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December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 173
ALERT ALERT Commercial Airplane Group 747
ALERTALERT Service Bulletin Number: 747-53A2500 Date: December 21, 2004 Revision 1: September 25, 2008 ATA System: 5311 5312 5321 5211 SUBJECT: FUSELAGE - Main Frame - Inspections Based on Fatigue Test Results
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.
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Table of Contents December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 173 BOEING SERVICE BULLETIN 747-53A2500
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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 32
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 32 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 32
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 33
3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 33
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 2: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES . . . . . . . . . . . . 57 FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES . . . . . . . . . . . . 68 FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 FIGURE 7: INSPECTION OF AREA 7 - BODY STATION 260, 340, AND 400 BULKHEADS AND NOSE
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WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400 . . . . . . . . . . 90 F I G U R E 8 : I N S P E C T I O N O F A R E A 8 - M A I N E N T R Y D O O R S - G R O U P 1 , 3 , 5 , 6 , 7 , 8 , A N D 1 0 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 FIGURE 9: INSPECTION OF AREA 9 - MAIN ELECTRONICS BAY ACCESS DOOR CUTOUT . . . 103 FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES 105 FIGURE 11: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES 110 FIGURE 12: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 4 AIRPLANES . 115 FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND 10 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 9 FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES 125 FIGURE 15: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 2, 4, AND 9 AIRPLANES 130 FIGURE 16: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 FIGURE 18: INSPECTION OF AREA 1 - FRAM E INSPECTION COMMON TO UPPER DECK FLOOR BEAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 FIGURE 19: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 9 AIRPLANES 157 FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES 161 FIGURE 21: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 8 AIRPLANES . 168 APPENDIX A: LOGIC DIAGRAM - GROUP 1 AND 6 AIRPLANES . . . . . . . . . . . . . . . . . . 172 APPENDIX B: LOGIC DIAGRAM - GROUP 2, 3, 4, 5, 7, 9, AND 10 AIRPLANES. . . . . . . . . . . 173
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ALERT ALERT Commercial Airplane Group 747
ALERTALERT Service Bulletin Number: 747-53A2500 Revision Transmittal Sheet Date: December 21, 2004 Revision 1: September 25, 2008 ATA System: 5311 5312 5321 5211 SUBJECT: FUSELAGE - Main Frame - Inspections Based on Fatigue Test Results This Revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes inspected as given in the original issue of this service bulletin. Operators should incorporate the additional inspection requirements for Area 1 and Area 6 during the next scheduled inspection.
No airplanes have been added to the service bulletin effectivity. However, 747 Large Cargo Freighter (LCF) airplanes RT631-RT632, RT743, and RT876 were moved from Group 1 to new Group 8. 747-200F airplanes through line number 685 were moved from Group 2 to new Group 9. 747-200C airplanes through line number 685 were moved from Group 3 to new Group 10.
Federal Aviation Administration (FAA) Airworthiness Directives 2006-05-02 and 2004-07-22 R1 are related to this service bulletin.
REASON FOR REVISION This revision is sent to add new inspection requirements for Area 1, and to add to and to clarify some inspection requirements for Area 6. Inspection Area 1 (upper deck floor beams) has been changed to include inspections of the fuselage frames in the areas where the upper deck floor beams are attached. Inspection Area 6 has been changed to include inspection of more fuselage frames in the area above Main Entry Door 1 on 747-200C and 747-200F airplanes after line number 685, and on all 747-400, 747-400D, and 747-400F airplanes. For 747- 200C and 747-200F airplanes through line number 685, this inspection area is included in Boeing Service Bulletin 747-53A2732.
In addition, Compliance information and inspection area requirements for 747 Large cargo Freighter (LCF) airplanes have been added.
These sections were changed:
1. In Summary Background section and in Reason, Paragraph 1.C., referenced Boeing Service Related Problem (SRP) 747-SRP-53-0311. Also, updated Summary illustration.
2. In Description Paragraph 1.D., a description of the inspections required on Group 8 airplanes has been added.
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3. In Compliance, Paragraph 1.E., Compliance information for new Group 8 airplanes has been added.
Related airworthiness directives have also been added.
4. In Approval, Paragraph 1.F., the approval statement has been updated and Alternative Method of Compliance information for related airworthiness directives has been added.
5. In Manpower, Paragraph 1.G., the estimate has been updated to include inspection of the frames in the upper deck floor beam attachment areas in Area 1.
6. In References, Paragraph 1.J., updated references list.
7. In Work Instructions, Paragraph 3.B., descriptions of the inspections required in the various Inspection Areas for Group 8 airplanes have been added.
8. In Work Instructions, Paragraph 3.B., Area 1 inspection, instructions were added for detailed inspection of the frame inner chord, the frame outer chord, and the frame web in the area between the upper and lower chords of the upper deck floor beams. Instructions were added to inspect Group 8 airplanes as given in Figure 21.
9. In Work Instructions, Paragraph 3.B., Area 5 inspection, step 5 has been revised to refer to Figure 17 (was Figure 19).
10. In Work Instructions, Paragraph 3.B., Area 6 inspection, instructions were added to inspect Group 9 airplanes as given in Figure 19. Instructions were added to inspect Group 10 airplanes as given in Figure
20.
11. Figures 6 and 14 (for Area 6) have been revised to clarify and add inspection requirements for the area above the Main Entry Door No. 1 cutout. On these airplanes, also do detailed inspections of the body frames at STA 400 through STA 500, from the top of the upper deck floor to Stringer 8.
12. Figure 18 (for Area 1) has been added for detailed inspection of the frame inner chord, the frame outer chord, and the frame web in the area between the upper and lower chords of the upper deck floor beams.
This inspection is necessary on both sides of the airplane at each frame from body station 260 to body station 520.
13. Figure 19 (for Area 6 on Group 9 airplanes) has been added to show that on these airplanes it is not necessary to do inspections of the frames above the upper deck floor above Main Entry Door 1 left.
14. Figure 20 (for Area 6 on Group 10 airplanes) has been added to show that on these airplanes it is not necessary to do inspections of the frames above the upper deck floor above Main Entry Door 1 left and right.
15. Figure 21 (for Area 1 on Group 8 airplanes) has been added to show the detailed inspection requirements for the upper deck floor beams on Group 8 airplanes.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
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REVISION HISTORY Original Issue: December 21, 2004 Revision 1: September 25, 2008
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December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 173
ALERT ALERT Commercial Airplane Group 747
ALERTALERT Service Bulletin Number: 747-53A2500 Summary Date: December 21, 2004 Revision 1: September 25, 2008 ATA System: 5311 5312 5321 5211 SUBJECT: FUSELAGE - Main Frame - Inspections Based on Fatigue Test Results
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, if necessary, of certain fuselage structure. These inspections and repairs are necessary for safe operation of 747-400 airplanes and nose cargo door 747 airplanes past the design life goal. Tests by Boeing have determined that the structure shown in this service bulletin is subject to fatigue cracks.
Boeing has completed extended pressure fatigue tests on a 747SR and a 747-400 fuselage test article. Boeing has also used updated analysis methods on the 747 fuselage structure. The tests and analysis have identified areas of the fuselage where fatigue cracks can occur. Inspection and repair of these areas is necessary for safe operation of 747 airplanes past the design life goal.
The inspections in this service bulletin will make sure that fatigue cracks in the areas of fuselage internal structure shown do not become critical.
Additional service bulletins will be required to be accomplished in certain specific areas, as a result of fatigue crack findings in the 747 fleet. Also, Supplemental Structural Inspection Document (SSID), D6-35022 Revision G and Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 require inspections to be accomplished, starting at 20,000 total flight-cycles.
Boeing Service Related Problem (SRP) 747-SRP-53-0211 is related to this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-53-0311 is related to this service bulletin.
ACTION (PRR 85901-44RS) Do internal detailed inspections for cracks in these areas of internal fuselage structure:
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1. Upper deck floor beams.
2. Section 42 frames.
3. Section 46 frames.
4. Nose wheel well bulkheads, sidewall panels, and the STA 360 and 380 main deck floor beams.
5. Section 41 frame structure in the area between the upper deck floor beam chords, from STA 260 to 520.
Do internal and external detailed inspections of the main entry doors and door cutouts for cracks.
Do internal and external detailed inspections of the fuselage skin for cracks at all four corners of the main electronics bay access door cutout.
If cracks are found, refer to the structural repair manual for repair instructions. If the damage is beyond the limits shown in the structural repair manual, ask Boeing for repair data. Also, ask Boeing for repair data if an applicable repair is not included in the structural repair manual.
EFFECTIVITY All 747-200C, 747-200F, 747-400, 747-400D, and 747-400F series airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Federal Aviation Administration (FAA) Airworthiness Directives 2006-05-02 and 2004-07-22 R1 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection or repair procedures given in this service bulletin.
MANPOWER
MATERIAL INFORMATION None.
Airplanes Total Task Hours Elapsed Hours All 1990 322
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FRAMES
LOWER LOBE SECTION 42
INSPECT THE 1000 STA 520 STA 260 BULKHEAD 140 STA
INSPECT THE
BODY STATION
INSPECT THE BODY
WHEEL WELL STRUCTURE
BULKHEADS AND NOSE STATION 340 AND 400
ENTRY DOORS AND
DOOR CUTOUTS
INSPECT THE MAIN
INSPECT THE UPPER DECK FLOOR
BEAMS AND INSPECT THE FRAMES IN
THE AREA COMMON TO THE UPPER DECK FLOOR BEAMS520 STA
UPPER DECK
FLOOR BEAMS
INSPECT THE
INSPECT THE
UPPER LOBE FRAMES SECTION 42
ACCESS DOOR CUTOUT
ELECTRONICS BAY
AT THE MAIN
INSPECT THE SKIN
DECK FLOOR BEAMS 360 AND 380 MAIN
INSPECT THE STA
DOORS AND DOOR
INSPECT THE
MAIN ENTRY
CUTOUTS
DOORS AND DOOR
CUTOUTS
MAIN ENTRY
INSPECT THE 1000 STA 1480 STA 1480 STA 2360 STA
DOORS AND DOOR SECTION 46 SECTION 46 FRAMES
LOWER LOBE
CUTOUTS
MAIN ENTRY
INSPECT THE
UPPER LOBE FRAMES
INSPECT THE
INSPECT THE
DECK FLOOR BEAMS
INSPECT THE UPPER
RIGHT SIDE OPPOSITE
LEFT SIDE SHOWN SECTION 42
RIGHT SIDE OPPOSITE
LEFT SIDE SHOWN SECTION 41
RIGHT SIDE OPPOSITE
LEFT SIDE SHOWN SECTION 46
RIGHT SIDE OPPOSITE
LEFT SIDE SHOWN SECTION 44 FWD FWD FWD FWD W59427
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