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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2478 Original Issue: February 07, 2002 Revision 3: October 17, 2011 ATA System: 5361 SUBJECT: FUSELAGE - Section 46 and Section 48 - Vertical Stabilizer Seal - Skin Damage Protection at Seal Interface - Inspection 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: February 07, 2002 747-53A2478Revision 3: October 17, 2011 1 of 52
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 2 of 52 BOEING SERVICE BULLETIN 747-53A2478
ALERTALERT
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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 0 B. Concurrent Requirements ...................................... 2 0 C. Reason ................................................ 2 1 D. Description .............................................. 2 3 E. Compliance .............................................. 2 4 F. Approval ............................................... 3 1 G. Manpower .............................................. 3 1 H. Weight and Balance Changes .................................... 3 2 I. Electrical Load Data ......................................... 3 2 J. References .............................................. 3 2
1. Existing Data: ......................................... 3 2
2. Data supplied with this Service Bulletin: ........................... 3 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 3 K. Publications Affected ........................................ 3 3 L. Interchangeability and Intermixability of Parts ........................... 3 4
2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 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: ........................ 3 5
3. Parts Modified and Reidentified: ............................... 3 5
4. Parts Removed and Not Replaced: .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 8 FIGURE 1: LOGIC DIAGRAM ....................................... 4 6 FIGURE 2: ACCESS / RESTORATION .................................. 4 7 FIGURE 3: FUSELAGE SKIN INSPECTION ............................... 4 9 FIGURE 4: FUSELAGE SKIN REWORK .................................. 5 1
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 3 of 52 BOEING SERVICE BULLETIN 747-53A2478
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 4 of 52 BOEING SERVICE BULLETIN 747-53A2478
ALERTALERT
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2478Original Issue: February 07, 2002 Revision 3: October 17, 2011 ATA System: 5361 SUBJECT: FUSELAGE - Section 46 and Section 48 - Vertical Stabilizer Seal - Skin Damage Protection at Seal Interface - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplane(s) changed in accordance with Revision 1 or Revision 2 of this service bulletin. Do repeat inspections in accordance with Revision 3.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-14-02 is related to this service bulletin.
REASON FOR REVISION This revision is sent to change the repeat inspection requirements for all airplanes, to add the requirement for rub strip installation for airplanes with wear or blend that exceeds Structural Repair Manual limits and to add the requirement to clean the skin at each inspection interval. Since the release of Revision 2 of this service bulletin, one operator has reported wear through the fuselage skin between Body Station (STA) 2598 and STA 2638, stringers S-2L to S-3L. The wear developed in less than 3,657 flight hours since the previous inspection, which was less than the repeat inspection interval given in Revision 2 of the service bulletin. The wear occurred through both the Teflon filled coating and the full thickness of the 0.050 inch thick skin to create a hole approximately 16 inches in length.
These sections were changed:
1. Paragraph 1.C., Reason: Revision information is added.
2. Paragraph 1.D., Description: Revision information is added.
3. Paragraph 1.E., Compliance: Conditions, compliance times and repeat inspection intervals are changed.
Requirement for rub strip installation is added. Requirement to clean skin is added.
4. Paragraph 1.F., Approval: Approval information information is updated.
5. Paragraph 1.G., Manpower: Manpower estimates are changed.
6. Paragraph 1.J., References: New references are added to existing data.
7. Paragraph 3.A., General Information: Note allowing sequence of steps to be changed is removed. New notes are added.
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Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 5 of 52
8. Paragraph 3.B., Work Instructions: Alternative access method is added. HFEC inspection requirement is clarified. Repair options are clarified. Rub strip installation requirement is added. Instruction to apply Teflon filled coating is changed. Instruction to clean the skin is added. Optional economic based additional inspections and procedures are added.
9. Figure 3: HFEC inspection requirement is clarified.
10. Figure 4: Teflon filled coating minimum thickness requirement is added.
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 February 07, 2002Original Issue:
March 27, 2008Revision 1:
July 15, 2010Revision 2:
October 17, 2011Revision 3:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 6 of 52 BOEING SERVICE BULLETIN 747-53A2478
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2478Original Issue: February 07, 2002 Revision 3: October 17, 2011 ATA System: 5361 SUBJECT: FUSELAGE - Section 46 and Section 48 - Vertical Stabilizer Seal - Skin Damage Protection at Seal Interface - 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 this service bulletin will detect cracks and accelerated skin wear damage from the vertical stabilizer seal beyond allowable limits. The fuselage skin is subject to wear damage in the area of the vertical stabilizer seal interface in Section 46 (Section 47 on 747-400 Large Cargo Freighter, LCF) and Section 48, which causes thinning of the skin and could lead to cracking. Undetected cracking in the pressurized Section 46 could reach sufficient length to cause in-flight depressurization of the airplane.
Prior to the release of Revision 1 of this service bulletin, BMS 10-86 Teflon filled coating along with primer has shown to reduce wear caused by the movement of the vertical stabilizer seal on the fuselage skin. Boeing has determined that primer and BMS 10-86 Teflon filled coating does not provide the required wear resistance.
Service Bulletin 747-53-2192, "Body-To-Vertical Fin Interface Seal Chafing Protection", dated July 21, 1981 provided operators of line numbers 0001 - 0414 with the option to apply enamel coating or BMS 10-86 Teflon filled coating. Service bulletin 747-53-2192 was released after two operators reported seal wear damage on four airplanes ranging in service time from 15,332 to 27,204 flight hours. Subsequent to Service Bulletin 747-53-2192 three operators reported seal wear damage on three airplanes ranging in service time from 8,265 to 40,805 flight hours. Service Bulletin 747-53-2192 is being replaced by this service bulletin, thereby eliminating the option of enamel coating under the vertical stabilizer seal for airplane line numbers 0001 - 0414.
On airplanes after line number 1264, BMS 10-86 Teflon filled coating along with primer was applied at the vertical stabilizer seal interface in Section 46 and Section 48 during production.
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Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 7 of 52
BMS 10-86 Teflon filled coating was applied in Service Bulletin 747-53-2192 and the original issue of this service bulletin to prevent skin wear damage, but is no longer terminating action for Revision 1 of this service bulletin.
Subsequent to the release of the original issue of this service bulletin, an operator reported seal wear damage on three airplanes. The airplanes had received BMS 10-86 Teflon filled coating during production. The wear damage had occurred on airplanes ranging in service time between from 21,318 to 26,432 flight hours. The maximum depth of wear damage reported was 0.018 inches and was found on airplane line number 1300 with a service time of 21,371 flight hours. Application of BMS 10-86 Teflon filled coating per Service Bulletin 747-53-2192 and the original issue of this service bulletin is no longer terminating action for this service bulletin.
Since the release of Revision 2 of this service bulletin, one operator has reported wear through the fuselage skin between Body Station (STA) 2598 and STA 2638, stringers S-2L to S-3L. The wear developed in less than 3,657 flight hours since the previous inspection, which was less than the repeat inspection interval given in Revision 2 of the service bulletin. The wear occurred through both the Teflon filled coating and the full thickness of the 0.050 inch thick skin to create a hole approximately 16 inches in length.
Accomplishment of this service bulletin will ensure detection of crack and wear damage and provide proper fuselage skin coating at the vertical stabilizer seal interface in Section 46 and Section 48.
Boeing Service Related Problem (SRP) 747-SRP-53-0161, 747-SRP-53-0296 and 747 FTD 53-06007 are related to this service bulletin.
ACTION Get access to the fuselage skin at the vertical stabilizer seal interface. Do a detailed inspection of the fuselage skin for wear damage and cracks at the vertical stabilizer seal interface. In addition, if skin is blended in Section 46 and not reinforced, inspect the blended area with surface HFEC for cracks. If damage exists, repair in accordance with the structural repair manual (SRM) or Boeing Service Bulletin 747-53-2721 . If any crack is found or if wear exceeds SRM limits, also install rub strips in accordance with Boeing Service Bulletin 747-53-2721 . Apply BMS 10-86 Teflon filled coating as necessary. Clean the skin at the vertical stabilizer seal interface.
Follow-up with repeat visual or HFEC inspections. Optional: replace the seals and inspect for and repair paint blistering at the vertical stabilizer seal interface.
As an alternative to repeated inspections, install CRES rub strips on the affected skin panels in accordance with 747-53-2721.
The skin panels affected by this service bulletin are divided into the following zones:
– Zone 1: STA 2280 to STA 2360 (STA 2340+40 to STA 2360 for 747LCF, STA 2072 to STA 2360 for 747SP) – Zone 2: STA 2360 to STA 2397 – Zone 3: STA 2397 to STA 2417 – Zone 4: STA 2517 to STA 2557 – Zone 5: STA 2557 to STA 2598 – Zone 6: STA 2598 to STA 2638 NOTE: The SRM subjects referenced in this service bulletin have been updated to reflect new allowable damage limits.
EFFECTIVITY All 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, and 747SR series airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
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Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 8 of 52 BOEING SERVICE BULLETIN 747-53A2478
ALERTALERT
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-14-02 is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for the original release of this service bulletin only for Group 1 airplanes in warranty as of July 12, 2001. For inspection labor hour reimbursement for Group 1 airplanes in warranty as of that date, send a warranty claim to Boeing Warranty. If the condition described in the original release of this service bulletin is found during the inspection for Group 1 airplanes in warranty as of that date and additional labor hours are required, send a warranty claim to Boeing Warranty. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order.
Boeing warranty remedies are not available for either Group 1 or Group 2 airplanes for the additional work required by Revision 1, Revision 2 or Revision 3 of this service bulletin.
MANPOWER Elapsed HoursTotal Task Hours Airplanes
16.7533.50Group 1 and Group 2 airplanes.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 9 of 52 BOEING SERVICE BULLETIN 747-53A2478
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2478
ALERT ALERT
INSPECT THE FUSELAGE SKIN FOR WEAR
AND CRACKS AT THE VERTICAL STABILIZER SEAL INTERFACE. IF DAMAGE EXISTS, REPAIF IN ACCORDANCE WITH SRM OR SB 747-53-2721
IF CRACK IS FOUND OR IF WEAR EXCEEDS SRM
LIMITS, ALSO INSTALL RUB STRIPS IN ACCORDANCE WITH SB 747-53-2721. APPLY BMS 10-86 TEFLON FILLED COATING AS NECESSARY. CLEAN THE SKIN. DO REPEAT INSPECTIONS.
AFT TORQUE BOX
ACCESS RUDDER PANEL -ORWARL ORQUE BOX ACCESS
PANEL STA 2628
DORSAL STA FIN 2521
VERTICAL
STABILIZER STA SEAL STA 1 2416 2360 STA :
2280 1 (STA 2072 ON 747SP) (STA 2340+40 ON 747LCF)
VERTICAL
HORIZONTAL STABILIZER STABILIZER SEAL AFT
PRESSURE
BULKHEAD
TYPICAL PASSENGER AIRPLANE SHOWN,
SP AND BOEING LCF SIMILAR (LEFT SIDE SHOWN RIGHT SIDE OPPOSITE) V71088 Original Issue: February 07, 2002 Revision 3: October 17, 2011 747-53A2478
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 52
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2478 Original Issue: February 07, 2002 Revision 3: October 17, 2011 ATA System: 5361 SUBJECT: FUSELAGE - Section 46 and Section 48 - Vertical Stabilizer Seal - Skin Damage Protection at Seal Interface - 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.
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.
NOTE: 747-8 and 747-8F series airplanes are not affected by this service bulletin.
DESCRIPTIONCONFIGURATIONGROUP Line number 0001 - 1264 Airplanes that are in the effectivity of service bulletin 747-53A2478 R0.
-1 Line number 1265 and on. Airplanes that have received BMS 10-86 Teflon Filled Coating in production.
-2 Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR GroupVariable Number 1RA001 - RA034 1RA101 - RA115
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Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 11 of 52
GroupVariable Number 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA266 1RA301 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA418 1RA501 - RA502 1RA521 - RA528 1RA532 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 - RA635 1RA651 - RA652 1RA671 - RA677 1RA701 - RA702 1RA721 - RA731 1RA741 - RA745 1RA749 - RA750 1RA761 - RA762 1RA781 - RA784 1RA901 - RA916 1RB001 - RB016 1RB041 - RB044 1RB071 - RB075 1RB101 - RB102 1RB411 - RB413 1RB421
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 07, 2002 747-53A2478Revision 3: October 17, 2011 12 of 52 BOEING SERVICE BULLETIN 747-53A2478