Boeing ASB 747-53A2484: Revision 1, text

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Commercial Airplane Group 747 Service Bulletin Number: 747-53A2484 Date: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 22 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 28

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 28

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 1: ACCESS AND RESTORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 FIGURE 2: STRINGER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 . . . . . . . . . . . . . . . . . 39 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460. . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 . . . . . . . . . . . . . . . . . 54 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480. . . . . . . . . . . . . . . . . . . . . . 59 FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500 . . . . . . . . . . . . . . . . . 69 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500. . . . . . . . . . . . . . . . . . . . . . 74 FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460 . . . . . . . . . . . . . . . . . 84 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460 . . . . . . . . . . . . . . . . . . . . . 89 FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480 . . . . . . . . . . . . . . . . 99

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FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480 . . . . . . . . . . . . . . . . . . . . 104 FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500 . . . . . . . . . . . . . . . . 114 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500 . . . . . . . . . . . . . . . . . . . . 119 FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460 . . . . . . . . . . . . . . . 129 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460. . . . . . . . . . . . . . . . . . . . 134 FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480 . . . . . . . . . . . . . . . 144 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480. . . . . . . . . . . . . . . . . . . . 149 FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500 . . . . . . . . . . . . . . . 159 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500. . . . . . . . . . . . . . . . . . . . 164 FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460 . . . . . . . . . . . . . . . 174 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460 . . . . . . . . . . . . . . . . . . . 179 FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480 . . . . . . . . . . . . . . . 189 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480 . . . . . . . . . . . . . . . . . . . 194 FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500 . . . . . . . . . . . . . . . 204 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500 . . . . . . . . . . . . . . . . . . . 209

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Commercial Airplanes 747 Service Bulletin Number: 747-53A2484 Revision Transmittal Sheet Original Issue: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed as given in the initial release of this service bulletin.

Airplane RS699 was added to Group 1 of the service bulletin effectivity. Airplanes RT631 and RT632, which have been converted to the Large Cargo Freighter (LCF) configuration, were moved from Group 3 to new Group

Federal Aviation Administration (FAA) Airworthiness Directive 2005-15-08 is related to this service bulletin.

REASON FOR REVISION This revision is sent to:

— In Effectivity, Paragraph 1.A., added airplane RS699 to Group 1. This airplane was omitted from the effectivity of the original release of this bulletin.

— Moved airplanes RT631 and RT632, which have been converted to the Large Cargo Freighter (LCF) configuration, from Group 3 to new Group 4.

— In WORK INSTRUCTIONS, Paragraph 3.B., revised access instructions due to different interior configurations.

— In Compliance, Paragraph 1.E., added reference to AD 2005-15-08. Also, added compliance table and revised compliance information to agree with AD 2005-15-08.

— In Material - Price and Availability, Paragraph 2.A., updated kit information to add new repair kits which contain repair angles made from improved materials.

— In Industry Support Information, Paragraph 2.B., updated industry support statement.

— In Figures 4, 6, 10, 12, 16, 22, and 26, corrected fastener quantities and fastener locations.

— In Figures 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, and 26, revised views to show new updated repair parts.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

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.

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REVISION HISTORY Original Issue: June 26, 2003 Revision 1: February 12, 2009

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Commercial Airplane Group 747 Service Bulletin Number: 747-53A2484 Summary Date: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes

CONCURRENT REQUIREMENTS None.

BACKGROUND Inspection of fuselage stringers adjacent to the window belt on the upper deck on 747 airplanes with Stretched Upper Decks (SUD) will make sure that stringer cracks do not grow to include the fuselage skin at the window areas of the upper deck. If stringer cracks at these locations are not found and repaired, the cracks can grow to include the fuselage skin along the window belt of the upper deck. Such skin cracks can result in extensive damage to the skin at the window belt, with related rapid decompression of the fuselage.

Operators have told Boeing about cracks in the fuselage Stringers 8L, 8R, 10L and 10R at the Body Station 460, 480 and 500 frame locations. The airplanes in these reports had between 29,873 and 90,333 flight-hours, and between 9,691 and 25,513 flight cycles.

Installation of the repair shown in this service bulletin (new frame clips and new, additional stringer splice and doublers) will restore the stringers’ strength. For locations where no stringer cracks are found, installation of the preventive modification shown in this service bulletin (new frame clips and a new load-spreading doubler) will prevent stringer cracks form occurring.

Boeing Service Related Problem (SRP) 747-SRP-53-0174 is related to this service bulletin.

Boeing Structural Item Interim Advisory (SIIA) 747-178 is related to this service bulletin.

ACTION Get access to Stringers 8 and 10, on the left and right side of the airplane upper deck, between Body Stations (BS) 440 and 520. At Stringers 8L, 8R, 10L and 10R, do a detailed inspection of the stringers where the frame clips attach to the stringers, at BS 460, BS 480 and BS 500 frame locations. If cracks are found, install repairs as given in this service bulletin (if cracks exceed the repairable length as given in this service bulletin, use data from the 747 Structural Repair Manual with data given in this service bulletin to make the necessary repairs).

Do the inspections again at the times given in Paragraph 1.E., "Compliance". To stop the special inspections given in this service bulletin, install the preventive modification shown in this service bulletin.

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The airplane effectivity is divided into four groups, Group 1 airplanes are also in the effectivity of Service Bulletin 747-53A2265, and have 100 Degree countersink rivets installed in the fuselage skin. Group 2 airplanes are also in the effectivity of Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in the fuselage skin. Group 3 airplanes are not in the effectivity of Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in the fuselage skin. Group 4 airplanes have been modified to the 747- 400 Large cargo Freighter (LCF) configuration.

EFFECTIVITY 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes.

Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE See Service Bulletin Paragraph 1.E, Compliance.

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

MANPOWER

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Task Total Task Hours Elapsed Hours Preventive Modification (all 12 locations) 122 61 Repair (all 12 locations) 230 115

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CRACKS.

ARE FOUND.

CRACKS.

ARE FOUND.

S-10 S-8 460 STA 480 STASTA 500

RIGHT SIDE OPPOSITE STR-10

LEFT SIDE SHOWN,

EDGE OF WINDOW CUTOUT

EDGE OF

WINDOW CUTOUT CRACKS ARE FOUND.

DO A REPAIR IF

MODIFICATION IF NO CRACKS

INSTALL PREVENTIVE

EXAMINE THE STRINGER FOR STR-8 CLIP FRAME FRAME CLIP CRACKS ARE FOUND.

DO A REPAIR IF

MODIFICATION IF NO CRACKS

INSTALL PREVENTIVE

EXAMINE THE STRINGER FOR FWD FWD FWD BSEE SEE C A B C SEE A N68182

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Commercial Airplanes 747 Service Bulletin Number: 747-53A2484 Original Issue: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes

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.

Airplane models:

747-100B SUD 747-200B 747-300 747-400 747-400D

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

GROUP CONFIGURATION DESCRIPTION 1 - 747-300 Airplanes within the effectivity of Service Bulletin 747-53A2265 and have 100 Degree countersink rivets installed in the fuselage skin.

2 - 747-200B, 100B SUD and 300 Airplanes within the effectivity of Service Bulletin 747-53A2265 and have special 120 Degree countersink rivets installed in the fuselage skin.

3 - 747-300, 747-400, and 747-400D airplanes through line number 875, not included in the effectivity of Service Bulletin 747-53A2265, with special 120 Degree countersink rivets installed in the fuselage skin, except 747-400 Large Cargo Freighter airplanes.

4 - 747-400 Large Cargo Freighter (LCF) airplanes through line number 875,

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AEROLINEAS ARGENTINAS (ARG) 3 RT701–RT702

AEROSUR (REO) 1R S 2 3 5

AIR ATLANTA ICELANDIC (AID) 1 RS211 RS233 RS237 3 RS332–RS333 RT751

AIR CHINA (BEJ) 3 RT031–RT033

AIR CHINA CARGO (CGC) 3 RT101 RT103

AIR FRANCE (AFA) 2 RD721–RD722 3 RT071 RT121 RT591 RT711–RT712

AIR INDIA (AIN) 3 RS781–RS782

AIR NEW ZEALAND (ANZ) 3 RT671–RT672 RT703

AIR PACIFIC (APC) 3 RT502 RT504

AIR PULLMANTUR (PUL) 3R S 3 3 1

AIRBRIDGE CARGO (ABM) 3R S 7 6 2

ALL NIPPON AIRWAYS (ANA) 3 RT753 RT776–RT777

ATLAS AIR (TLS) 2R S 7 2 2 3 RT752 AVION AIRCRAFT TRADING H.F. (VNG) 3 RT633

BRITISH AIRWAYS (BAB) 3 RT471–RT489

CATHAY PACIFIC AIRWAYS (CAT) 3 RT451–RT458 RT508 RT511–RT512 RT781–RT782

CORSAIR (COR) 1 RS239–RS240

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