minus the web trim out and the associated filler(s).
8. Figure 9, 10: added these figures to give upper web repair for airplanes that have an existing inner chord repair or interim modification.
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:
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Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 6 of 118 BOEING SERVICE BULLETIN 747-53A2427
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July 14, 2011Revision 6:
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Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 7 of 118 BOEING SERVICE BULLETIN 747-53A2427
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 8 of 118 BOEING SERVICE BULLETIN 747-53A2427
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2427Original Issue: December 17, 1998 Revision 6: July 14, 2011 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 splice fitting, frame support, floor support, 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 affect 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 B for Revision 1, 2, 3, 4 and 5 change information previously described in this Service Bulletin.
After the release of Revision 5 of this service bulletin, several operators reported cracks in the bulkhead upper and lower web panels near the inner chord to shear deck connection. Cracks found in the upper bulkhead web were 0.55 inch to 0.80 inches in length and cracks found in the lower bulkhead web were 0.20 inch to 1.30 inches in length. Two operators have reported web cracks on airplanes with 8,435 and 8,940 total flight-cycles while other reports were for web cracks found on airplanes with greater than 20,000 total flight cycles.
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 and 747-SRP-53-0343 are related to this service bulletin.
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Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 9 of 118
ACTION (PRR 85901-103RS) Do open hole and surface high frequency eddy current (HFEC) inspections for cracks in the left and right side splice fitting, frame support, forward and aft inner chords and floor support. In addition, do open hole and surface HFEC inspections for cracks in the bulkhead upper web (left and right sides) and lower web (left side only) 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. No further action is required by this service bulletin after modification in accordance with Service Bulletin 747-53A2473.
If crack(s) are found in the aft inner chord only, accomplish the upper chord repair given in this service bulletin, or alternatively, accomplish a modification in accordance with Service Bulletin 747-53A2473.
If a crack is found in the 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 panel, accomplish the upper web repair given in this Service Bulletin, or alternatively, accomplish a bulkhead (Support Frame) modification in accordance with Service Bulletin 747-53A2473.
If a crack is found in the bulkhead lower web, accomplish the bulkhead modification or contact Boeing for repair data and do the repair.
For Group 1 and group 2 airplanes, an interim modification is to be accomplished by the time given in Paragraph
1.E., Compliance if the modification given in Service Bulletin 747-53A2473 is not accomplished by that time.
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 See Paragraph 1.E., Compliance for compliance information.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-14-07 is related to this service bulletin.
AD 2010-14-07 supersedes AD 2006-05-06 which superseded AD 2001-15-03.
Also, Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-07-22 R1 is related to this service bulletin.
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.
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Original Issue: December 17, 1998 747-53A2427Revision 6: July 14, 2011 10 of 118 BOEING SERVICE BULLETIN 747-53A2427
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BOEING SERVICE BULLETIN 747-53A2427
ALERT ALERT
MATERIAL INFORMATION None.
STA ACCOMPLISH OPEN HOLE AND SURFACE 2598 HFEC INSPECTIONS FOR CRACKS IN
THE FORWARD AND AFT INNER CHORDS,
FRAME SUPPORT FITTING, SPLICE FITTINGS AND UPPER WEB PANEL.
ACCOMPLISH REPAIRS AS NECESSARY
AND REGULAR REPEAT INSPECTIONS,
STA OR ALTERNATIVELY, ACCOMPLISH A 2598 BULKHEAD (SUPPORT FRAME) MODIFICATION.
HORIZONTAL
STABILIZER FRAME
SUPPORT
AFT INNER CHORD
ACCOMPLISH OPEN HOLE HFEC
INSPECTION FOR CRACKS IN THE LOWER WEB PANEL.
ACCOMPLISH REGULAR REPEAT INSPECTIONS. IF CRACKS ARE FOUND
ACCOMPLISH A BULKHEAD (SUPPORT UP
FRAME) MODIFICATION, OR CONTACT
BOEING FOR REPAIR DATA AND DO THE REPAIR.
Original Issue: December 17, 1998 Revision 6: July 14, 2011 747-53A2427
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 118
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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