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Commercial Airplanes 747 Service Bulletin Number: 747-53A2443 Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Modification 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 © 2002 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Unpublished Work.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: May 09, 2002 747-53A2443Revision 2: August 02, 2013 1 of 107
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 2 of 107 BOEING SERVICE BULLETIN 747-53A2443
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 2 0 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1
1. Existing Data: ......................................... 2 1
2. Data Supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 4 M. Software Accomplishment Summary ................................ 2 4
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary for Each Airplane ................................. 2 5
1. Kits/Parts: ........................................... 2 5
2. Parts and Materials Supplied by the Operator: ........................ 3 1
3. Parts Modified and Reidentified: ............................... 3 4
4. Parts Removed and Not Replaced: .............................. 3 4 D. Parts Necessary to Change Spares ................................. 3 4 E. Special Tooling - Price and Availability ............................... 3 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: LOGIC DIAGRAMS - GROUPS 1 AND 2 ........................... 4 1 FIGURE 2: ACCESS AND RESTORATION - GROUPS 1 AND 2 .................... 4 5 FIGURE 3: ACCESS AND RESTORATION - STATION 380 FLOOR BEAM - GROUP 2 [Group 2] . . 49 FIGURE 4: FLOOR BEAM MODIFICATION (PRIMARY AND ALTERNATIVE) - GROUPS 1 AND 2 . 54 FIGURE 5: FLOOR BEAM - DETAILED INSPECTION .......................... 5 9 FIGURE 6: FLOOR BEAM - OPEN HOLE HFEC INSPECTIONS - STRAPS REMOVED ....... 6 4 FIGURE 7: FLOOR BEAM UPPER CHORD - SURFACE HFEC INSPECTION ............. 6 7 FIGURE 8: FLOOR BEAM - OPEN HOLE HFEC INSPECTION - STRAPS NOT REMOVED ..... 7 0 FIGURE 9: STA 340 - 520 UPPER DECK FLOOR BEAMS - HOLE ZERO-TIMING (PRIMARY PREVENTIVE MODIFICATION INSTALLED) ................................. 7 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 3 of 107 BOEING SERVICE BULLETIN 747-53A2443
FIGURE 10: STA 420 - 520 UPPER DECK FLOOR BEAMS - HOLE ZERO-TIMING (ALTERNATIVE PREVENTIVE MODIFICATION INSTALLED) ........................ 9 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 4 of 107 BOEING SERVICE BULLETIN 747-53A2443
Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2443Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-07-22 R1 and AD 2005-13-05 are related to this service bulletin.
More work is necessary on airplanes changed as given in the Original Issue or Revision 1 of this service bulletin if the initial (preventive) modification was done before 15,000 total flight cycles. Airplanes that had the initial (preventive) modification done before 15,000 total flight cycles will require a second modification (fastener hole zero-timing) within 20,000 flight cycles after the initial (preventive) modification. Accomplishment of the second modification will allow continued operation to the Limit of Validity (LOV) of 35,000 total flight cycles.
No more work is necessary on airplanes changed as given in the Original Issue or Revision 1 of this service bulletin if the initial (preventive) modification was done at or after 15,000 total flight cycles.
REASON FOR REVISION This revision is sent to add a recommendation to not accomplish the preventive modification before 15,000 total flight cycles due to post modification requirements, to add a floor beam second modification (hole zero-timing) and to add an Alternative Preventive Modification at floor beam locations where access is not available to remove fasteners that are trapped by the frame.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. Summary Section: Updated Action section to reflect new requirements. Added WFD note. Added Summary Planning Table. Updated Material Information. Revised Summary illustration text to reflect changed actions.
2. In Paragraph 1.A., Effectivity: Group Configuration Table; Group 1, deleted airplane line number 1268.
3. In Paragraph 1.C., Reason: Added revision information.
4. In Paragraph 1.D., Description: Updated the action descriptions to reflect new requirements, added "More work" statement.
5. In Paragraph 1.G., Manpower: Added manpower estimates for floor beam hole zero-timing modification.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 5 of 107
6. In Paragraph 1.J., References: Added new references related to this revision.
7. In Paragraph 1.J.2.a., Drawings - Drawing sheets are revised to change hole sizes.
8. In Paragraph 1.M., Software Accomplishment Summary: Added new section.
9. In Paragraph 2.C.2, Parts and Materials Supplied by the Operator: Added parts for the floor beam hole zero-timing modification.
10. In Paragraph 3.A., General Information: Updated general notes to current requirements.
11. In Paragraph 3.B., PART 2 and PART 3, Inspection and Preventive Modification: Added Note which defines the Primary and Alternative Preventive Modifications.
12. In Paragraph 3.B., PART 4 and PART 5, After-Modification Repeat Detailed and Surface HFEC Inspections: Added new follow-on requirement.
13. Paragraph 3.B., PART 6., After-Modification - Floor Beam Hole Zero-Timing: New section added.
14. Figure 1: Updated Logic Diagram and added new sheets for new compliance tasks and times.
15. Figure 4: Added new Steps for accomplishment of the Alternative Preventive Modification.
16. Figure 6: Updated view.
17. Figure 7: Updated view.
18. Figure 8: Step 1 and 2, corrected STA locations in Notes column and corrected the quantity of fasteners called out in Table 1.
19. Figure 9: Added new Figure for floor beam hole zero-timing with the Primary Preventive Modification installed.
20. Figure 10: Added new Figure for floor beam hole zero-timing with the Alternative Preventive Modification installed.
The data given in Information Notice 747-53-2443 IN 01 is included in this revision. IN 01 was issued to advise that in the Group Configuration Table the line number range specified for Group 1 is for Group 2 and the line number range specified for Group 2 is for Group 1.
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 May 09, 2002Original Issue:
June 25, 2009Revision 1:
August 02, 2013Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 6 of 107 BOEING SERVICE BULLETIN 747-53A2443
Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2443Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Modification
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of the Inspections and the Preventive Modification shown in this service bulletin will ensure the structural integrity of the STA 340 through 520 upper deck floor beams. Cracks in these floor beams that are not found and repaired could extend and fully sever the floor beam adjacent to the body frame. This can lead to large deflection or deformation of the floor and of the body skin, frames, and stringers. This deflection or deformation could result in damage to wire bundles and unintended inputs to the flight control cables which could affect airplane controllability. Multiple adjacent floor beams which are severed could result in rapid depressurization of the airplane and loss of structural integrity.
The upper deck floor beams connect to the body frames in the flat sided areas of the upper body. Flight critical wire bundles and controls are routed through cutouts in the floor beams and frames.
Initially, two operators told Boeing about cracks in the upper deck floor beams on four 747-200F airplanes. These airplanes had flown 11,586 - 19,488 fight-cycles. The 747-400F floor beams are similar to the 747-200F and can be expected to experience similar problems. The 747 and 747-400 Passenger airplanes floor beams are made from 2024 aluminum which has an improved fatigue durability over the 7075 aluminum floor beams used on the 747-200F and 747-400F. For additional data, refer to Paragraph 1.C., Reason.
Service Bulletins 747-53A2420 and 747-53A2429 have been issued for inspection, modification and repair of the 747-200F airplane upper deck floor beams.
Since the initial release of service bulletin 747-53A2420, operators of 747-200F airplanes have told Boeing about the upper deck floor beam inspections accomplished on approximately twenty airplanes. In virtually all of these inspections, crack indications were found at the upper deck floor beam to frame attachment points.
Boeing Service Related Problem (SRP) 747-SRP-53-0102 and 747-SRP-53-0439 are related to this service bulletin.
The upper deck floor beams have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to Boeing Service Letter 747-SL-53-088.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 7 of 107
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 85900-235) Do an initial Detailed Inspection and open hole High Frequency Eddy Current (HFEC) Inspection at maximum of 15,000 total airplane flight-cycles followed by another Detailed inspection and open hole High Frequency Eddy Current (HFEC) Inspection and a Preventive Modification at a maximum of 20,000 total airplane flight-cycles, but not more than 5,000 flight-cycles after the initial inspection. Do follow up Detailed Inspections and open hole High Frequency Eddy Current (HFEC) or Surface HFEC Inspections that start at 15,000 flight-cycles after the Preventive Modification has been done.
Do the Inspections:
For Groups 1 and 2 airplanes gain access from below the upper deck floor beams by removing the ceiling liners from STA 340 to STA 520. Remove fasteners common to the floor beam straps as required to do the Inspections as given in the Logic Diagram for the inspections. Do the Detailed Inspection and High Frequency Eddy Current (HFEC) Inspections. Restore access and put the airplane back to a serviceable condition.
Do the Preventive Modification (Primary and Alternative):
For Group 2 airplanes remove the upper deck left and right partitions to gain access for the STA 380 floor beam modification. For Groups 1 and 2 airplanes gain access from below the upper deck floor beams by removing the ceiling liners from STA 340 to STA 520. Gain access to the Left side wall area above and below the upper deck floor from STA 420 to STA 440 and at STA 520. Gain access to the Right side wall area above and below the upper deck floor from STA 420 to STA 520. Remove the upper chord straps from the Left STA 340 to STA 480 and STA 520 upper deck floor beams and install new straps. Remove the upper chord straps from the Right STA 340 to STA 380 and STA 420 to STA 520 upper deck floor beams. Install new upper chord straps on the Right STA 340 to STA 520 upper deck floor beams. Restore access and put the airplane back to a serviceable condition.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 8 of 107 BOEING SERVICE BULLETIN 747-53A2443
NOTE: At floor beam locations from STA 420 to STA 520 where fasteners are trapped against the frame and access is not available to remove them, an option is given to grind off the fastener shank after the strap is removed. New fastener holes will not be drilled in the new strap at these locations. At floor beam locations where trapped fastener shanks are ground off, the modification installed is the Alternative Preventive Modification. At locations where there are no trapped fasteners or the trapped fasteners were removed and new fasteners installed, the modification installed is the Primary Preventive Modification.
Do the Floor Beam Hole Zero-Timing:
At floor beam locations where the Primary Preventive Modification was installed: Get access to the STA 340 - 520 upper deck floor beams. Zero-time the specified fastener holes in the floor beam and install new fasteners.
Restore access and put the airplane back to a serviceable condition.
At floor beam locations where the Alternative Preventive Modification was installed: Get access to the STA 420
- 520 upper deck floor beams. Remove the strap and do a HFEC surface inspection of the upper chord around the trapped fasteners for cracks. Zero-time the specified fastener holes in the strap and floor beam. Do a HFEC open hole inspection of the fastener holes in the floor beam and strap that are not zero-timed for cracks. Install the strap. Restore access and put the airplane back to a serviceable condition.
EFFECTIVITY 747-400F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives 2005-13-05 and 2004-07-22 R1 are related to this service bulletin.
Boeing recommends that Inspections, Preventive Modification and Floor Beam Hole Zero-Timing be accomplished as given in Figure 1: LOGIC DIAGRAM .
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts and Operator Supplied Parts/Materials.
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: May 09, 2002 747-53A2443Revision 2: August 02, 2013 9 of 107 BOEING SERVICE BULLETIN 747-53A2443
BOEING SERVICE BULLETIN 747-53A2443 STA 520 × STA 340 - STA BL 520 STA TYPICAL INSPECTION 500 AREA 480 STA STA 460 STA 440 STA 420 STA 400 STA 380 STA 360 STA 340 UP SEND DO VISUAL AND OPEN HOLE HFEC INSPECTIONS OF THE FLOOR BEAMS.
• DO THE PREVENTIVE MODIFICATION (PRIMARY OR ALTERNATIVE) THAT REPLACES AND
REMOVES THE STRAPS, DO VISUAL AND HFEC INSPECTIONS OF ALL HOLES COMMON TO STRAP AND INSTALL NEW STRAPS. DO REPEAT VISUAL AND HFEC INSPECTIONS AFTER COMPLETION OF THE PREVENTIVE MODIFICATION.
AT LOCATIONS WHERE THE PRIMARY PREVENTIVE MODIFICATION WAS INSTALLED, DO THE LOOR BEAM HOLE ZERO-TIMING. AT LOCATIONS WHERE THE ALTERNATIVE PREVENTIVE MODIFICATION WAS INSTALLED, REMOVE THE STRAP, DO DETAILED AND HFEC INSPECTIONS OF THE UPPER CHORD AND DO THE FLOOR BEAM HOLE ZERO-TIMING. V61754 (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR) Original Issue: May 09, 2002 Revision 2: August 02, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2443 Work - See page 1 for details. 10 of 107
Commercial Airplanes 747 Service Bulletin Number: 747-53A2443 Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Modification
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplane(s) shown below. Refer to PRR 85900-235 for data about this change.
Refer to Service Bulletin Index Document D6-30300, Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 747-400F airplanes line number 1087 to 1267.-1 747-400F airplanes line number 968 to 1069.-2 Airplane Models:
747-400F GroupVariable Number 1RL401 1RL411 - RL415 1RL651 - RL653 1RM851 - RM853 1RM856 1RM861 1RM871 - RM873 1RM881 - RM885 1RM891 - RM899 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 11 of 107
GroupVariable Number 1RM901 - RM903 1RM911 2RR701 2RR721 - RR722 1RR723 - RR724 2RR746 - RR747 1RR748 2RR851 - RR854 1RR855 - RR856 1RR861 - RR862 2RR951 - RR952
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason Accomplishment of the Inspections and the Preventive Modification shown in this service bulletin will ensure the structurally integrity of the STA 340 through 520 upper deck floor beams. Cracks in these floor beams that are not found and repaired could extend and fully sever the floor beam adjacent to the body frame. This can lead to large deflection or deformation of the floor and of the body skin, frames, and stringers. This deflection or deformation could result in damage to wire bundles and unintended inputs to the flight control cables which could affect airplane controllability. Multiple adjacent floor beams which are severed could result in rapid depressurization of the airplane and loss of structural integrity.
The upper deck floor beams connect to the body frames in the flat sided areas of the upper body. Flight critical wire bundles and controls are routed through cutouts in the floor beams and frames.
Initially, two operators told Boeing about cracks in the upper deck floor beams on four 747-200F airplanes. Cracks up to 4 inches long were found in the STA 380 floor web. Cracks up to 1.0 inch long were found in the upper chord of STA 380 floor beam. These airplanes had flown 11,586 - 19,488 fight-cycles. The 747-400F floor beams are similar to the 747-200F and can be expected to experience similar problems. The 747 and 747-400 Passenger airplanes floor beams are made from 2024 aluminum which has an improved fatigue durability over the 7075 aluminum floor beams used on the 747-200F and 747-400F. Details of the cracks found in STA 380 floor beam are shown in the table that follows.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 12 of 107 BOEING SERVICE BULLETIN 747-53A2443