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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2463 Original Issue: March 07, 2002 Revision 2: June 16, 2014 ATA System: 5310 5331 SUBJECT: FUSELAGE - Skin - Longitudinal Lap Joints Inspection and Repair 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Unpublished Work.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: March 07, 2002 747-53A2463Revision 2: June 16, 2014 1 of 112
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 2 of 112 BOEING SERVICE BULLETIN 747-53A2463
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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 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F. Approval ............................................... 2 4 G. Manpower .............................................. 2 6 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 8
1. Existing Data: ......................................... 2 8
2. Data Supplied with this Service Bulletin: ........................... 2 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 9 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 0 M. Software Accomplishment Summary ................................ 3 0
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary for Each Airplane ................................. 3 1
1. Kits/Parts: ........................................... 3 1
2. Parts and Materials Supplied by the Operator: ........................ 3 1
3. Parts Modified and Reidentified: ............................... 3 1
4. Parts Removed and Not Replaced: .............................. 3 1 D. Parts Necessary to Change Spares ................................. 3 1 E. Special Tooling - Price and Availability ............................... 3 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 5 FIGURE 1: DELETED ............................................ 4 2 FIGURE 2: EXTERIOR ACCESS ...................................... 4 3 FIGURE 3: INTERNAL ACCESS ...................................... 4 6 FIGURE 4: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUP 1 [Group 1] ....... 5 7 FIGURE 5: LOCATION OF LAP JOINTS 0.090 INCHES OR LESS, GROUPS 2 - 14 [Group 2-14] . . 58 FIGURE 6: EXTERNAL LFEC UPPER ROW SKIN INSPECTION - GROUP 1 [Group 1] ........ 6 5 FIGURE 7: EXTERNAL LFEC UPPER ROW SKIN INSPECTION - GROUPS 2 - 14 [Group 2-14] . . . 66 FIGURE 8: INTERNAL MFEC LOWER ROW SKIN INSPECTION .................... 7 7 FIGURE 9: LOCATION OF LAP JOINTS 0.071 INCHES OR LESS ................... 7 8 FIGURE 10: POST-MODIFICATION INSPECTION - INTERNAL HFEC INSPECTION ......... 8 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 11: POST-MODIFICATION INSPECTION - OPEN-HOLE HFEC INSPECTION ........ 9 7 Appendix A: SKIN / STRINGER DIAGRAMS - GROUP 1 [Group 1] .................... 9 9 Appendix B: SKIN / STRINGER DIAGRAMS - GROUPS 2 - 14 [Group 2-14] .............. 1 0 0 Appendix C: STRINGER 6 AND 14 INSPECTION IN SECTION 41 ................... 1 1 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 4 of 112 BOEING SERVICE BULLETIN 747-53A2463
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2463Original Issue: March 07, 2002 Revision 2: June 16, 2014 ATA System: 5310 5331 SUBJECT: FUSELAGE - Skin - Longitudinal Lap Joints Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directives AD 86-09-07 R1, AD 2004-07-22 R1, AD 2004-13-02, AD 2006-22-09, AD 2010-14-10, and AD 2010-21-04 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.
More work is necessary on airplanes changed or inspected in accordance with the original issue and Revision 1 of this service bulletin. The (more) work is necessary at lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners in the lap joint is 0.090 inches or less. At these lap joints, a structural modification is to be accomplished by the time given in Paragraph 1.E., Compliance.
No airplanes have been added to the service bulletin effectivity.
REASON FOR REVISION This revision is sent to give instructions to do structural modification and post-modification inspections. A structural modification is necessary at lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.090 inches or less. Revision 1 of this service bulletin gave instructions to do a structural modification at lap joints where the skin thickness at the upper fastener row is 0.071 inches or less. Subsequent to Revision 1 release of this service bulletin, additional analysis was done, which showed that lap joints where the thickness of the upper (overlapping) skin is 0.090 inches or less should be modified by the time given in Paragraph 1.E., Compliance. At the time of Revision 2 release of this service bulletin, Boeing records show that no operators have contacted Boeing for a structural modification instructions in accordance with Revision 1 of this service bulletin. In addition to the modification instructions, minor clarifications are added to show skin thicknesses in the lap joints. Also, information related to Group 1 airplane has been deleted. Boeing record shows that Group 1, which includes RR201 airplane only, has been permanently withdrawn from service and scrapped.
These sections were changed:
1. In Summary, Background, updated to show that the modification given in this service bulletin applies to lap joints where skin thickness is 0.090 inches or less. Added the latest SRP number, description of structure affected by widespread fatigue damage (WFD) description, and summary evaluation table.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 5 of 112
2. In Summary, Action, updated to show that the modification given in this service bulletin applies to lap joints where skin thickness is 0.090 inches or less. Also, deleted the notes since the detailed information in the notes are already given in Paragraph 3., Accomplishment Instructions.
3. In Summary, Compliance, updated FAA AD references with the effective date of the FAA AD. Added FAA AD 2010-14-10, which supersedes FAA AD 94-17-01, and FAA AD 2010-21-04, which supersedes AD 90-15-06 and AD 94-12-09.
4. In Summary, updated the summary figure to change the skin thickness from 0.071 to 0.090 for the structural modification.
5. In Paragraph 1.C., Reason, updated to show that the modification given in this service bulletin applies to lap joints where skin thickness is 0.090 inches or less. Added the latest SRP number and a reason for this revision. Deleted the list of changed sections for Revision 1.
6. In Paragraph 1.D., Description, added information about the structural modification requirement, "more work" statement, and affected maintenance zones tables. Deleted the notes since the detailed information in the notes are already given in Paragraph 3., Accomplishment Instructions.
7. In Paragraph 1.E., Compliance:
– Updated FAA AD references with the effective date of the FAA AD.
– Added FAA AD 2010-14-10, which supersedes FAA AD 94-17-01, and FAA AD 2010-21-04, which supersedes AD 90-15-06 and AD 94-12-09.
– Moved post-repair inspection requirements to a new table.
– Added a general reference to Paragraph 3., Accomplishment Instructions, for the required actions.
– Added applicable "Part" of Paragraph 3., Accomplishment Instructions, for the required actions.
– Added tables to give compliance information for structural modification and post-modification inspection instructions.
– Added clarifications to the existing conditions and compliance times.
8. In Paragraph 1.F., Approval, updated alternative method of compliance (AMOC) approval paragraphs for the affected FAA ADs.
9. In Paragraph 1.G., Manpower, added manpower table for the post-modification inspection.
10. In Paragraph 1.H., Weight and Balance Changes, updated the skin thickness to 0.090 inch or less.
11. In Paragraph 1.J.1., Existing Data, updated the reference list.
12. In Paragraph 1.J.2., Data Supplied with this Service Bulletin, added drawings to be sent with this service bulletin.
13. In Paragraph 1.J.3., Installation Drawings Used in the Preparation of this Service Bulletin, added a drawing reference.
14. In Paragraph 1.K., Publications Affected, added a description of the effects on the fatigue critical structure and damage tolerance inspection due to the change given in this service bulletin.
15. Added Paragraph 1.M., Software Accomplishment Summary.
16. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, updated the information.
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17. In Paragraph 3.A., General Information, updated existing notes and added new notes.
18. In Paragraph 3.B., Work Instructions:
– Added "Part" labels for each major sections.
– Deleted work instructions related to Group 1 airplane.
– Added clarification regarding the structural modification.
– Added references to Paragraph 1.E., Compliance, when referring to compliance information.
– Added clarification regarding external doubler repairs and post-repair inspection instructions.
– Added references to the SRM for allowable damage limits and general damage removal instructions.
– Added clarification regarding SRM repairs in the area where the skin thickness is 0.090 inches or less and 0.071 inches or less.
– Added structural modification instructions.
– Added post-modification inspection instructions.
19. In FIGURE 4, information was deleted.
20. In FIGURE 5, added clarification for Str-44 between Sta. 400 - 520. Also added clarification for Str-4 between Sta. 1627 - 1741 and Sta. 1961 - 2002 on airplanes with main deck side cargo door. Updated footnotes to clarify inspection and modification requirements.
21. In FIGURE 6, information was deleted.
22. In FIGURE 7, updated the NDT reference and changed the skin thickness information at stringer 23 in Section 46.
23. In FIGURE 9, changed the skin thickness information at stringer 4 in Section 46.
24. In FIGURE 10 and FIGURE 11, added post-modification inspection instructions.
25. In APPENDIX A, information was deleted.
26. In APPENDIX B, changed the skin thickness information at stringer 23 in Section 46.
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 March 07, 2002Original Issue:
April 16, 2009Revision 1:
June 16, 2014Revision 2:
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Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 7 of 112 BOEING SERVICE BULLETIN 747-53A2463
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 8 of 112 BOEING SERVICE BULLETIN 747-53A2463
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2463Original Issue: March 07, 2002 Revision 2: June 16, 2014 ATA System: 5310 5331 SUBJECT: FUSELAGE - Skin - Longitudinal Lap Joints Inspection and Repair
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 in this service bulletin will help ensure that cracks and corrosion in the skin at lap joints in the fuselage are found and repaired. Small undetected cracks can propagate and join to form a large crack which could cause rapid in-flight decompression.
The skin segments on affected airplanes are joined by longitudinal lap joints which are cold bonded and are fastened by 3 rows of fasteners. The lap joints on affected 747 airplanes are manufactured using similar processes as the lap joints on 737 airplanes.
A 737 airplane experienced a rapid decompression while beginning descent. After the airplane landed safely it was inspected, and the skin above the forward entry door was found to be separated at the S-4R lap joint with a tear running along the lap joint for approximately 28 inches. The skin was bent back at the upper edge of the stringer at S-5R and formed a roughly rectangular opening in the airplane, hinged at S-5R. The opening went from approximately Body Station (BS) 328 to BS 300. The airplane had 78,198 flight-cycles and 77,115 flight hours. The crack was in the (lower) overlapped skin at the lower row of fasteners of the lap joint.
Upon further investigation of the damage, the (lower) overlapped skin panel of the damaged S-4R lap joint was found to have numerous scratches running horizontally on the faying surface. Metallurgical evaluation of the damage revealed that the scratches contributed to the initiation of the fatigue cracks.
Subsequent inspections on other 737 airplanes showed that there were cracks and corrosion in other lap joints at various locations. The cracks were in the (upper) overlapping skin panel at the upper row of fasteners.
Affected 747 airplanes have lap joints similar to 737 airplanes, and therefore the same fatigue cracking could occur on 747 airplanes where the thickness of the upper (overlapping) skin in a lap joint is 0.090 inches or less.
No reports of this type of cracking have been received on 747 airplanes. On affected 747 airplanes severe corrosion of the skin has occurred at the lap joint. On airplanes after line number 200 the lap joints are assembled using sealant and improved assembly processes.
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Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 9 of 112
Subsequent to Revision 1 release of this service bulletin, a review of all service bulletins that recommend repeat inspections was performed to determine if the inspections were appropriate for aging airplanes. This review indicated that lap joints where the thickness of the upper (overlapping) skin is 0.090 inches or less should be modified by the time given in Paragraph 1.E., Compliance, on aging 747 airplanes, line numbers 2 through 200.
Boeing Service Related Problem (SRP) 747-SRP-53-0135, 747OP-SRP-53-0292, and 747-SRP-53-0436 are related to this service bulletin.
The longitudinal lap joints have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
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 NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Inspections are to be done at all lap joints where the thickness of the upper (overlapping) skin at the upper fastener row is 0.090 inches or less. External low frequency eddy current (LFEC) inspections (for corrosion) are to be done at the upper row of fasteners of the lap joint and internal medium frequency eddy current (MFEC) inspections (for cracks) are to be done at the lower row of fasteners of the lap joint. These inspections are to be done by the times given in Paragraph 1.E., Compliance. Skin cracks and corrosion are to be repaired in accordance with Paragraph 3.B., Work Instructions, and Paragraph 1.E., Compliance.
At lap joints where the thickness of the upper (overlapping) skin at the upper row of fasteners is 0.090 inches or less, a structural modification is to be accomplished by the time given Paragraph 1.E., Compliance.
EFFECTIVITY 747-100, 747-200B, 747-200F Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
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Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 10 of 112 BOEING SERVICE BULLETIN 747-53A2463
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COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directives AD 86-09-07 R1, AD 2004-07-22 R1, AD 2004-13-02, AD 2006-22-09, AD 2010-14-10 , and AD 2010-21-04 are related to this service bulletin. The effective date of AD 2004-13-02 is July 29, 2004.
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.
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.
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Original Issue: March 07, 2002 747-53A2463Revision 2: June 16, 2014 11 of 112 BOEING SERVICE BULLETIN 747-53A2463
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BOEING SERVICE BULLETIN 747-53A2463
ALERT ALERT S-34 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 S-12 STA 1480
LAP JOINT (TYPICAL) S-12 S-19 CRACK UPPER SKIN PROTRUDING 1000 HEAD FASTENER S-19 (TYPICAL) STA FLUSH HEAD 520 S-23
UPPER - FASTENER
ROW (TYPICAL) STA SECTIONS 41 AND 42 140
LOWER -
ROW LFEC AND MFEC INSPECT SKIN LAP
CORROSION
JOINTS FOR CRACKS AND CORROSION
IN UPPER AND LOWER FASTENER ROWS
CRACKS IN
LOWER SKIN LOWER SKIN ACCOMPLISH A STRUCTURAL SECTION 41 SECTION MODIFICATION ON ALL LAP JOINTS STRINGER (TYPICAL) 42 AND 46 STRINGER (TYPICAL) WHERE THE SKIN THICKNESS IS 0.090 INCHES OR LESS V43416 Original Issue: March 07, 2002 Revision 2: June 16, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2463 Work - See page 1 for details. 12 of 112