Boeing ASB 747-53A2450: Boeing - Service Bulletin, text

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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2450 Original Issue: May 04, 2000 Revision 7: November 02, 2011 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inspection - Stringers 15 Through 31 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2000 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 1 of 97

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Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 2 of 97 BOEING SERVICE BULLETIN 747-53A2450

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Table of Contents

Revision Transmittal Sheet5

Summary7

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

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 2 1 B. Concurrent Requirements ...................................... 2 1 C. Reason ................................................ 2 1 D. Description .............................................. 2 5 E. Compliance .............................................. 2 6 F. Approval ............................................... 2 9 G. Manpower .............................................. 3 0 H. Weight and Balance Changes .................................... 3 1 I. Electrical Load Data ......................................... 3 1 J. References .............................................. 3 1

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

2. Data supplied with this Service Bulletin: ........................... 3 2

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 2 K. Publications Affected ........................................ 3 2 L. Interchangeability and Intermixability of Parts ........................... 3 2

2. MATERIAL INFORMATION ........................................ 3 3 A. Material - Price and Availability ................................... 3 3 B. Industry Support Information .................................... 3 5 C. Parts Necessary For Each Airplane ................................. 3 5

1. Kits/Parts: ........................................... 3 5

2. Parts and Materials Supplied by the Operator: ........................ 4 0

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

4. Parts Removed and Not Replaced: .............................. 4 3 D. Parts Necessary to Change Spares ................................. 4 3 E. Special Tooling - Price and Availability ............................... 4 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 4

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5 A. GENERAL INFORMATION ..................................... 4 5 B. WORK INSTRUCTIONS ....................................... 4 6 FIGURE 1: DELETED ............................................ 4 8 FIGURE 2: ACCESS / RESTORATION FOR CONFIGURATION WITH PASSENGERS IN THE AFT BODY .................................................. 4 9 FIGURE 3: ACCESS / RESTORATION FOR CONFIGURATION WITH CARGO IN THE AFT BODY . 51 FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION .............. 5 3 FIGURE 5: INSPECTION - GROUP 1 AND GROUP 3 .......................... 6 0 FIGURE 6: INSPECTION - GROUP 2 AND GROUP 4 .......................... 7 4 FIGURE 7: FASTENER INSTALLATION .................................. 8 8

Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 3 of 97 BOEING SERVICE BULLETIN 747-53A2450

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Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 4 of 97 BOEING SERVICE BULLETIN 747-53A2450

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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2450Original Issue: May 04, 2000 Revision 7: November 02, 2011 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inspection - Stringers 15 Through 31 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, Revision 1, Revision 2, Revision 3, Revision 4, Revision 5 or Revision 6 of this service bulletin. Continue repeat inspections in accordance with Revision 7 of this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2009-18-07, AD 2010-01-01 and AD 2010-20-08 are related to this service bulletin.

REASON FOR REVISION This revision is sent to add High Frequency Eddy Current inspection of the aft edge of the STA 2231 Frame Aft Inner Chord, of the forward edge of the STA 2231 Frame Forward Inner Chord and of the forward and aft edges of the STA 2231 Frame Strap. This revision is also sent to extend the existing inspection area to include the STA 2231 Frame between stringers 15 and 16. Instructions are added to remove and reinstall a fitting to give access to a trapped fastener location and to add alternative inspections for airplanes with SRM repairs installed.

Airplanes RM128, RT456, RT461, RT501, RT506-RT510, RT513, RT516, RT518-RT520, RT524, RT528, RT572, RT573-RT579, RT642, RT655-RT657, RT751, RT752, RT781, RT782, RT837, RT967 are moved from group 2 to group 4. These airplanes have been converted to Boeing Converted Freighter airplanes.

These sections were changed:

1. Paragraph 1.A. Effectivity: Airplanes RM128, RT456, RT461, RT501, RT506-RT510, RT513, RT516, RT518-RT520, RT524, RT528, RT572, RT573-RT579, RT642, RT655-RT657, RT751, RT752, RT781, RT782, RT837, RT967 are moved from group 2 to group 4.

2. Paragraph 1.C., Reason: Revision information is added.

3. Paragraph 1.D., Description: Revision information is added.

4. Paragraph 1.E., Compliance: New inspection requirements are added. Post repair inspections are clarified.

5. Paragraph 1.F., Approval: New approval information is added.

Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 5 of 97

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6. Paragraph 1.G., Manpower: Manpower estimates are updated.

7. Paragraph 1.J., References: References are added to 'Existing Data'. A drawing is added to 'Installation Drawings Used in the Preparation of this Service Bulletin'.

8. Paragraph 2.A. Material - Price and Availability: Price and availability data is updated. New kits are added.

9. Paragraph 2.C.1., Kits/Parts: Two new top kits and a supplemental are added.

10. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: New fasteners are added.

11. Paragraph 3.A., General Information: Notes are added.

12. Paragraph 3.B., Work Instructions: Steps are added to remove and reinstall access panels. Steps are added to give the new inspection requirements. Instruction for repeat inspection is clarified.

13. Figure 3: Insulation blanket removal is clarified.

14. Figure 4: Instructions are added to remove fitting to give access to trapped fastener location. Fastener removal locations are added.

15. Figures 5 and 6: HFEC inspection of the aft edge of the STA 2231 Frame Aft Inner Chord, of the forward edge of the STA 2231 Frame Forward Inner Chord and of the forward and aft edges of the STA2231 Frame Strap is added. Outer reveal panel removal step is deleted. Inspection area is increased up to stringer S-15 for some inspections. Alternative inspections are added for airplanes with SRM reveal repairs installed.

16. Figure 7: Instructions are added to reinstall fitting that was removed to give access to trapped fastener location. Fastener installation locations are added. Some fastener part numbers are changed.

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 04, 2000Original Issue:

July 06, 2000Revision 1:

January 04, 2001Revision 2:

July 24, 2003Revision 3:

October 09, 2003Revision 4:

January 29, 2009Revision 5:

August 26, 2010Revision 6:

November 02, 2011Revision 7:

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2450Original Issue: May 04, 2000 Revision 7: November 02, 2011 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inspection - Stringers 15 Through 31

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 this service bulletin will make sure that the body frame at station 2231 at stringers 15 through 31 does not have cracks which could cause damage to adjacent body structure which could result in rapid depressurization of the airplane. This frame is the forward edge frame for the number 5 main entry door opening.

Frame cracks that are not found and repaired could extend with continued operation and fully cut the frame. If the frame becomes fully cut, skin cracks could occur which could cause a rapid depressurization of the airplane.

Before the release of the original issue of this service bulletin, four operators reported cracks in the strap and inner chord angle at station 2231 frame. Refer to Paragraph 1.C., Reason, for additional service history. Between the release of Revision 1 and Revision 2, seven operators have reported cracks in the strap, reveal, and inner chord angle at station 2231 frame on thirteen airplanes. Refer to Paragraph 1.C., Reason, for details. Between the release of Revision 2 and Revision 7 of this service bulletin, there have been further reports of cracking in the station 2231 frame on 120 airplanes. Refer to Paragraph 1.C., Reason, for details.

A structural reassessment of the 747 airplane was conducted 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 safe operation of 747 airplanes throughout their operational life. From this requirement, the main entry door forward edge frame at body station 2231 was determined to be significant, in that it is critical to airplane structural integrity. Therefore, a flight safety inspection program which will continue throughout the operational life of the airplane is specified in this service bulletin.

Airplane line numbers 1305 and on were delivered with a redesigned Station 2231 Frame which has improved fatigue durability.

Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 7 of 97

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After the release of Revision 4 of this service bulletin, Boeing received several operator reports of cracks found in the left and right side Station 2231 frame inner chord and strap between stringers 16 and 22. The inspection area as given in Revision 4 of this service bulletin did not include the frame area above stringer 23.

Based on these reports, additional Boeing analysis indicated that the Station 2231 frame design improvement which was implemented in production for airplane line numbers 1305 and on, was not sufficient to prevent cracking of the frame inner chord.

Between the release of Revision 6 and Revision 7 of this service bulletin, Boeing received reports from operators of cracking found above stringer 17 at locations that were not in the inspection areas given in this service bulletin.

Boeing also received a report for the first time of cracking that initiated at the aft edge of the inner chord rather than initiating at a fastener location.

Boeing Structural Item Interim Advisory (SIIA) SIIA 747-93 is related to this service bulletin.

Boeing Service Related Problem (SRP) 747-53-0364 is related to this service bulletin.

ACTION Do a detailed inspection of the Station 2231 Frame Assembly at stringers 15 through 31. The strap, inner chord angles, and frame web are to be inspected for cracks. Also do High Frequency Eddy Current (HFEC) and Low Frequency Eddy Current Inspections of the Station 2231 Frame Assembly. Also do surface and open-hole HFEC inspections of the STA 2231 frame inner chord. If cracks are found, repair before next flight. Repair per SRM or contact Boeing for repair instructions.

EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2009-18-07, AD 2010-01-01 and AD 2010-20-08 are related to this service bulletin.

See Service Bulletin Paragraph 1.E. for compliance information.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

32.00120.50Groups 1 and 2

32.00120.50Groups 3 and 4 (with two MED #5)

18.5068.50Groups 3 and 4 (with one MED #5) Refer to Paragraph 1.G., Manpower.

Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 8 of 97 BOEING SERVICE BULLETIN 747-53A2450

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BOEING SERVICE BULLETIN 747-53A2450

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MATERIAL INFORMATION None STA 2231 ACCESS • 5-151 MAIN UPPER - 5-16L SILL ACCESS → FWD • 5-171 NOTE: ACCESS IS FROM THE MAIN DECK - 5-18L AND FROM THE LOWER LOBE.

DOOR 5 LEFT - 5-191 DOOR 5 RIGHT OPPOSITE INSPECTION AREA • S-20L

- 5-211

- 5-221 DO A DETAILED INSPECTION - 5-23L

FOR CRACKS ON THE STRAP, INNER CHORDS FORWARD AND AFT DOOR 5 LEFT 5-241 OF THE WEB AND EXPOSED WEB ADJACENT TO THE • 5-25L

INNER CHORDS FROM STRINGER 15 THROUGH 31.

ALSO DO HFEC AND LFEC 5-261 STATION 2231 FRAME ASSEMBLY INSPECTIONS FOR CRACKS ON MAIN DECK UP S-31L LOWER

PER THIS SERVICE FLOOR MAIN BULLETIN. > FWD SILL V22507 Original Issue: May 04, 2000 Revision 7: November 02, 2011 747-53A2450

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Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 10 of 97 BOEING SERVICE BULLETIN 747-53A2450

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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.

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.

DESCRIPTIONCONFIGURATIONGROUP 747-100/-200B Passenger Airplane Line Number 001-203.-1 747-100/-100B/-100B SUD/-200B/-300/-400/-400D/SR Passenger Airplanes Line Number 204-765, 767-777, 779-903, 905- 931, 933-1358.

-2 747-200F Line Number 001-203.-3 747-200B/-200C/-200F/-300/-400/-400F Line Number 204-1419.-4 Airplane Models:

747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR

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GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA261 2RA262 - RA266 1RA301 - RA312 2RA313 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA414 2RA415 - RA418 1RA501 - RA502 1RA521 - RA527 2RA528 1RA532 - RA540 2RA541 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 - RA635 1RA651 - RA652 1RA671 - RA677 1RA701 - RA702 1RA721 - RA724 2RA725 - RA731 1RA741 - RA743 2RA744 - RA745

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