Boeing ASB 747-53A2473: Boeing - Service Bulletin, text

TextPartly OCR

Some pages are OCR from a scan. OCR can misread letters and numbers.

Query with SQL

duckdb -csv -c "SELECT p.page, p.text_source, p.text, f.rights_holder, f.license
  FROM 'https://openairdocs.org/data/latest/service_document_file_page.parquet' p JOIN 'https://openairdocs.org/data/latest/service_document_file.parquet' f USING (file_sha256)
  WHERE p.file_sha256 = '6c7ad8329392be6bba30ee77f477049ea95cf6b1bdef0421341231a038d79d5d'
  ORDER BY p.page"

Prints the whole list as CSV. It reads the release’s Parquet files over HTTPS, so there’s nothing to download first. Install DuckDB to run it.

SELECT p.page, p.text_source, p.text, f.rights_holder, f.license
FROM 'https://openairdocs.org/data/latest/service_document_file_page.parquet' p JOIN 'https://openairdocs.org/data/latest/service_document_file.parquet' f USING (file_sha256)
WHERE p.file_sha256 = '6c7ad8329392be6bba30ee77f477049ea95cf6b1bdef0421341231a038d79d5d'
ORDER BY p.page

Run it at the DuckDB prompt, or in any tool that reads Parquet over HTTPS. More ways to query the release are on Use the data.

Page 1Open in PDF

Commercial Airplanes 747 Service Bulletin Number: 747-53A2473 Original Issue: March 24, 2005 Revision 4: December 01, 2011 ATA System: 5313 SUBJECT: FUSELAGE - Section 48 - Body Station 2598 Bulkhead - Horizontal Stabilizer Hinge Support Frame Cracking - Modification and Repair 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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: March 24, 2005 747-53A2473Revision 4: December 01, 2011 1 of 250

3.0

Page 2Open in PDF

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 2 of 250 BOEING SERVICE BULLETIN 747-53A2473

BLANK PAGE

Page 3Open in PDF

Table of Contents

Revision Transmittal Sheet7

Summary9

1. PLANNING INFORMATION ........................................ 1 5 A. Effectivity ............................................... 1 5

1. Airplanes ............................................ 1 5

2. Spares Affected ........................................ 2 6 B. Concurrent Requirements ...................................... 2 6 C. Reason ................................................ 2 6 D. Description .............................................. 2 8 E. Compliance .............................................. 3 1 F. Approval ............................................... 4 6 G. Manpower .............................................. 4 7 H. Weight and Balance Changes .................................... 4 9 I. Electrical Load Data ......................................... 5 2 J. References .............................................. 5 2

1. Existing Data: ......................................... 5 2

2. Data supplied with this Service Bulletin: ........................... 5 2

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 3 K. Publications Affected ........................................ 5 3 L. Interchangeability and Intermixability of Parts ........................... 5 3

2. MATERIAL INFORMATION ........................................ 5 5 A. Material - Price and Availability ................................... 5 5 B. Industry Support Information .................................... 5 6 C. Parts Necessary For Each Airplane ................................. 5 6

1. Kits/Parts: ........................................... 5 6

2. Parts and Materials Supplied by the Operator: ........................ 7 4

3. Parts Modified and Reidentified: ............................... 7 5

4. Parts Removed and Not Replaced: .............................. 7 5 D. Parts Necessary to Change Spares ................................. 7 5 E. Special Tooling - Price and Availability ............................... 7 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 7 6

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 7 7 A. GENERAL INFORMATION ..................................... 7 7 B. WORK INSTRUCTIONS ....................................... 7 8 FIGURE 1: ACCESS ............................................ 9 6 FIGURE 2: INSPECTION ......................................... 1 0 0 FIGURE 3: SUPPORT FRAME MODIFICATION ............................. 1 0 5 FIGURE 4: DELETED ........................................... 1 1 4 FIGURE 5: DELETED ........................................... 1 1 5 FIGURE 6: AFT INNER CHORD REPAIR OR INTERIM-MODIFICATION - PARTS AND FASTENER REMOVAL ........................................... 1 1 6 FIGURE 7: UPPER FORWARD INNER CHORD AND FRAME SUPPORT FITTING - INSPECTION . 121 FIGURE 8: UPPER FORWARD INNER CHORD AND FRAME SUPPORT FITTING - FASTENER INSTALLATION ........................................ 1 2 5

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 3 of 250 BOEING SERVICE BULLETIN 747-53A2473

Page 4Open in PDF

FIGURE 9: POST-MODIFICATION INSPECTION PART 1 - SUPPORT FRAME AND ACCESS CUT-OUT DETAILED INSPECTION ................................... 1 3 0 FIGURE 10: POST-MODIFICATION INSPECTION PART 1 - LOWER FLOOR SUPPORT CHORD SURFACE HFEC INSPECTION ..................................... 1 3 2 FIGURE 11: POST-MODIFICATION INSPECTION PART 1 - OUTER CHORD LFEC INSPECTION . 137 FIGURE 12: POST-MODIFICATION INSPECTION PART 1 - OUTER CHORD SURFACE AND OPEN HOLE HFEC INSPECTION ..................................... 1 3 9 FIGURE 13: POST-MODIFICATION INSPECTION PART 1 - SUPPORT FRAME OUTER CHORD AND FRAME SUPPORT FITTING ULTRASONIC (UT) INSPECTION .............. 1 4 2 FIGURE 14: POST-MODIFICATION INSPECTION PART 2 - HINGE SUPPORT OPEN HOLE HFEC INSPECTION ......................................... 1 4 4 FIGURE 15: POST-MODIFICATION INSPECTION PART 3 - SUPPORT FRAME INSPECTIONS . . 151 FIGURE 16: POST-MODIFICATION INSPECTION PART 3 - SUPPORT FRAME INSPECTIONS . . 155 FIGURE 17: POST-MODIFICATION INSPECTION PART 3 - SUPPORT FRAME INSPECTIONS . . 157 FIGURE 18: POST-MODIFICATION INSPECTION PART 3 - SUPPORT FRAME INSPECTIONS . . 159 FIGURE 19: AFT INNER CHORD - INSPECTION FOR UPPER AND LOWER CORNER REPAIRS . 162 FIGURE 20: LEFT SIDE UPPER CORNER WEB CRACK REPAIR (CONCURRENT WITH MODIFICATION) [Group 1, 4, Configuration 1] ................................. 1 6 6 FIGURE 21: RIGHT SIDE UPPER CORNER WEB CRACK REPAIR (CONCURRENT WITH MODIFICATION) [Group 1, 4, Configuration 1] ................................. 1 7 0 FIGURE 22: LEFT SIDE UPPER CORNER WEB CRACK REPAIR (CONCURRENT WITH MODIFICATION) [Group 2, Configuration 1, 3; Group 3, Configuration 1, 3; Group 5] ............ 1 7 4 FIGURE 23: RIGHT SIDE UPPER CORNER WEB CRACK REPAIR (CONCURRENT WITH MODIFICATION) [Group 2, Configuration 1, 3; Group 3, Configuration 1, 3; Group 5] ............ 1 7 7 FIGURE 24: LEFT SIDE LOWER CORNER WEB CRACK REPAIR (CONCURRENT WITH MODIFICATION) [Group 1, Configuration 1-2; Group 2, Configuration 1-4; Group 3, Configuration 1-4; Group 4, Configuration 1-2] ....................................... 1 8 0 FIGURE 25: EXISTING LEFT SIDE UPPER CORNER WEB REPAIR (REPAIRED IN ACCORDANCE WITH SERVICE BULLETIN 747-53A2427) [Group 1, 4, Configuration 2] ............. 1 8 4 FIGURE 26: EXISTING RIGHT SIDE UPPER CORNER WEB REPAIR (REPAIRED IN ACCORDANCE WITH SERVICE BULLETIN 747-53A2427) [Group 1, 4, Configuration 2] ............. 1 8 8 FIGURE 27: EXISTING LEFT SIDE UPPER CORNER WEB REPAIR (REPAIRED IN ACCORDANCE WITH SERVICE BULLETIN 747-53A2427) [Group 2, Configuration 2, 4; Group 3, Configuration 2, 4] ................................................. 1 9 2 FIGURE 28: EXISTING RIGHT SIDE UPPER CORNER WEB REPAIR (REPAIRED IN ACCORDANCE WITH SERVICE BULLETIN 747-53A2427) [Group 2, Configuration 2, 4; Group 3, Configuration 2, 4] ................................................. 1 9 6 FIGURE 29: POST-MODIFICATION INSPECTION PART 4 - LEFT SIDE UPPER CORNER WEB POST-REPAIR INSPECTIONS ............................... 2 0 0 FIGURE 30: POST-MODIFICATION INSPECTION PART 4 - RIGHT SIDE UPPER CORNER WEB POST-REPAIR INSPECTIONS ............................... 2 0 5 FIGURE 31: POST-MODIFICATION INSPECTION PART 4 - LEFT SIDE LOWER CORNER WEB POST-REPAIR INSPECTIONS ............................... 2 1 0 FIGURE 32: LEFT SIDE UPPER CORNER WEB CRACK INSPECTION AND REPAIR (POST-MODIFIED AIRPLANES) [Group 1, 4, Configuration 3] ......................... 2 1 3 FIGURE 33: RIGHT SIDE UPPER CORNER WEB CRACK INSPECTION AND REPAIR (POST-MODIFIED AIRPLANES) [Group 1, 4, Configuration 3] ......................... 2 1 7 FIGURE 34: LEFT SIDE UPPER CORNER WEB CRACK INSPECTION AND REPAIR (POST-MODIFIED AIRPLANES) [Group 2-3, Configuration 5; Group 5] .................... 2 2 1

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 4 of 250 BOEING SERVICE BULLETIN 747-53A2473

Page 5Open in PDF

FIGURE 35: RIGHT SIDE UPPER CORNER WEB CRACK INSPECTION AND REPAIR (POST-MODIFIED AIRPLANES) [Group 2-3, Configuration 5; Group 5] .................... 2 2 5 FIGURE 36: LEFT SIDE LOWER CORNER WEB CRACK INSPECTION AND REPAIR (POST-MODIFIED AIRPLANES) [Group 1, Configuration 3; Group 2-3, Configuration 5; Group 4, Configuration 3;

Group 5] ............................................ 2 2 9 FIGURE 37: POST-MODIFICATION INSPECTION PART 1 - LEFT SIDE UPPER CORNER WEB . . 234 FIGURE 38: POST-MODIFICATION INSPECTION PART 1 - RIGHT SIDE UPPER CORNER WEB . 237 FIGURE 39: POST-MODIFICATION INSPECTION PART 1 - LEFT SIDE LOWER CORNER WEB . . 240 Appendix A: SERVICE BULLETIN REVISION 1 REFERENCE CHANGE INFORMATION ....... 2 4 2 APPENDIX B: SERVICE BULLETIN REVISION 2 REFERENCE CHANGE INFORMATION ....... 2 4 7 APPENDIX C: OPERATOR SUPPLIED MATERIALS ............................ 2 4 8

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 5 of 250 BOEING SERVICE BULLETIN 747-53A2473

Page 6Open in PDF

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 6 of 250 BOEING SERVICE BULLETIN 747-53A2473

BLANK PAGE

Page 7Open in PDF

Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2473Original Issue: March 24, 2005 Revision 4: December 01, 2011 ATA System: 5313 SUBJECT: FUSELAGE - Section 48 - Body Station 2598 Bulkhead - Horizontal Stabilizer Hinge Support Frame Cracking - Modification and Repair This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplane(s) changed in accordance with Revision 3 of this service bulletin, but only if a post-modification inspection was accomplished in accordance with paragraph 3.B.8, Part 1, step a.6. of Revision 3 of this service bulletin and an additional condition specified in this revision applies.

If both the above noted conditions apply, a one time surface high-frequency eddy current (HFEC) inspection of the support frame outer chord for cracks is to be accomplished at one fastener location on each side of the bulkhead.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-14-07 is related to this service bulletin.

REASON FOR REVISION This revision is sent to give a revised sheet 7 (DCN B) of drawing 624U0061 which adds one fastener location (each side) to the support frame outer chord crack inspection. The added fastener location was inadvertantly omitted from the drawing sheet provided with the previous release of this service bulletin. The revised sheet 7 of drawing 624U0061 also includes a changed/corrected use of flagnote 2.

This revision is also sent to change the group applicability assigned to Figures 10, 12 and 13 and to Table 6 of Paragraph 1.E., Compliance. In the previous release of this service bulletin, these group applicabilities were not complete and therefore, for some groups, more than the data extracted according to the group applicability would be needed to accomplish the work instruction.

These sections were changed:

1. Paragraph 1.E., Compliance: Changed group applicability assigned to Table 6 from Group 1, 3 to Group

1-3. Also, added compliance Table 11 for the more work requirement associated with this revision.

2. Paragraph 1.J.2., References, Data supplied with this Service Bulletin: Changed revision level for drawing 624U0061, sheet 7 from DCN A to DCN B.

3. Accomplishment Instruction 3.B.8., Part 1: Added instruction for a one time inspection which is the more work requirement associated with this revision.

4. Figure 10: Changed the group applicability assigned to the figure from Group 1-3 to Group 1-5.

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 7 of 250

Page 8Open in PDF

5. Figure 12: Added flagnote 19 to identify the more work inspection location and changed the group applicability assigned to the figure from Group 4-5 to Group 1-5.

6. Figure 13: Changed the group applicability assigned to the figure from Group 4-5 to Group 1-5.

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 24, 2005Original Issue:

February 20, 2007Revision 1:

August 28, 2009Revision 2:

July 14, 2011Revision 3:

December 01, 2011Revision 4:

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 8 of 250 BOEING SERVICE BULLETIN 747-53A2473

Page 9Open in PDF

Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2473Original Issue: March 24, 2005 Revision 4: December 01, 2011 ATA System: 5313 SUBJECT: FUSELAGE - Section 48 - Body Station 2598 Bulkhead - Horizontal Stabilizer Hinge Support Frame Cracking - Modification and Repair

CONCURRENT REQUIREMENTS None

BACKGROUND This service bulletin gives instruction for a modification to the support frame at body station 2598. This modification makes the support frame more resistant to fatigue cracks in the areas that must be inspected to satisfy requirements given in the FAA Airworthiness Directives and Boeing service bulletins identified in the table below.

This modification can be done to permanently satisfy requirements related to these Airworthiness Directives and service bulletins as shown below.

NoteFAA Airworthiness DirectiveBoeing Service Bulletin

(a)2001-15-03, Amendment 39-12337, superseded by 2010-14-07, Amendment 39-16352.

747-53A2427

(a)2001-14-07, Amendment 39-12318, superseded by 2010-14-07, Amendment 39-16352.

747-53A2449

(b)2003-19-08, Amendment 39-13311, superseded by 2010-14-07, Amendment 39-16352.

747-53A2467

(c), (d)2010-14-07, Amendment 39-16352747-53-2473 747-53A2473

(a) All inspection requirements terminated - no more work necessary after the modification.

(b) Inspection of the support frame aft inner chord per Boeing service bulletin 747-53A2467 is not necessary after the modification; however, inspection of the upper aft outer chords, and the diagonal brace attachment fittings, flanges, and rods per service bulletin 747- 53A2467 is necessary after the modification.

(c) This AD supersedes 2001-15-03, Amendment 39-12337; 2001-14-07, Amendment 39- 12318; 2003-19-08, Amendment 39-13311; and 2006-05-06, Amendment 39-14503 except for the inspection requirements stated in note (b) above.

(d) Post-modification inspection is required as given in the requirements of this AD.

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 9 of 250

Page 10Open in PDF

NOTE: Refer to Appendix A and B for the change information previously described in Revision 1 and Revision 2 of this service bulletin.

Since the release of Revision 2 of this service bulletin, several operators have reported finding cracks in the support frame upper and lower corner web at the aft inner chord to upper floor chord joint. Cracks in the upper web have been reported to be between approximately 0.80 inch to 0.55 inch long, and between 0.20 inch to

1.30 inch long in the lower web. Two operators have reported web cracks on airplanes with 8,435 and 8,940 total flight cycles. Other reports have described web cracks found on airplanes with greater than 20,000 total flight cycles.

Revision 3 is being sent to add a new high-frequency eddy current (HFEC) inspection for cracks in the support frame left and right side upper corner web, and left side lower corner web at the aft inner chord to upper and lower floor support joint. Instructions and parts for a local web repair is provided for any crack that is found within specified limits during the initial support frame modification inspection or during post-modification inspections.

Boeing Service Related Problem (SRP) 747-SRP-53-0343 is related to this service bulletin.

ACTION (PRR 85901-103RS)

MODIFICATION Two web doublers, new upper and lower hinge back-up fittings, and a new inner chord are to be installed on the aft side of the support frame on each side of the airplane. Lift and hold the horizontal stabilizer using external supports, or an optional special tool that Boeing can supply, while the modification work is done. This is necessary to permit removal of the stabilizer hinge back up structure from the aft side of the support frame. Inspection of specified areas/locations of the support frame with surface high-frequency eddy current (HFEC) and open hole HFEC is to be done before the new parts are installed. Oversize fasteners are to be installed at specified locations where insurance cuts are required to remove material that could contain an undetected crack. This mixture of inspection work, insurance cuts, structural reinforcement and new parts is necessary to terminate the inspection requirements identified above.

In addition, a surface HFEC inspection for cracks in the support frame left and right side upper corner web, and left side lower corner web is required before modification work is done. If no cracks are found then repeat HFEC inspections will be necessary during post-modification inspections. If any crack is found within defined web trim out limits, local repairs are provided in this service bulletin that can be done concurrently with the modification work. Any crack that is found to extend outside of defined web trim out limits will require contacting Boeing for repair data.

POST-MODIFICATION Do a one-time General Visual Inspection (GVI) of the upper forward inner chord, frame support fitting and splice fitting for the installation of BACB30NX10K*, BACB30NX10K*X (1/64 oversize) or BACB30NX10K*Y (1/32 oversize) fasteners, and if installed do a one-time review of airplane maintenance records to verify that during the initial modification installation an open hole high frequency eddy current (HFEC) inspection was accomplished and holes were zero-timed. If an open hole HFEC inspection was accomplished and holes were zero-timed during the initial modification installation, no further action is required at these fastener locations. If the accomplishment of an open hole HFEC inspection and zero-time of holes can not be verified, additional modification work is necessary. If .247/.250, .263/.266 (1/64 oversize) or 278/.281 (1/32 oversize) inch diameter fasteners are installed, remove fasteners and do an open hole HFEC inspection. If no cracks are found, zero-time holes and install BACB30NX10K* fasteners.

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 10 of 250 BOEING SERVICE BULLETIN 747-53A2473

Page 11Open in PDF

Do a one-time GVI of the frame web and upper shear deck (floor support) chord aft side for (2) fasteners that were installed as part of an aft inner chord repair removal. If a repair was not installed or if bolts are installed at the (2) fastener locations specified , no further action is required at these fastener locations. If a repair removal was accomplished and 7/32 inch diameter rivets are installed, additional work is required. If a repair removal was accomplished and 3/16 inch diameter rivets are installed, remove rivets and do an open hole HFEC inspection.

If no cracks are found, install new bolts.

Do a one-time GVI for repair(s) installed on the left and right side aft inner chords. If a repair was not installed, no further action is required for this inspection. If any repair is installed, more work is required.

For all airplanes modified in accordance with this service bulletin, post-modification inspections have been added. See Paragraph 1.E., Compliance.

In addition, a surface HFEC inspection for cracks in the support frame left and right side upper corner web, and left side lower corner web is required on a modified support frame. If no cracks are found then repeat HFEC inspections will be necessary during post-modification inspections. If any crack is found within defined web trim out limits on a modified support frame, repairs are provided in this service bulletin that can be installed in addition to the existing modification. Any crack that is found to extend outside of defined web trim out limits will require contacting Boeing for repair data.

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 Service Bulletin Paragraph 1.E. for compliance information.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2006-05-06 was superseded by AD 2010-14-07, which is related to this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection procedures or the modification and repair given in this service bulletin.

MANPOWER Support Frame Modification Elapsed HoursTotal Task HoursAirplanes

104.50305.00All (no web crack repair installed)

107.00315.00All (with web crack repair installed) Support Frame Upper Corner Fastener Inspection/Rework Elapsed HoursTotal Task HoursAirplanes

7.7515.50All

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 11 of 250 BOEING SERVICE BULLETIN 747-53A2473

Page 12Open in PDF

Support Frame Post-Modification Inspections Elapsed HoursTotal Task HoursAirplanes

87.00200.00All - Part 1, 2, 3 & 4

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

Original Issue: March 24, 2005 747-53A2473Revision 4: December 01, 2011 12 of 250 BOEING SERVICE BULLETIN 747-53A2473

Pages 13–24 of 250