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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2494 Original Issue: September 18, 2003 Revision 1: January 09, 2015 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inner Chord Crack Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2003 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 1 of 48
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 2 of 48 BOEING SERVICE BULLETIN 747-53A2494
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 2 0 B. Concurrent Requirements ...................................... 2 0 C. Reason ................................................ 2 0 D. Description .............................................. 2 1 E. Compliance .............................................. 2 2 F. Approval ............................................... 2 4 G. Manpower .............................................. 2 5 H. Weight and Balance Changes .................................... 2 7 I. Electrical Load Data ......................................... 2 7 J. References .............................................. 2 7
1. Existing Data: ......................................... 2 7
2. Data Supplied with this Service Bulletin: ........................... 2 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 7 K. Publications Affected ........................................ 2 7 L. Interchangeability and Intermixability of Parts ........................... 2 8 M. Software Accomplishment Summary ................................ 2 8
2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 2 9 C. Parts Necessary for Each Airplane ................................. 2 9
1. Kits/Parts: ........................................... 2 9
2. Parts and Materials Supplied by the Operator: ........................ 2 9
3. Parts Modified and Reidentified: ............................... 2 9
4. Parts Removed and Not Replaced: .............................. 2 9 D. Parts Necessary to Change Spares ................................. 2 9 E. Special Tooling - Price and Availability ............................... 2 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1 A. GENERAL INFORMATION ..................................... 3 1 B. WORK INSTRUCTIONS ....................................... 3 2 FIGURE 1: THIS FIGURE IS DELETED .................................. 3 5 FIGURE 2: ACCESS / RESTORATION FOR CONFIGURATION WITH PASSENGERS IN THE AFT BODY [Group 1, 3] ........................................... 3 6 FIGURE 3: ACCESS / RESTORATION FOR CONFIGURATION WITH CARGO IN THE AFT BODY [Group 2 , 4 ] ............................................... 3 8 FIGURE 4: INSPECTION [Group 1-4, Configuration 1] .......................... 4 0 FIGURE 5: HFEC INSPECTION ...................................... 4 3 APPENDIX A: LOGIC DIAGRAM [Group 1-4, Configuration 1] ........................ 4 6 APPENDIX B: LOGIC DIAGRAM [Group 1-4, Configuration 2] ........................ 4 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 3 of 48 BOEING SERVICE BULLETIN 747-53A2494
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 4 of 48 BOEING SERVICE BULLETIN 747-53A2494
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2494Original Issue: September 18, 2003 Revision 1: January 09, 2015 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inner Chord Crack Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplane(s) changed or inspected in accordance with the original issue of this service bulletin. Do HFEC initial inspection and repeat inspections in accordance with this revision.
Airplanes RT631-RT632, RT743 and RT876, which have been modified to the 747 Large Cargo Freighter (LCF) configuration, have been removed from the effectivity of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-01-09 is related to this service bulletin.
REASON FOR REVISION This revision is sent to include HFEC initial inspection and repeat inspections for the Body Station (STA) 2231 Frame Inner Chord. This revision is also sent to include new SRM repairs. The inspections in this service bulletin are similar to the inspections in Boeing Service Bulletin 747-53A2450 R07, which begin before 16,000 total flight cycles.
These sections were changed:
1. In the Background paragraph in the Summary section, changed to include new work, SRP references and planning data table.
2. In the Action paragraph in the Summary section, changed to include new work.
3. In the Effectivity paragraph in the Summary section, changed to better describe affected airplanes.
4. In the Compliance paragraph in the Summary section, updated to direct to Paragraph 1.E..
5. Summary illustration updated to include new work.
6. In Paragraph 1.A., Effectivity, airplanes RT631, RT632, RT743, and RT876 have been removed from the effectivity, and Group configurations added to the table.
7. In Paragraph 1.C., Reason, changed to include new work and added new paragraphs describing the reason for revision.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 5 of 48
8. In Paragraph 1.D., Description, updated work summary, added reason for revision and maintenance zone data.
9. In Paragraph 1.E., Compliance, added Airworthiness Directive statement and new compliance information in tabular format.
10. In Paragraph 1.F., Approval, updated approval statement and added new Airworthiness Directive statement.
11. In Paragraph 1.G., Manpower, added new manpower tables for repeat inspections.
12. In Paragraph 1.J., References, added new SRP and AD references.
13. In Paragraph 1.K., Publications Affected, a Damage Tolerance statement was added.
14. In Paragraph 2.B., Industry Support Information, revised the statement.
15. In Paragraph 3.B., Work Instructions, updated to include new general information and new inspections.
16. FIGURE 1 was deleted and Logic Diagram moved to Appendix A and Appendix B.
17. In FIGURE 2, added group information.
18. In FIGURE 3, added group information.
19. In FIGURE 4, added group information, changed sheet 2 and step table.
20. FIGURE 5 was added for HFEC Inspection.
21. APPENDIX A and APPENDIX B were added to include new Logic Diagrams.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY September 18, 2003Original Issue:
January 09, 2015Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 6 of 48 BOEING SERVICE BULLETIN 747-53A2494
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2494Original Issue: September 18, 2003 Revision 1: January 09, 2015 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inner Chord Crack Inspection and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of this service bulletin will make sure that the body frame at station 2231 at stringer 26 does not have any nicks, scratches, and / or gouges, and has no cracks. Cracks can initiate at nicks, scratches, and / or gouges. If not repaired, cracks could result in damage to the adjacent structure which could result in rapid depressurization of the airplane.
The body frame at station 2231 is forward of the number 5 main entry door opening. The door 5 lower main sill goes through a cutout in the station 2231 frame at stringer 26. Boeing investigation indicates that during production, the door lower main sill chord can rub the station 2231 frame. If the sill rubs the frame, nicks, scratches, and / or gouges in the frame inner chord can occur which can cause frame cracks. Cracks in the inner chords and web at this location could extend with continued operation and fully cut the frame. If the frame becomes fully cut, skin cracks could occur which could cause a rapid depressurization of the airplane.
One operator has reported cracked inner chords (forward and aft) and a cracked web at station 2231 and stringer 26L. Refer to Paragraph 1.C., Reason, for a detailed service history.
Airplane line numbers 1334 and on were delivered with additional checks to ensure no nicks, scratches, and/or gouges were added during the production process.
Inspections accomplished in accordance with Service Bulletin 747-53A2450 R07 are an acceptable substitute for the inspections specified in this service bulletin. Airplane line numbers 1-1419, except 747SP and 747-400 LCF, are affected by Service bulletin 747-53A2450 R07 .
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 7 of 48
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required Boeing Service Related Problems (SRP) 747-SRP-53-0202 and 747-SRP-53-0452 are related to this service bulletin.
ACTION Do a detailed inspection for nicks, scratches, and / or gouges of the station 2231 frame inner chords (forward and aft), and web, at stringer 26 at the edge and side of the inner chords and do a surface High Frequency Eddy Current (HFEC) inspection of the Station 2231 frame inner chords (forward and aft), for cracks. If any nicks, scratches, and / or gouges are found, repair in accordance with the Structural Repair Manual (SRM) before next flight. If cracks are found do a repair in accordance with the SRM, or contact Boeing for repair instructions, before further flight. Repeat the HFEC inspection for cracks in accordance with Paragraph 1.E., Compliance.
EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F and 747SR Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of November 22, 2002. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Elapsed HoursTotal Task HoursAirplanes 34Groups 1 and 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 8 of 48 BOEING SERVICE BULLETIN 747-53A2494
ALERTALERT
Elapsed HoursTotal Task HoursAirplanes 34Groups 2 and 4 (with two MED #5)
1.52Groups 2 and 4 (with one MED #5)
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 9 of 48 BOEING SERVICE BULLETIN 747-53A2494
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2494
ALERT ALERT STA 2231 SEE ( DOOR 5 LEFT DOOR 5 RIGHT OPPOSITE →FUD DOOR 5 LEFT MAIN DECK S-25L FLOOR LOWER MAIN SILL S-26L UP FWD
DO A DETAILED VISUAL INSPECTION FOR
NICKS, SCRATCHES, AND/OR GOUGES AND
UP A SURFACE HFEC INSPECTION FOR CRACKS, ON THE INNER CHORDS (FORWARD AND
AFT), INNER CHORD EDGES, AND WEB
INBD EDGE, IN THE HEAVILY SHADED AREA AND A-A HEAVILY SHADED EDGE.
Original Issue: September 18, 2003 Revision 1: January 09, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2494 Work - See page 1 for details. 10 of 48
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2494 Original Issue: September 18, 2003 Revision 1: January 09, 2015 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inner Chord Crack Inspection and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to 747-100, -100B, -100B SUD, -200B, -200C, -200F, -300, -400, -400D, -400F and 747SR Airplanes, line numbers 1-1333, except 747 Large Cargo Freighter (LCF) airplanes, in four Groups. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747-400, 747-400D and 747SR airplanes, line number 1 through 1304, except Combi, Special Freighter, Boeing Converted Freighter (BCF) and 747 Large Cargo Freighter (LCF) airplanes.
-1 That have not completed the original issue of this service bulletin.1 That have completed the original issue of this service bulletin.2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 11 of 48
DESCRIPTIONCONFIGURATIONGROUP 747-200B, 747-200C, 747-200F, 747-300, 747-400 and 747-400F Freighter, Convertible, Combi, Special Freighter, and BCF airplanes, line number 1 through 1304.
-2 That have not completed the original issue of this service bulletin.1 That have completed the original issue of this service bulletin.2 747-400 Passenger airplanes, from line number 1305 through 1333.-3 That have not completed the original issue of this service bulletin.1 That have completed the original issue of this service bulletin2 747-400F airplanes, from line number 1305 through 1333.-4 That have not completed the original issue of this service bulletin.1 That have completed the original issue of this service bulletin2 Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA266 1RA301 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA418 1RA501 - RA502 1RA521 - RA528 1RA532 - RA548 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 18, 2003 747-53A2494Revision 1: January 09, 2015 12 of 48 BOEING SERVICE BULLETIN 747-53A2494