# Boeing Alert Service Bulletin 747-53A2484: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2009-0636; AD 2010-01-02 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-53A2484](https://openairdocs.org/service-documents/boeing/747-53a2484.md) - Title as filed: U.S. DOT/FAA - Service Information - Pages: 218 - PDF: https://openairdocs.org/files/sha256/ad/a1/ada1f810f11668188f8221f43744ceaa8aa3c22e7e80370ba1c1d5cb122adfe7 - Page: https://openairdocs.org/service-documents/boeing/747-53a2484/file/ada1f810f116 ## Text Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 218 Commercial Airplane Group 747 Service Bulletin Number: 747-53A2484 Date: June 26, 2003 Revision 1: February 12, 2009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Repair - 747 SUD Airplanes BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. ### Page 2 BLANK PAGE June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 218 BOEING SERVICE BULLETIN 747-53A2484 BLANK PAGE ### Page 3 Table of Contents June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 218 BOEING SERVICE BULLETIN 747-53A2484 Table of Contents Revision Transmittal Sheet .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 ### Page 4 Table of Contents June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 218 BOEING SERVICE BULLETIN 747-53A2484 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 ### Page 5 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 218 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 4. 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. ### Page 6 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 218 BOEING SERVICE BULLETIN 747-53A2484 REVISION HISTORY Original Issue: June 26, 2003 Revision 1: February 12, 2009 ### Page 7 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 218 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. ### Page 8 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 218 BOEING SERVICE BULLETIN 747-53A2484 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 ### Page 9 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 218 BOEING SERVICE BULLETIN 747-53A2484 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 ### Page 10 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 218 BOEING SERVICE BULLETIN 747-53A2484 BLANK PAGE ### Page 11 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 218 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, ### Page 12 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 218 BOEING SERVICE BULLETIN 747-53A2484 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 ### Page 13 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 218 BOEING SERVICE BULLETIN 747-53A2484 DRAGONAIR (DRG) 2 RS741 RS771 3 RT510 DUBAI AIR WING (DAW) 3 RT102 EVERGREEN INTERNATIONAL A/L (EVR) 4 RT631–RT632 EXPORT RESTRICTED AIRPLANES (YWV) 2 RS751–RS752 3 RT602 RT606 FINOVA (GRB) 2 RS761 GENERIC CUSTOMER/SUPPLIER (XXX) 2 RD382 GOVERNMENT OF JAPAN (JAG) 3 RT681–RT682 JAL INTERNATIONAL (JAL) 1 RS251–RS252 RS254 2 RS256 3 RS259 RS265–RS267 RT641–RT652 RU801 KALITTA AIR (KAC) 3 RT021–RT022 KLM - ROYAL DUTCH AIRLINES (KLM) 3 RT001–RT007 RT531–RT533 KOREAN AIR (KAL) 3 RT061 RT571–RT576 LUFTHANSA GERMAN AIRLINES (DLH) 3 RT041–RT047 RT431–RT438 MARTINAIR HOLLAND (MTH) 3 RT501 RT506–RT507 RT509 NORTHWEST AIRLINES (NWA) 3 RT401–RT410 OASIS HONG KONG AIRLINES (OHK) 3 RT503 ORIENT THAI AIRLINES (OTH) 1 RS253 RS292 RS712 2 RS001–RS002 RS257 ### Page 14 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 218 BOEING SERVICE BULLETIN 747-53A2484 PAKISTAN INT'L AIRLINES (PIA) 1R S 3 0 1 2 RS302–RS304 3 RS305–RS306 PHUKET AIRLINES (PHK) 1 RS238 RS241 RS711 2 RD381 RD605 QANTAS (QAN) 1 RS272–RS273 2 RS274–RS276 3 RT551–RT563 RT741–RT742 SATAIR (SAI) 2 RD606 SAUDI ARABIAN AIRLINES (SVA) 1 RS311–RS315 2 RS316–RS320 SAUDI ROYAL FLIGHT (SRF) 1R S 6 9 9 SOUTH AFRICAN AIRWAYS (SAA) 1 RS212 RS232 RS236 SOUTHERN AIR (SOF) 1R S 7 2 1 2 RD383 RD601–RD602 RD607 3R S 7 8 6 SURINAM AIRWAYS (SUR) 2R S 7 1 3 TAAG (ANGOLA AIRLINES) (ANG) 2R S 7 4 2 3R S 7 0 3 THAI AIRWAYS INTERNATIONAL (TII) 3 RT691–RT693 TRANSAERO AIRLINES (TRX) 1R S 2 7 1 2R S 2 5 5 R S 2 5 8 3R S 2 6 3 R S 2 6 8 UNICAL AVIATION (UNL) 2R S 3 4 1 3R S 3 4 2 UNITED AIR LINES (UAL) 3 RT601 RT603–RT605 RT607–RT610 ### Page 15 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 218 BOEING SERVICE BULLETIN 747-53A2484 WELLS FARGO (FSB) 3 RT505 IDENTIFICATION BY VARIABLE NUMBER Variable Group RD381–RD383 2 RD601–RD607 2 RD721–RD722 2 RS001–RS002 2 RS201 1 RS211–RS212 1 RS221–RS222 1 RS231–RS241 1 RS251–RS254 1 RS255–RS258 2 RS259 3 RS263 3 RS265–RS268 3 RS271–RS273 1 RS274–RS276 2 RS291–RS292 1 RS301 1 RS302–RS304 2 RS305–RS306 3 RS311–RS315 1 RS316–RS320 2 RS331–RS333 3 RS341 2 RS342 3 RS699 1 RS701–RS702 1 RS703 3 RS711–RS712 1 RS713 2 RS721 1 RS722 2 RS731–RS732 3 RS741–RS743 2 RS751–RS752 2 RS761 2 ### Page 16 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 218 BOEING SERVICE BULLETIN 747-53A2484 2. Spares Affected None. RS762 3 RS771 2 RS781–RS782 3 RS786 3 RT001–RT007 3 RT021–RT022 3 RT031–RT033 3 RT041–RT047 3 RT061 3 RT071 3 RT101–RT103 3 RT121 3 RT401–RT410 3 RT431–RT438 3 RT451–RT458 3 RT471–RT489 3 RT501–RT512 3 RT531–RT533 3 RT551–RT563 3 RT571–RT576 3 RT591 3 RT601–RT610 3 RT631–RT632 4 RT633 3 RT641–RT652 3 RT671–RT672 3 RT681–RT682 3 RT691–RT693 3 RT701–RT703 3 RT711–RT712 3 RT741–RT742 3 RT751–RT753 3 RT776–RT777 3 RT781–RT782 3 RU801 3 Variable Group ### Page 17 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 218 BOEING SERVICE BULLETIN 747-53A2484 B. Concurrent Requirements None. C. Reason 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. 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. D. Description 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. ### Page 18 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 218 BOEING SERVICE BULLETIN 747-53A2484 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. No more work is necessary on airplanes changed as given in the initial release of this service bulletin. Accomplishment of the inspections in service bulletin 747-53A2265 concurrent with the inspections in this service bulletin on commonly affected airplanes is recommended due to common access. E. Compliance Boeing recommends that you do the inspections and related tasks as given below: Group 1-3: Table 1 - Stringer Inspection Airplanes with 19,000 Total Flight Cycles or less Condition Action Compliance Time (Whichever Occurs Last) Repeat Interval (Not to Exceed) All Do a detailed inspection as given in Paragraph 3.B., Work Instructions, PART 1 - INSPECTION Before 8,000 total flight cycles within 2,000 flight cycles after August 30, 2005, not to exceed 20,000 total flight cycles 3,000 flight cycles (a) Cracks Found Repair as given in Paragraph 3.B., Work Instructions, PART 2 - REPAIR Before further flight -( a ) (a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500. Group 1-3: Table 2 - Stringer Inspection Airplanes with 19,001 Total Flight Cycles or more Condition Action Compliance Time (Whichever Occurs Last) Repeat Interval (Not to Exceed) All Do a detailed inspection as given in Paragraph 3.B., Work Instructions, PART 1 - INSPECTION - 1,000 flight cycles after August 30, 2005 3,000 Flight Cycles (a) Cracks Found Repair as given in Paragraph 3.B., Work Instructions, PART 2 - REPAIR Before Further Flight -( a ) (a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500. ### Page 19 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 218 BOEING SERVICE BULLETIN 747-53A2484 Federal Aviation Administration (FAA) Airworthiness Directive 2005-15-08 is related to this service bulletin. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/ JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the manager of the FAA Seattle ACO approves the accomplishment of the applicable inspection, repair, and modification procedures of this service bulletin as an alternative method of compliance to the corresponding inspection, repair, and modification requirements of paragraphs (f), (g) and (h) of FAA AD 2005-15-08. This AMOC only applies to the areas inspected, repaired, or modified as given in this service bulletin. All provisions of AD 2005-15-08 that are not specifically referenced above remain fully applicable and must be complied with. G. Manpower The table below shows an estimate of the task-hours necessary to do this inspection, repair and preventive modification for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts Group 4: Table 3 - Stringer Inspection Condition Action Compliance Time Repeat Interval (Not to Exceed) All Do a detailed inspection as given in Paragraph 3.B., Work Instructions, PART 1 - INSPECTION within 1,000 flight cycles after the date on Revision 1 of this service bulletin 1,500 flight cycles (a) Cracks Found Repair as given in Paragraph 3.B., Work Instructions, PART 2 - REPAIR Before further flight (a) (a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500. ### Page 20 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 218 BOEING SERVICE BULLETIN 747-53A2484 — Time to find the tools. NOTE: The manpower estimates for open and close access have been determined assuming lavatory modules are installed, this is the most labor intensive configuration. All operators that have other monuments in these locations should require less time to open and close access. H. Weight and Balance Changes For all airplanes, use the tables below to find the weight and balance changes. Add the weight changes and the moment changes for all of the Preventive Modifications and/or Repairs that you make on the airplane to get the total Weight and Moment changes. Task Number of Persons Task-Hours Elapsed Hours Open Access 2 37 18.5 Inspect (all locations) 23 1 . 5 Install Repair (one stringer/frame location) 21 26 Install Preventive Modification (one stringer/frame location) 23 1 . 5 Close Access 2 59 29.5 TOTAL FOR EACH AIRPLANE 114 57.0 Preventive Modification (Location) Change in Weight (Pounds) Change in Moment (Pound-Inches) BS 460, S-8L +0.43 +197.8 BS 480, S-8L +0.43 +206.4 BS 500, S-8L +0.43 +215.0 BS 460, S-8R +0.43 +197.8 BS 480, S-8R +0.43 +206.4 BS 500, S-8R +0.43 +215.0 BS 460, S-10L +0.43 +197.8 BS 480, S-10L +0.43 +206.4 BS 500, S-10L +0.43 +215.0 BS 460, S-10R +0.43 +197.8 BS 480, S-10R +0.43 +206.4 BS 500, S-10R +0.43 +215.0 ### Page 21 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 218 BOEING SERVICE BULLETIN 747-53A2484 I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Service Related Problem (SRP) 747-SRP-53-0174. b. 747 Maintenance Manual (AMM) Subject 25-21-02, 25-21-04, 25-22-03, 25-25-01, 25-28- 15, 25-40-03, 25-24-00, 25-19-03 and 25-19-04. c. 747 Structural Repair Manual (SRM) Subject 53-00-03 or 53-10-03. d. 747 Nondestructive Test (NDT) Manual Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16, and Part 6, Subject 51-00-00, Figure 4 or Figure 23. e. Boeing Standard Overhaul Practices Manual (BSOPM) 20-43-03. f. 747 Structural Item Interim Advisory (SIIA) 747-178. g. Boeing Service Bulletin 747-53A2265, "FUSELAGE - NOSE SECTION 41 - BODY FRAME STRUCTURE INSPECTIONS AND CRACK REPAIRS". h. Boeing Parts Standards Document D-590. i. Boeing Drawing 012W6100. j. FAA Airworthiness Directive 2005-15-08. 2. Data supplied with this Service Bulletin: None. Repair (Location) Change in Weight (Pounds) Change in Moment (Pound-Inches) BS 460, S-8L +1.13 +519.8 BS 480, S-8L +1.13 +524.4 BS 500, S-8L +1.13 +565.0 BS 460, S-8R +1.13 +519.8 BS 480, S-8R +1.13 +524.4 BS 500, S-8R +1.13 +565.0 BS 460, S-10L +1.13 +519.8 BS 480, S-10L +1.13 +524.4 BS 500, S-10L +1.13 +565.0 BS 460, S-10R +1.13 +519.8 BS 480, S-10R +1.13 +524.4 BS 500, S-10R +1.13 +565.0 ### Page 22 Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 218 BOEING SERVICE BULLETIN 747-53A2484 3. Installation Drawings Used in the Preparation of this Service Bulletin: These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected None L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. Drawing Number Title 65B07653 SKIN PANEL INSTL - UPR, S-6 TO S-14 STA 340 TO 520 65B01716 FRAME INSTALLATION - BODY STATION 460 65B01717 FRAME INSTALLATION - BODY STATION 480 65B01718 FRAME INSTALLATION - BODY STATION 500 65B27201 BODY SECTION 41 INSTL. -200B SUD MOD ### Page 23 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 218 BOEING SERVICE BULLETIN 747-53A2484 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA B. Industry Support Information Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. Kit Number Name Date ROLT (weeks) QTY Unit Price thru 31-Mar-2009 691U1042-1 Top Kit, Repair Instl (a) (a) (a) (a) 691U1042-5 Top Kit, Preventive Instl Available 19 10 $7,290 691U1042-13 Top Kit, Repair Instl Jan 2009 33 30 $25,436 691U1042-15 Subkit, Repair Instl Jan 2009 33 - $12,718 691U1042-16 Subkit, Repair Instl Jan 2009 33 - $12,718 691U1042-17 Subkit, Part Kit - Repair Jan 2009 33 - $12,066 691U1042-18 Subkit, Part Kit - Repair Jan 2009 33 - $12,066 691U1042-19 Supplemental Kit Jan 2009 30 - $4,796 691U1042-21 Supplemental Kit Jan 2009 30 - $2,398 691U1042-22 Supplemental Kit Jan 2009 30 - $2,398 691U1042-2 Subkit, Fastener Kit Jan 2009 33 - $652 (a) 691U1042-1 Top Kit is no longer available. ### Page 24 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 218 BOEING SERVICE BULLETIN 747-53A2484 NOTE: One top kit for the preventive modification and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for the preventive modification on each airplane. One top kit for the repair and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for the repair on each airplane. Existing Kit Name Supplemental Kit New Replacing Kit 691U1042-1 (a) Top Kit, Repair Instl 691U1042-19 (f) 691U1042-13 (k) 691U1042-3 (b) Subkit, Repair Instl - LH 691U1042-21 (g) 691U1042-15 (l) 691U1042-4 (c) Subkit, Repair Instl - RH 691U1042-22 (h) 691U1042-16 (m) 691U1042-9 (d) Subkit, Part Kit - Repair - LH 691U1042-21 (g) 691U1042-17 (n) 691U1042-10 (e) Subkit, Part Kit - Repair -RH 691U1042-22 (h) 691U1042-18 (o) (a) Replaced by 691U1042-13. (b) Replaced by 691U1042-15. (c) Replaced by 691U1042-16. (d) Replaced by 691U1042-17. (e) Replaced by 691U1042-18. (f) Supplements 691U1042-1 and is only necessary if 691U1042-1 has shipped. Discard existing 691U1042-105 through -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers from existing -1 kit. (g) Supplements 691U1042-3 or -9 and is only necessary if 691U1042-3 or -9 has shipped. Discard existing 691U1042-105, -107, -109, -111, -113, and -115 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers from existing -3 or -9 kit. (h) Supplements 691U1042-4 or -10 and is only necessary if 691U1042-4 or -10 has shipped. Discard existing 691U1042-106, -108, -110, -112, -114, and -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers from existing -4 or -10 kit. (k) Equivalent to 691U1042-1 plus 691U1042-19 after 691U1042-105 through -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -1 kit. (l) Equivalent to 691U1042-3 plus 691U1042-21 after 691U1042-105, -107, -109, -111, -113, and -115 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -3 kit. (m) Equivalent to 691U1042-4 plus 691U1042-22 after 691U1042-106, -108, -110, -112, -114, and -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -4 kit. (n) Equivalent to 691U1042-9 plus 691U1042-21 after 691U1042-105, -107, -109, -111, -113, and -115 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -9 kit. (o) Equivalent to 691U1042-10 plus 691U1042-22 after 691U1042-106, -108, -110, -112, -114, and -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -10 kit. ### Page 25 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 218 BOEING SERVICE BULLETIN 747-53A2484 Kit 691U1042 New Part Number QTY Name Notes-12 -11 -8 -7 -5 6 9 1 U 1 0 4 2 - 5 ....- T O P K I T , P R E V E N T A T I V E INSTL 691U1042-7 . . . - 1 SUBKIT, PREVENTATIVE INSTL 691U1042-8 . . - . 1 SUBKIT, PREVENTATIVE INSTL 691U1042-11 . - 1 1 . SUBKIT, PART KIT 691U1042-12 - . 1 1 . SUBKIT, FASTENER KIT 691U1042-118 . 6 . . . DOUBLER 691U1042-119 . 3 . . . FRAME CLIP 691U1042-120 . 3 . . . FRAME CLIP B A C B 3 0 N X 6 K 3 4 0 .... B O L T ( a ) B A C B 3 0 N X 6 K 3 Y 1 8 .... B O L T ( a ) B A C B 3 0 N X 6 K 4 Y 5 .... B O L T ( a ) B A C B 3 0 N X 6 K 5 Y 3 .... B O L T ( a ) B A C B 3 0 N X 8 K 4 Y 1 2 .... B O L T ( a ) B A C B 3 0 V T 6 K 3 1 2 .... B O L T ( a ) B A C C 3 0 A C 6 2 9 .... C O L L A R B A C C 3 0 A C 8 1 2 .... C O L L A R B A C C 3 0 B H 6 4 0 .... C O L L A R B A C C 3 0 B L 6 1 2 .... C O L L A R BACS40R010B040F . 2 . . . SHIM (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 012W6100 are used to determine the part numbers used as substitutes. Kit 691U1042 New Part Number QTY Name Notes-18 -17 -16 -15 -13 -2 691U1042-2 . . 1 1 . - SUBKIT, FASTENER KIT 691U1042-13 ....-. T O P K I T , U P P E R D E C K WINDOW BELT REPAIR, STA 460 - STA 500 691U1042-15 . . . - 1 . SUBKIT, UPPER DECK WINDOW BELT REPAIR, LEFT SIDE 691U1042-16 . . - . 1 . SUBKIT, UPPER DECK WINDOW BELT REPAIR, RIGHT SIDE ### Page 26 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 218 BOEING SERVICE BULLETIN 747-53A2484 691U1042-17 . - . 1 . . PART KIT - REPAIR, LEFT SIDE 691U1042-18 - . 1 . . . PART KIT - REPAIR, RIGHT SIDE 6 9 1 U 1 0 4 2 - 1 0 0 1 2 1 2 .... R E P A I R S T R A P 6 9 1 U 1 0 4 2 - 1 0 1 3 3 .... F R A M E C L I P 6 9 1 U 1 0 4 2 - 1 0 2 3 3 .... F R A M E C L I P 6 9 1 U 1 0 4 2 - 1 0 3 6 6 .... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 1 7 6 6 .... S T R I N G E R S E G M E N T 6 9 1 U 1 0 4 2 - 1 3 3 . 1 .... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 3 4 1 ..... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 3 5 . 1 .... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 3 6 1 ..... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 3 7 . 1 .... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 3 8 1 ..... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 3 9 . 1 .... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 4 0 1 ..... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 4 3 . 1 .... R E P A I R A N G L E 6 9 1 U 1 0 4 2 - 1 4 4 1 ..... R E P A I R A N G L E 691U1042-145 (691U1042-141 optional) . 1 .... R E P A I R A N G L E 691U1042-146 (691U1042-142 optional) 1 ..... R E P A I R A N G L E B A C B 3 0 N X 6 K 3 ..... 4 0 B O L T , P R O T RUDING HD (a) B A C B 3 0 N X 6 K 3 Y ..... 1 8 B O L T , P R O T RUDING HD (a) B A C B 3 0 N X 6 K 4 ..... 6 6 B O L T , P R O T RUDING HD (a) B A C B 3 0 N X 6 K 4 Y ..... 6 B O L T , P R O T RUDING HD (a) B A C B 3 0 N X 6 K 5 ..... 6 6 B O L T ( a ) B A C B 3 0 N X 6 K 5 Y ..... 2 B O L T , P R O T RUDING HD (a) B A C B 3 0 N X 8 K 4 ..... 1 2 H I - L O K ( a ) B A C B 3 0 V T 6 K 3 ..... 1 2 B O L T , P R O T RUDING HEAD (a) B A C B 3 0 V T 6 K 5 ..... 1 2 B O L T ( a ) B A C C 3 0 A C 6 ..... 2 9 C O L L A R B A C C 3 0 B H 6 ..... 1 7 2 C O L L A R B A C C 3 0 B H 8 ..... 1 2 C O L L A R B A C C 3 0 B L 6 ..... 2 4 C O L L A R B A C F 3 F 0 0 7 D 0 1 9 N N 1 1 .... F I L L E R - F L A T B A C F 3 F 0 0 8 D 0 2 9 N N 1 1 .... F I L L E R , F L A T Kit 691U1042 New Part Number QTY Name Notes- 1 8- 1 7- 1 6- 1 5- 1 3 - 2 ### Page 27 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 218 BOEING SERVICE BULLETIN 747-53A2484 B A C R 1 5 F V 7 K E 9 ..... 5 1 R I V E T ( a ) B A C R 1 5 G F 7 D 9 ..... 5 1 R I V E T , 1 0 0 D E G ( a ) BACS40R010B048F 2 2 .... S H I M , L A M I N A T E D (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. Kit 691U1042 New Part Number QTY Name Notes-22 -21 -19 691U1042-19 . . - SUPPLEMENTAL KIT, UPPER DECK WINDOW BELT REPAIR, STA 460 - STA 500 691U1042-21 . - 1 SUPPLEMENTAL KIT, LEFT SIDE 691U1042-22 - . 1 SUPPLEMENTAL KIT, RIGHT SIDE 691U1042-133 . 1 . REPAIR ANGLE 691U1042-134 1 . . REPAIR ANGLE 691U1042-135 . 1 . REPAIR ANGLE 691U1042-136 1 . . REPAIR ANGLE 691U1042-137 . 1 . REPAIR ANGLE 691U1042-138 1 . . REPAIR ANGLE 691U1042-139 . 1 . REPAIR ANGLE 691U1042-140 1 . . REPAIR ANGLE 691U1042-143 . 1 . REPAIR ANGLE 691U1042-144 1 . . REPAIR ANGLE 691U1042-145 (691U1042-141 optional) . 1 . REPAIR ANGLE 691U1042-146 (691U1042-142 optional) 1 . . REPAIR ANGLE BACF3F007D019NN 1 1 . FILLER- FLAT BACF3F008D029NN 1 1 . FILLER, FLAT Kit 691U1042 New Part Number QTY Name Notes-18 -17 -16 -15 -13 -2 ### Page 28 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 218 BOEING SERVICE BULLETIN 747-53A2484 2. Parts and Materials Supplied by the Operator: 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. Part Number / Specification QTY Name Notes BMS 5-95 1 Pint Sealant (a) BMS 10-11, Type 1 1 Pint Primer (a) - - Chemical Conversion coating (b) BACB30NX6K6Y 6 Bolt (c) BACR15GF7D( ) - Rivet (d) BACR15FV7KE( ) - Rivet (e) (a) refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Reference: BSOPM 20-43-03 (c) Can be necessary at some frame clip locations when the repair or preventive modification is done (d) For Group 1 airplanes, additional rivets of grip lengths from 7 to 14 can be necessary if removal of rivets from fuselage skin is necessary to allow stringer repair. (e) For Group 2, 3 and 4 airplanes, additional rivets of grip lengths from 7 to 14 can be necessary if removal of rivets from fuselage skin is necessary to allow stringer repair. ### Page 29 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 218 BOEING SERVICE BULLETIN 747-53A2484 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches. — Tolerance on linear dimensions, other than rivet and bolt edge distance, is plus or minus 0.03 inch. — Tolerance on rivet and bolt edge distance is plus or minus 0.05 inch unless otherwise specified. — Angular tolerance is plus or minus 2 degrees. — Hole dimensions for standard solid rivets are given in 747 Structural Repair Manual, Chapter 51. — Torque limits to tighten nuts and bolts are given in 747 Structural Repair Manual, Chapter 51. 4. For approved fastener and process material substitutions, refer to 747 Structural Repair Manual, Chapter 51, Alternate fasteners are given in 747 Structural Repair Manual Chapter 51 and Boeing Drawing 012W6100. 5. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 6. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. B. WORK INSTRUCTIONS PART 1 - INSPECTION 1. Get access to the inspection areas as given in Figure 1. 2. Do a detailed inspection as given in Figure 2. 3. Actions after you do the inspection: ### Page 30 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 218 BOEING SERVICE BULLETIN 747-53A2484 a. If you do not find any cracks in any of the inspection areas, either: (1) Install the Preventive Modifications in the areas as given in "PART 3 - PREVENTIVE MODIFICATION" of these Accomplishment Instructions. -OR- (2) Close access to the inspection areas as given in Figure 1 and do the inspections of the un-cracked areas again at the times specified in the Compliance paragraphs of this service bulletin. b. If you find any cracks at any of the inspection areas, do the repair at cracked locations as given in "PART 2 - REPAIR" of these Accomplishment Instructions: And either: (1) Install the Preventive Modifications in the un-cracked areas as given in "PART 3 - PREVENTIVE MODIFICATION" of these Accomplishment Instructions. -OR- (2) Close access to the inspection areas as given in Figure 1 and do the inspections of the un-cracked areas again at the times specified in the Compliance paragraphs of this service bulletin. PART 2 - REPAIR 1. Group 1: For repairs on Group 1 Airplanes, remove and discard Rivets BACR15FV7KE9 (with special "Briles" countersink head) from Fastener Kit 691U1042-2 before you begin a repair at any location. These rivets are not used on Group 1 airplanes. 2. Group 2-4: For repairs on Group 2, 3 and 4 Airplanes, remove and discard Rivets BACR15GF7D9 (with standard 100 degree countersink head) from Fastener Kit 691U1042-2 before you begin a repair at any location. These rivets are not used on Group 2, 3 and 4 airplanes. 3. Repair cracked stringers as given in the table below:. Stringer Repair Table Stringer Body Station Figure 8L 460 4 480 6 500 8 8R 460 10 480 12 500 14 ### Page 31 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 218 BOEING SERVICE BULLETIN 747-53A2484 NOTE: If you cannot repair a stringer as given in this service bulletin, install a new section of stringer as given below: 1. For cracks at Body Station 460, cut the stringer at Body Stations 480 and 440. Use the Repair parts shown in this service bulletin at Body Station 480 and the stringer splice installation from Chapter 53 of the 747 SRM for Body Station 440 to install a new section of stringer between Body Stations 480 and 440. Install the Preventive Modification parts at Body Station 460. See Chapter 53 of the 747 Structural Repair Manual (SRM) to identify the correct stringer material for the new stringer section. 2. For cracks at Body Station 480, cut the stringer at Body Stations 460 and 500. Use the Repair parts shown in this service bulletin at Body Stations 460 and 500 to install a new section of stringer between Body Stations 460 and 500. Install the Preventive Modification parts at Body Station 480. See Chapter 53 of the 747 Structural Repair Manual (SRM) to identify the correct stringer material for the new stringer section. 3. For cracks at Body Station 500, cut the stringer at Body Stations 480, and remove the stringer end from the existing stringer splice at Body Station 520. Use the Repair parts shown in this service bulletin at Body Station 480 and the stringer splice installation from Chapter 53 of the 747 SRM for Body Station 520 to install a new section of stringer between Body Stations 460 and 500. Install the Preventive Modification parts at Body Station 480. See Chapter 53 of the 747 Structural Repair Manual (SRM) to identify the correct stringer material for the new stringer section. 4. For cracks at multiple body stations (460 thru 500), use a single stringer splice and refer to Notes 1 thru 3 above to determine the splice installation method for the ends of the new stringer section. At frame locations where there is no splice repair installed, install the Preventive Modification parts as given in this service bulletin. 4. Close access as given in Figure 1. 10L 460 16 480 18 500 20 10R 460 22 480 24 500 26 Stringer Repair Table ### Page 32 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 218 BOEING SERVICE BULLETIN 747-53A2484 PART 3 - PREVENTIVE MODIFICATION 1. Make modifications to stringers as given in the table below: 2. Close access as given in Figure 1. Stringer Modification Table Stringer Body Station Figure 8L 460 3 480 5 500 7 8R 460 9 480 11 500 13 10L 460 15 480 17 500 19 10R 460 21 480 23 500 25 ### Page 33 FIGURE 1: ACCESS AND RESTORATION June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 218 BOEING SERVICE BULLETIN 747-53A2484 FIGURE 1: ACCESS AND RESTORATION SIDEWALL STOAWAGE UNIT (TYPICAL) DOOR DOOR LAVATORY U15 PASSENGER COMPARTMENT TYPICAL UPPER DECK 440 STA 520 STA LAVATORY U14 2 11 6 7 4 9 10853 121 N83542 (SHEET 1 OF 3) ### Page 34 FIGURE 1: ACCESS AND RESTORATION June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 218 BOEING SERVICE BULLETIN 747-53A2484 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. ACCESS STEP TASK NAME AMM SUBJECT NOTES 1 Remove/Keep Passenger Seats 25-25-01 Between Stations 470 and 520. Operators may have any of the equipment listed at this location. Lavatories 25-40-03 Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03 2 Remove/Keep Sidewall Stowage Units 25-28-15 Between Stations 440 and 520, as necessary 3 Remove/Keep Window Reveals 25-21-02 Between Stations 460 and 520 4 Remove/Keep Ceiling Panel 25-22-03 One panel, forward of Station 460, if installed 5 Remove/Keep Sidewall and Ceiling Insulation 25-21-04 Between Stations 440 and 520 6 Remove/Keep Lavatories, U-16, U-18, or U- 20 25-40-03 Operators may have any of the equipment listed at this location.Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03 Passenger Seats 25-25-01 RESTORATION STEP TASK NAME AMM SUBJECT NOTES 7 Install (Kept) Lavatories, U-16, U-18, or U- 20 25-40-03 Operators may have any of the equipment listed at this location.Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03 Passenger Seats 25-25-01 8 Install (Kept) Sidewall and Ceiling Insulation 25-21-04 - 9 Install (Kept) Ceiling Panel 25-22-03 - 10 Install (Kept) Window Reveals 25-21-02 - 11 Install (Kept) Sidewall Stowage Units 25-28-15 - (SHEET 2 OF 3) ### Page 35 FIGURE 1: ACCESS AND RESTORATION June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 218 BOEING SERVICE BULLETIN 747-53A2484 12 Install (Kept) Passenger Seats 25-25-01 Between Stations 470 and 520. Operators may have any of the equipment listed at this location. Lavatories 25-40-03 Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03 RESTORATION STEP TASK NAME AMM SUBJECT NOTES (SHEET 3 OF 3) ### Page 36 FIGURE 2: STRINGER INSPECTION June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 218 BOEING SERVICE BULLETIN 747-53A2484 FIGURE 2: STRINGER INSPECTION LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE S-10 STA 460 STA 480500 STA S-8 FWD BSEE SEE C A SEE A N68208 (SHEET 1 OF 3) ### Page 37 FIGURE 2: STRINGER INSPECTION June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 218 BOEING SERVICE BULLETIN 747-53A2484 STR-10R OPPOSITE TYPICAL CRACKS CLIP STR-10L FRAME STR-8R OPPOSITE TYPICAL CRACKS STR-8L EDGE OF WINDOW CUTOUT CLIP FRAME FWD FWD 1 C B 1 N68215 (SHEET 2 OF 3) ### Page 38 FIGURE 2: STRINGER INSPECTION June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 218 BOEING SERVICE BULLETIN 747-53A2484 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. STEP TASK NAME PROCEDURE REFERENCES NOTES 1 Inspect Stringer Detailed Inspection - Look at both sides of the stringer. Make a note about the locations and lengths of any cracks found (SHEET 3 OF 3) ### Page 39 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 218 BOEING SERVICE BULLETIN 747-53A2484 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 S-10L S-8L STA 460 STA 480500 STA FWD BSEE AND C A SEE A N68231 (SHEET 1 OF 5) ### Page 40 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 218 BOEING SERVICE BULLETIN 747-53A2484 30 CLIP STR-8L DOUBLER CLIP (3 LOCATIONS) (4 LOCATIONS) (3 LOCATIONS) (WITH FILLER) (WITHOUT FILLER) RADIUS FILLER STR-8L UP FWD UP FWD B C 5 2 1 6 B D 6 6B C 6 7 83 7 84 3 A 6 63A 4 A N68293 (SHEET 2 OF 5) ### Page 41 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 218 BOEING SERVICE BULLETIN 747-53A2484 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure. (SHEET 3 OF 5) ### Page 42 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 218 BOEING SERVICE BULLETIN 747-53A2484 NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. STEP TASK NAME PART NUMBER QTY NOTES 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-119 1 - 5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installationDoubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 4. COUNTERSINK FASTENER C D EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER 6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL) (OPTIONAL) S36173 (SHEET 4 OF 5) ### Page 43 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 218 BOEING SERVICE BULLETIN 747-53A2484 The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. CODE NAME PART NUMBER HOLE DIA NOTES A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 - (SHEET 5 OF 5) ### Page 44 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 218 BOEING SERVICE BULLETIN 747-53A2484 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 S-10L S-8L STA 460 STA 480500 STA FWD A BSEE SEE A N68325 (SHEET 1 OF 10) ### Page 45 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 218 BOEING SERVICE BULLETIN 747-53A2484 0.060 MIN. FROM CUT IN STRINGER CRACK TIP TO 0.44 MIN. EDGE MARGIN LOCATION OF CUT IN STRINGER CRACK TIP CRACK STR-8L STR-8L UP FWD UP FWD DORSEE C ESEEC 1 5 2 B 33 4 3 2 2 N68333 (SHEET 2 OF 10) ### Page 46 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 218 BOEING SERVICE BULLETIN 747-53A2484 0.060 MIN. FROM OPTIONAL STRINGER CUT FOR SMALL CRACKS CUT IN STRINGER CRACK TIP TO 0.25 (MINIMUM) CRACK LOCATION OF CUT IN STRINGER RADIUS IN STRINGER (MAXIMUM) CUT TO TANGENT LINE OF CRACK TIP UP FWD D 2 4 2 SEE E W13592 (SHEET 3 OF 10) ### Page 47 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 218 BOEING SERVICE BULLETIN 747-53A2484 30 STR-8L B A B A UP FWD E 9 19 2112 7 19 2015 10 6 19 20 19 20 8 19 20 19 20 13 1716 N68495 (SHEET 4 OF 10) ### Page 48 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 218 BOEING SERVICE BULLETIN 747-53A2484 STR-8L RADIUS FILLER (WITHOUT FILLER) (WITH FILLER) (4 LOCATIONS) STR- 8L REPAIR SEGMENT STRINGERREPAIR ANGLE STRAPS FILLER UP FWD E 3 4 E 11 11E 3 1411 1411 A 3 FWD INBD A 3 A 3 4 A4 A 4 A4 A 4 B 5 C C 3 C 3 5 C 4 B4 A 4 A4 A 4 A A 3 A-A B-B 3 F G D D 11 D D D D D GD G 18 F 34 F 4 F 5 F 5 F 5 F 5 F 5 F 5 F 5 FF 55 F 5 F G G G N68588 (SHEET 5 OF 10) ### Page 49 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 218 BOEING SERVICE BULLETIN 747-53A2484 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure. (SHEET 6 OF 10) ### Page 50 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 218 BOEING SERVICE BULLETIN 747-53A2484 NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 143 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-143 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners). — The minimum radius is 0.50 inch when you cut the stringer. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. STEP TASK NAME PART NUMBER QTY NOTES 1 Remove / Discard Frame Clip - 1 - 2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details. 3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures. (SHEET 7 OF 10) ### Page 51 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 218 BOEING SERVICE BULLETIN 747-53A2484 4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Filler BACF3F008D029NN 1 - 8 Put / Hold Repair Angle 691U1042-143 1 - 9 Put / Hold Frame Clip 691U1042-101 1 - 10 Cut Frame Clip 691U1042-101 1 cut the inboard end of the frame clip as necessary to get the correct length. 11 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 12 Install Frame Clip 691U1042-101 1 Use temporary fasteners 13 Put / Hold Repair Angle 691U1042-103 1 - 14 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 15 Install Repair Angle 691U1042-103 1 Use temporary fasteners 16 Cut Repair Strap 691U1042-100 2 - 17 Put / Hold Repair Strap 691U1042-100 2 - 18 Drill Holes - refer to Fastener Code F for locations and hole sizes STEP TASK NAME PART NUMBER QTY NOTES (SHEET 8 OF 10) ### Page 52 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 218 BOEING SERVICE BULLETIN 747-53A2484 The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 19 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installationRepair Angle 691U1042-103 1 Frame Clip 691U1042-101 1 Repair Angle 691U1042-143 1 Filler BACF3F008D029NN 1 Stringer Segment 691U1042-117 1 20 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Filler BACF3F008D029NN 1 Repair Angle 691U1042-143 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 21 Install Frame Clip 691U1042-101 1 refer to Fastener Code E 22 Install Fasteners - if previously removed. Refer to Fastener Code G CODE NAME PART NUMBER HOLE DIA NOTES A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - STEP TASK NAME PART NUMBER QTY NOTES COUNTERSINK FASTENER C D EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER 6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL) (OPTIONAL) S36173 (SHEET 9 OF 10) ### Page 53 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 218 BOEING SERVICE BULLETIN 747-53A2484 B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 - D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. CODE NAME PART NUMBER HOLE DIA NOTES (SHEET 10 OF 10) ### Page 54 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 218 BOEING SERVICE BULLETIN 747-53A2484 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 S-8L S-10L STASTASTA 460480500 FWD A AND CBSEE SEE A N68630 (SHEET 1 OF 5) ### Page 55 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 218 BOEING SERVICE BULLETIN 747-53A2484 CLIP CLIP STR-8L 30 (3 LOCATIONS) (WITH FILLER) (WITHOUT FILLER) RADIUS FILLER DOUBLER (3 LOCATIONS)(3 LOCATIONS) STR-8L UP FWD UP FWD 7 84 2 1 B 5 C 3 A 6 4 A 6 5 A 6 B D 6 6B C 6 7 83 N68631 (SHEET 2 OF 5) ### Page 56 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 218 BOEING SERVICE BULLETIN 747-53A2484 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure. (SHEET 3 OF 5) ### Page 57 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 218 BOEING SERVICE BULLETIN 747-53A2484 NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. STEP TASK NAME PART NUMBER QTY NOTES 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-119 1 - 5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length and shape 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installationDoubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 6. COUNTERSINK FASTENER C D EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER 6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL) (OPTIONAL) S36173 (SHEET 4 OF 5) ### Page 58 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 218 BOEING SERVICE BULLETIN 747-53A2484 The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. CODE NAME PART NUMBER HOLE DIA NOTES A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 - (SHEET 5 OF 5) ### Page 59 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 218 BOEING SERVICE BULLETIN 747-53A2484 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480 S-10L S-8L 460480500 STASTA STA FWD BSEE A SEE A N68655 (SHEET 1 OF 10) ### Page 60 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480 June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 218 BOEING SERVICE BULLETIN 747-53A2484 0.060 MIN. FROM STR-8L CRACK TIP STR-8L CUT IN STRINGER CRACK TIP TO 0.44 MIN. EDGE MARGIN LOCATION OF CUT IN STRINGER CRACK FWD UP UP FWD 1 DORSEE C 3 3 3 2 5 B ESEE 2 4 2 C N68662 (SHEET 2 OF 10) The text continues at https://openairdocs.org/service-documents/boeing/747-53a2484/file/ada1f810f116.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.