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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2499 Original Issue: August 11, 2005 Revision 3: July 15, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 41, 42, and 46 Body Skin Lap Joint Inspections and Modifications 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 © 2005 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Unpublished Work.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: August 11, 2005 747-53A2499Revision 3: July 15, 2014 1 of 378
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 11, 2005 747-53A2499Revision 3: July 15, 2014 2 of 378 BOEING SERVICE BULLETIN 747-53A2499
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Table of Contents
Revision Transmittal Sheet7
Summary ..................................................... 1 1
1. PLANNING INFORMATION ........................................ 1 5 A. Effectivity ............................................... 1 5
1. Airplanes ............................................ 1 5
2. Spares Affected ........................................ 2 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 3 D. Description .............................................. 2 4 E. Compliance .............................................. 2 8 F. Approval ............................................... 3 7 G. Manpower .............................................. 4 0 H. Weight and Balance Changes .................................... 4 3 I. Electrical Load Data ......................................... 4 3 J. References .............................................. 4 3
1. Existing Data: ......................................... 4 3
2. Data Supplied with this Service Bulletin: ........................... 4 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 7 K. Publications Affected ........................................ 4 7 L. Interchangeability and Intermixability of Parts ........................... 4 7 M. Software Accomplishment Summary ................................ 4 7
2. MATERIAL INFORMATION ........................................ 4 9 A. Material - Price and Availability ................................... 4 9 B. Industry Support Information .................................... 5 0 C. Parts Necessary for Each Airplane ................................. 5 0
1. Kits/Parts: ........................................... 5 0
2. Parts and Materials Supplied by the Operator: ........................ 6 6
3. Parts Modified and Reidentified: ............................... 6 6
4. Parts Removed and Not Replaced: .............................. 6 6 D. Parts Necessary to Change Spares ................................. 6 6 E. Special Tooling - Price and Availability ............................... 6 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 7 A. GENERAL INFORMATION ..................................... 6 7 B. WORK INSTRUCTIONS ....................................... 7 1 FIGURE 1: LOGIC DIAGRAM (DELETED - REVISION 1) ........................ 7 9 FIGURE 2: LAP JOINT INSPECTION [Group 1, 16-18] .......................... 8 0 FIGURE 3: LAP JOINT INSPECTION [Group 2] .............................. 9 1 FIGURE 4: LAP JOINT INSPECTION [Group 3] ............................. 1 0 7 FIGURE 5: LAP JOINT INSPECTION [Group 4, 19] ........................... 1 2 1 FIGURE 6: LAP JOINT INSPECTION [Group 5] ............................. 1 3 7 FIGURE 7: LAP JOINT INSPECTION [Group 6] ............................. 1 5 1 FIGURE 8: LAP JOINT INSPECTION [Group 7] ............................. 1 6 7 FIGURE 9: LAP JOINT INSPECTION [Group 8] ............................. 1 8 3 FIGURE 10: LAP JOINT INSPECTION [Group 9] ............................. 1 9 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 11: LAP JOINT INSPECTION [Group 10] ............................ 2 0 9 FIGURE 12: LAP JOINT INSPECTION [Group 11] ............................ 2 2 3 FIGURE 13: LAP JOINT INSPECTION [Group 12] ............................ 2 3 7 FIGURE 14: LAP JOINT INSPECTION [Group 13] ............................ 2 5 1 FIGURE 15: LAP JOINT INSPECTION [Group 14] ............................ 2 6 6 FIGURE 16: SECTION 41, STRINGER 6 - LAP JOINT MODIFICATION [Group 1-15, 19] ....... 2 7 9 FIGURE 17: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION [Group 1, 14-18] ...... 2 8 3 FIGURE 18: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION [Group 2-12, 19] ...... 2 8 5 FIGURE 19: SECTION 41, STRINGER 23 - LAP JOINT MODIFICATION [Group 13] ......... 2 8 7 FIGURE 20: SECTION 41, STRINGER 44 - LAP JOINT MODIFICATION [Group 1-15, 19] ...... 2 8 9 FIGURE 21: SECTION 42, STRINGER 44 - LAP JOINT MODIFICATION [Group 1, 13-15] ...... 2 9 2 FIGURE 22: SECTION 42, STRINGER 44 - LAP JOINT MODIFICATION [Group 2-12, 19] ...... 2 9 4 FIGURE 23: LAP JOINT INSPECTION [Group 15] ............................ 2 9 6 FIGURE 24: SECTION 41, STRINGER 6 - LAP JOINT MODIFICATION [Group 16-18] ........ 3 0 9 FIGURE 25: SECTION 41, STRINGER 44 - LAP JOINT MODIFICATION [Group 16-18] ........ 3 1 1 FIGURE 26: SECTION 41, STRINGER 6 - LAP JOINT POST-MODIFICATION INSPECTION [Group 1, 14-15] ................................................. 3 1 3 FIGURE 27: SECTION 41, STRINGER 6 - LAP JOINT POST-MODIFICATION INSPECTION [Group 2-13, 19] ............................................... 3 1 7 FIGURE 28: SECTION 41, STRINGER 6 - LAP JOINT POST-MODIFICATION INSPECTION [Group 16-18] ................................................. 3 2 2 FIGURE 29: SECTION 41, STRINGER 23 - LAP JOINT POST-MODIFICATION INSPECTION [Group 1, 14-18] ............................................. 3 2 6 FIGURE 30: SECTION 41, STRINGER 23 - LAP JOINT POST-MODIFICATION INSPECTION [Group 2-13, 19] ............................................... 3 3 0 FIGURE 31: SECTION 41, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION [Group 1, 14-15] ............................................. 3 3 4 FIGURE 32: SECTION 41, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION [Group 2-13, 19] ............................................... 3 3 7 FIGURE 33: SECTION 41, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION [Group 16-18] ................................................. 3 4 0 FIGURE 34: SECTION 42, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION [Group 1, 13-15] ............................................. 3 4 3 FIGURE 35: SECTION 42, STRINGER 44 - LAP JOINT POST-MODIFICATION INSPECTION [Group 2-12, 19] ............................................... 3 4 6 FIGURE 36: SECTION 41, STRINGER 6 - POST-MODIFICATION INSPECTION OF LAP JOINT MODIFICATION INSTALLED BETWEEN STA 340 AND STA 400 AS GIVEN IN SERVICE BULLETIN 747-53-2272 - EXTERNAL LFEC AND DETAILED INSPECTIONS OF SKIN - LEFT SIDE [Group 6, 11, 19] .................................... 3 4 9 FIGURE 37: SECTION 41, STRINGER 6 - POST-MODIFICATION INSPECTION OF LAP JOINT MODIFICATION INSTALLED BETWEEN STA 340 AND STA 400 AS GIVEN IN SERVICE BULLETIN 747-53-2272 - EXTERNAL LFEC AND DETAILED INSPECTIONS OF SKIN - RIGHT SIDE [Group 6, 11, 19] .................................... 3 5 3 FIGURE 38: SECTION 41, STRINGER 6 - POST-MODIFICATION INSPECTION OF LAP JOINT MODIFICATION INSTALLED BETWEEN STA 340 AND STA 400 AS GIVEN IN SERVICE BULLETIN 747-53-2272 - EXTERNAL HFEC INSPECTION OF DOUBLER - LEFT SIDE [Group 6, 11, 19] ............................................ 3 5 7 FIGURE 39: SECTION 41, STRINGER 6 - POST-MODIFICATION INSPECTION OF LAP JOINT MODIFICATION INSTALLED BETWEEN STA 340 AND STA 400 AS GIVEN IN SERVICE Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BULLETIN 747-53-2272 - EXTERNAL HFEC INSPECTION OF DOUBLER - RIGHT SIDE [Group 6, 11, 19] ............................................ 3 6 0 FIGURE 40: SECTION 41, STRINGER 6 - POST-MODIFICATION INSPECTION OF LAP JOINT MODIFICATION INSTALLED BETWEEN STA 340 AND STA 400 AS GIVEN IN SERVICE BULLETIN 747-53-2272 - INTERNAL DETAILED AND HFEC INSPECTIONS OF THE SKIN - LEFT SIDE [Group 6, 11, 19] ................................. 3 6 3 FIGURE 41: SECTION 41, STRINGER 6 - POST-MODIFICATION INSPECTION OF LAP JOINT MODIFICATION INSTALLED BETWEEN STA 340 AND STA 400 AS GIVEN IN SERVICE BULLETIN 747-53-2272 - INTERNAL DETAILED AND HFEC INSPECTIONS OF THE SKIN - RIGHT SIDE [Group 6, 11, 19] ................................ 3 6 7 Appendix A: REDUCED EDGE MARGIN PROCEDURES ........................ 3 7 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 11, 2005 747-53A2499Revision 3: July 15, 2014 5 of 378 BOEING SERVICE BULLETIN 747-53A2499
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 11, 2005 747-53A2499Revision 3: July 15, 2014 6 of 378 BOEING SERVICE BULLETIN 747-53A2499
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2499Original Issue: August 11, 2005 Revision 3: July 15, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 41, 42, and 46 Body Skin Lap Joint Inspections and Modifications This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes that had lap joint modifications accomplished as given in previous revisions of this service bulletin before 20,000 total flight cycles. Post-modification inspections will be required within 15,000 flight cycles after modification in order to allow continued operation to the Limit of Validity (LOV) of 35,000 total flight cycles.
In addition, more work is necessary on airplane line numbers 604 - 685 that had external doublers installed as given in Service Bulletin 747-53-2272 at Stringer 6 from Station 340 to Station 400. Post-modification inspection at Stringer 6 from Station 340 to Station 400 is now required as given in this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-26-10 is related to this service bulletin.
REASON FOR REVISION This revision is sent to add modification instructions and compliance information for Large Cargo Freighter (LCF) airplanes and to add post-modification inspections for all airplanes. This revision is also sent to add post-modification inspections for Group 6, 11 and 19 airplanes with stringer 6 lap joint modification installed between STA 340 and STA 400 as given in Service Bulletin 747-53-2272. These airplanes have upper skin gage of 0.056 inch and are not covered by the post-modification inspections given in Service Bulletin 747-53-2253.
These sections were changed:
1. In the Summary: Added Widespread Fatigue Damage (WFD) statement. Added Planning Table and new SRP and FTD references. Updated the Action section, related Airworthiness Directives, and summary illustration.
2. In Paragraph 1.A., Effectivity: RT526, RT530, RT578, RT579, RT654, RT691 and RT692 are moved from Group 1 to Group 15. Airplane RT631 is moved from Group 16 to new Group 17. Airplane RT632 is moved from Group 16 to new Group 18. Airplanes RR204, RR551, RR552 and RR553 are moved from Group 4 to new Group 19. Revised some Group descriptions in the Group/Configuration table.
3. In Paragraph 1.C., Reason: Added reason for Revision 3, added WFD statement, and new SRP and FTD references.
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Original Issue: August 11, 2005 747-53A2499Revision 3: July 15, 2014 7 of 378
4. In Paragraph 1.D., Description: Added instructions for post-modification inspections. Added "more work" statements for Revision 3. Clarified lap joints affected for reference Service Bulletin 747-53A2312.
Removed AD references from related service bulletin table. Added reference Service Bulletin 747-53A2487.
5. In Paragraph 1.E., Compliance: Updated related AD information. Updated compliance Tables 1 and 2 so that existing compliance times are based from the effective dates of related Airworthiness Directives where applicable. Updated compliance Table 3 to clarify the action and compliance information. Added compliance tables for Group 16-18 modifications and for Group 1-19 post-modification inspections.
Added information for post-repair inspection requirements.
6. In Paragraph 1.F., Approval: Updated Alternative Method of Compliance (AMOC) statements to reflect new compliance tables. Added new AMOC statements for AD 2010-26-10, AD 2012-10-03, and AD 2013-16-24. Deleted AMOC statements for ADs that have been superseded.
7. In Paragraph 1.G., Manpower: Revised manpower estimates for modification of some configurations.
Added manpower estimates for post-modification inspections of all Groups.
8. In Paragraph 1.J.1., Existing Data, updated the reference list.
9. In Paragraph 1.K., Publications Affected: Added "or in existing documents" to the Damage Tolerance Inspection statement.
10. In Paragraph 1.M., Software Accomplishment Summary: This new service bulletin section has been added.
11. In Paragraph 3.A., General Information: Updated existing general notes and added some new notes to reflect current standards and requirements. Removed note regarding inspection threshold for skin panels that have been replaced, this information is now in Paragraph 1.E., Compliance.
12. In Paragraph 3.B., Work Instructions: Updated Group applicability to reflect new Groups. Added modification instructions for Group 16-18 airplanes. Changed modification and inspection instructions for Groups 6, 11, 19 airplanes. Added post-repair and post-modification inspection instructions for all airplanes.
13. In Figures 5, 7, 8-9 and 11-14: Added note for airplanes with doubler installed as given in Service Bulletin 747-53A2487.
14. In Figure 15: View L reference is clarified. Added note for airplanes with doubler installed during BCF conversion. Added note for airplanes with doubler installed as given in Service Bulletin 747-53A2487.
15. In Figure 17: Group 16-18 airplanes are added.
16. In Figure 23: Added View M with associated Step 5 and footnote (e) for inspection at Stringer 4L, STA 1960 to STA 2000. Added footnote (f) for airplanes with doubler installed during BCF conversion. Added footnote (g) for airplanes with doubler installed as given in Service Bulletin 747-53A2487.
17. Figures 24-25: These new figures are added for lap joint modifications for LCF airplanes.
18. Figures 26-35: These new figures are added for post-modification inspections of all Groups.
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19. Figures 36-41: New figures are added for Group 6, 11, 19, airplanes for post-modification inspections of stringer 6 lap joint modification doublers installed between STA 340 and STA 400 as given in Service Bulletin 747-53-2272.
20. Revised "cracks found" and "no cracks found" conditions to "any crack found" and "no crack found", respectively, throughout the service bulletin. Also, added acceptable service bulletin revision levels when referencing work to be done as given in Service Bulletin 747-53A2817.
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 important changes.
REVISION HISTORY August 11, 2005Original Issue:
October 30, 2008Revision 1:
August 12, 2010Revision 2:
July 15, 2014Revision 3:
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Original Issue: August 11, 2005 747-53A2499Revision 3: July 15, 2014 9 of 378 BOEING SERVICE BULLETIN 747-53A2499
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 11, 2005 747-53A2499Revision 3: July 15, 2014 10 of 378 BOEING SERVICE BULLETIN 747-53A2499
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2499Original Issue: August 11, 2005 Revision 3: July 15, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 41, 42, and 46 Body Skin Lap Joint Inspections and Modifications
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 This service bulletin gives data for the inspection and repair of certain fuselage skin longitudinal lap joints. These inspections and repairs are necessary for safe operation of airplanes past the design goal for economic usage.
Boeing has completed extended pressure fatigue tests on a 747-100SR and a 747-400 fuselage test article.
Analysis of these test results have identified areas of the fuselage lap joints where fatigue cracks can occur.
Boeing has also used updated analysis methods on the 747 skin longitudinal lap joints. Inspection and repair of these areas is necessary for safe operation of airplanes past the design goal for economic usage.
The inspections in this service bulletin will make sure that fatigue cracks in the overlapping skin at the upper row of fasteners in certain fuselage lap joints are found and repaired before they become critical. Skin cracks not detected prior to reaching critical crack length may result in the inability to withstand current regulatory fail-safe loads, in-flight depressurization of the airplane or loss of structural integrity.
Revision 1: Subsequent to the release of the original issue of this service bulletin, a review of all lap joints was accomplished for the affected airplanes. It was determined that all lap joints with an upper skin thickness of
0.090 inches or less should be inspected at the times given in Paragraph 1.E., Compliance. In addition, a review of all service bulletins which recommend repeat inspections was accomplished to determine if the inspections were appropriate on aging airplanes. This review indicated that certain lap joints where the skin thickness is less than or equal to 0.071 inches should be modified at the times given in Paragraph 1.E., Compliance.
The skin lap joints affected by this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to 747-SL-53-088.
Boeing Service Related Problem (SRP) 747-SRP-53-0211, 747-OP-SRP-53-0279 and 747-SRP-53-0434 are related to this service bulletin.
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Original Issue: August 11, 2005 747-53A2499Revision 3: July 15, 2014 11 of 378
Boeing Fleet Team Digest (FTD) 747 FTD 53-13001 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
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 ChangesYesWeight 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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-91RS) Lap joint inspection Do external High Frequency Eddy Current (HFEC) inspections of certain lap joints for cracks. These lap joints are in Section 41, Section 42, and Section 46. In addition, do internal and external Low Frequency Eddy Current (LFEC) inspections at certain doublers common to these lap joints. If no crack is found, do the inspection again at the time shown in this service bulletin. If any crack is found, remove the fastener in the cracked hole and sufficient adjacent fasteners and do open hole HFEC inspections to find the crack length. Repair before any more flights. Repair as given in the structural repair manual or ask Boeing for repair data. As part of the repair, do open-hole HFEC inspections of the skin at all existing fastener locations common to the repair.
Lap joint modification Do eddy current inspections of the lap joints in sections 41 and 42 that will be modified. If any crack is found, repair the crack and contact Boeing for lap joint modification instructions. For areas where no crack is found, do the lap joint modifications.
Lap joint post-modification inspections Do internal surface HFEC inspections for any crack in the skin or internal doubler at the perimeter fasteners common to the modification and repeat the inspections. If any crack is found contact Boeing for repair instructions and do the work instructed by Boeing.
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