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Commercial Airplanes 747 Service Bulletin Number: 747-53A2562 Original Issue: June 16, 2005 Revision 3: July 11, 2013 ATA System: 5311 SUBJECT: FUSELAGE - Main Frame - Nose Wheel Well Side and Top Panel - Web and Stiffener Replacement 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Unpublished Work.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: June 16, 2005 747-53A2562Revision 3: July 11, 2013 1 of 136
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 16, 2005 747-53A2562Revision 3: July 11, 2013 2 of 136 BOEING SERVICE BULLETIN 747-53A2562
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 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 2 D. Description .............................................. 2 4 E. Compliance .............................................. 2 5 F. Approval ............................................... 2 7 G. Manpower .............................................. 2 8 H. Weight and Balance Changes .................................... 2 9 I. Electrical Load Data ......................................... 2 9 J. References .............................................. 2 9
1. Existing Data: ......................................... 2 9
2. Data Supplied with this Service Bulletin: ........................... 3 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 1 K. Publications Affected ........................................ 3 1 L. Interchangeability and Intermixability of Parts ........................... 3 1 M. Software Accomplishment Summary ................................ 3 1
2. MATERIAL INFORMATION ........................................ 3 3 A. Material - Price and Availability ................................... 3 3 B. Industry Support Information .................................... 3 4 C. Parts Necessary for Each Airplane ................................. 3 4
1. Kits/Parts: ........................................... 3 4
2. Parts and Materials Supplied by the Operator: ........................ 6 2
3. Parts Modified and Reidentified: ............................... 6 4
4. Parts Removed and Not Replaced: .............................. 6 4 D. Parts Necessary to Change Spares ................................. 6 4 E. Special Tooling - Price and Availability ............................... 6 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 5 A. GENERAL INFORMATION ..................................... 6 5 B. WORK INSTRUCTIONS ....................................... 6 7 FIGURE 1: THIS FIGURE IS DELETED .................................. 7 7 FIGURE 2: REMOVAL OF TOP PANEL [Group 1-3] ........................... 7 8 FIGURE 3: REMOVAL OF LEFT SIDE PANEL .............................. 8 1 FIGURE 4: INSTALLATION OF LEFT SIDE PANEL [Group 1-2, 4] ................... 8 4 FIGURE 5: REMOVAL OF RIGHT SIDE PANEL ............................. 8 7 FIGURE 6: INSTALLATION OF RIGHT SIDE PANEL [Group 1-2, 4] .................. 9 0 FIGURE 7: INSTALLATION OF LEFT SIDE PANEL [Group 3] ...................... 9 3 FIGURE 8: INSTALLATION OF RIGHT SIDE PANEL [Group 3] ..................... 9 7 FIGURE 9: INSTALLATION OF TOP PANEL [Group 1-2] ........................ 1 0 1 FIGURE 10: INSTALLATION OF TOP PANEL [Group 3] ......................... 1 0 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 11: THIS FIGURE IS DELETED ................................. 1 0 7 FIGURE 12: REMOVALS FOR ACCESS AT NOSE WHEEL WELL STA 260 BULKHEAD ....... 1 0 8 FIGURE 13: REMOVALS FOR ACCESS AT NOSE WHEEL WELL STA 340 BULKHEAD ....... 1 1 1 FIGURE 14: REMOVAL OF TOP PANEL COMPONENTS [Group 4] .................. 1 1 3 FIGURE 15: INSTALLATION OF NEW TOP PANEL COMPONENTS [Group 4] ............ 1 1 6 FIGURE 16: RESTORATION AT NOSE WHEEL WELL STA 340 BULKHEAD ............. 1 1 9 FIGURE 17: RESTORATION AT NOSE WHEEL WELL STA 260 BULKHEAD ............. 1 2 1 FIGURE 18: POST MODIFICATION INSPECTION - SIDE PANEL WEB EXTERNAL DETAILED INSPECTION ................................................. 1 2 3 FIGURE 19: POST MODIFICATION INSPECTION - TOP PANEL WEB EXTERNAL DETAILED INSPECTION ................................................. 1 2 6 FIGURE 20: POST MODIFICATION INSPECTION - TOP AND SIDE PANEL STIFFENER INTERNAL DETAILED AND HFEC INSPECTIONS ........................... 1 2 9 APPENDIX A: NOSE WHEEL WELL MODIFICATION - SUGGESTED SEQUENCE OF STEPS .... 1 3 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2562Original Issue: June 16, 2005 Revision 3: July 11, 2013 ATA System: 5311 SUBJECT: FUSELAGE - Main Frame - Nose Wheel Well Side and Top Panel - Web and Stiffener Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed as given in the original issue, Revision 1, or Revision 2 of this service bulletin. Airplanes that were previously modified as given in this service bulletin will require the addition of post modification inspections as identified in paragraph 1.E., Compliance, but no additional modification work is required.
Airplanes RL403, RL655, RM887, RL752, and RL420 were added to Group 4 of this service bulletin effectivity.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2006-22-15 is related to this service bulletin.
REASON FOR REVISION This revision is sent to add five airplanes to the effectivity of this service bulletin, and to add post modification inspection instructions.
These sections were changed:
1. In the Summary: Updated the Background information, added Planning Data table, and updated the Action section with post modification inspection requirement.
2. In paragraph 1.A., Effectivity: Added airplanes RL403, RL655, RM887, RL752, and RL420 to Group 4 and updated the Group/Configuration Table. Also, airplanes that have been modified to Boeing Converted Freighter configuration as of the time of development of Revision 3 of this service bulletin have been moved to Group 2.
3. In paragraph 1.C., Reason: Updated the background information, added reference to related service letter and Fleet Team Digest articles, and added the reason for Revision 3.
4. In paragraph 1.D., Description: Added post modification inspection action, added "more work" statement for Revision 3, and added maintenance zone information.
5. In paragraph 1.E., Compliance: Added compliance Tables 1 and 2 for nose wheel well modification.
Added Tables 3 and 4 for post modification inspections.
6. In paragraph 1.F., Approval: Added Alternative Method of Compliance (AMOC) and Method of Compliance (MOC) statements related to AD 2006-22-15.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 16, 2005 747-53A2562Revision 3: July 11, 2013 5 of 136
7. In paragraph 1.H., Weight and Balance Changes: Added weight and moment changes resulting from modification.
8. In paragraph 1.J.2., Data Supplied with this Service Bulletin: Updated list of drawings and parts lists to be supplied with the service bulletin.
9. In paragraph 1.K., Publications Affected: Added statement for damage tolerance based inspections.
10. In paragraph 2.A., Material - Price and Availability: Added new 141U1192-53 top kit for Group 1 - 3 airplanes. Updated price and re-order lead time information for 141U1192-2 top kit.
11. In paragraph 2.C.1., Parts Necessary for Each Airplane: Added bill of material for 141U1192-53 top kit. Updated footnotes in all tables.
12. In paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added supplemental parts that are needed if a 141U1192-1 top kit is used for Group 1-3 airplanes.
13. In paragraph 3.A., General Information: Updated general notes.
14. In paragraph 3.B., Work Instructions: Revised PART 2 instructions to include a detailed inspection of existing structure before installation of new nose wheel well panels. Added PART 6 and PART 7 for post modification inspections.
15. In Figure 4: Added reference to correct left side panel kit for Group 4 airplanes.
16. In Figure 6: Added reference to correct right side panel kit for Group 4 airplanes.
17. Figures 18, 19, and 20: These new figures were added for post modification inspections.
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.
REVISION HISTORY June 16, 2005Original Issue:
July 28, 2005Revision 1:
May 31, 2007Revision 2:
July 11, 2013Revision 3:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 16, 2005 747-53A2562Revision 3: July 11, 2013 6 of 136 BOEING SERVICE BULLETIN 747-53A2562
Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2562Original Issue: June 16, 2005 Revision 3: July 11, 2013 ATA System: 5311 SUBJECT: FUSELAGE - Main Frame - Nose Wheel Well Side and Top Panel - Web and Stiffener Replacement
CONCURRENT REQUIREMENTS None.
BACKGROUND This Service Bulletin gives instruction for a modification to the nose wheel well top and side panels. This modification makes the nose wheel well top and side panels more resistant to fatigue cracks in the areas that must be inspected to satisfy requirements given in the FAA Airworthiness Directive AD 2006-22-15. This modification can be done to permanently satisfy requirements related to this Airworthiness Directive, and terminate inspections of Service Bulletin 747-53A2465.
Three operators have reported finding cracks in the nose wheel well side panel webs on four airplanes. The cracks ranged from 1.5 inches to 14.5 inches in length. The airplanes on which these cracks were found had between 15,900 and 32,018 flight cycles. In addition, a 17.5 inch crack was found in the side panel web of the Boeing 747-400 fatigue test airplane, which had accumulated 58,890 pressure cycles.
One operator has also reported a 13 inch long crack in the nose wheel well top panel web of an airplane with 15,726 flight cycles.
Two operators have also reported finding cracks in the nose wheel well side panel stiffeners on two airplanes.
The cracks were between 12 and 13 inches in length and were found on airplanes with between 19,577 and 31,863 flight cycles.
As of the time of development of Revision 3 of this service bulletin, Boeing has received a total of 16 reports of cracking in the nose wheel well top panel and side panel webs and/or stiffeners. One airplane lost pressurization due to cracking in a nose wheel well side panel.
Boeing has determined that all the cracks were caused by fatigue. Furthermore, the nose wheel well top and side panels have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Although loss of pressurization due to cracks in the nose wheel well structure is not necessarily an airplane safety concern, WFD could result in a depressurization event with damage significant enough to adversely affect the structural integrity of the fuselage.
Accomplishment of this service bulletin will install new nose wheel well side and top panel structure, and will eliminate the concern of WFD in the nose wheel well. For more information about WFD, refer to 747-SL-53-088.
The modification given in this service bulletin terminates the repetitive inspections given in Service Bulletin 747-53A2465.
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Original Issue: June 16, 2005 747-53A2562Revision 3: July 11, 2013 7 of 136
Boeing Structural Item Interim Advisory SIIA 747-129 is related to this Service Bulletin.
Boeing Service Related Problem (SRP) 747-SRP-53-0133 and 747-SRP-53-0231 are related to this Service Bulletin.
Boeing Fleet Team Digest articles 747 FTD 53-04002 and 747 FTD 53-12006 are 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 Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-63RS) Open the nose landing gear doors, and jack the airplane. Remove the nose landing gear, nose landing gear doors, nose landing gear door actuator, passenger seats, floor covering, floor panels, and insulation as necessary to get access to the upper, left, and right hand webs in the nose wheel well.
Group 1-3:
Replace the top panel web and the left and right side panel webs. Also, replace the horizontal stiffeners spanning between the vertical beams, and the stiffeners common to the top panel.
Group 4:
Replace the left and right side panel webs. Also, replace the horizontal stiffeners spanning between the vertical beams, and the stiffeners common to the top panel.
Install all parts removed for access at completion of the modification, and return airplane to a serviceable condition.
Do post modification inspections (detailed and eddy current) at the times specified in paragraph 1.E., Compliance.
If any crack is found, contact Boeing for repair instructions and do the repair.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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EFFECTIVITY 747-100/-100B/-100B SUD/-200B/-200C/-200F/-300/-400/-400D/-400F/-SP/-SR airplanes. Refer to Paragraph
1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2006-22-15 is related to this service bulletin.
Refer to Paragraph 1.E for compliance information.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 747-53A2562 0000000000000 GROUP 1-3:
INSTALL NEW TOP PANEL
WEB STRUCTURE STA 280 STA 400 STA 340 STA 400 BLO GROUP 1-4:
INSTALL NEW SIDEWALL
WEB STRUCTURE - LEFT
UP AND RIGHT SIDE > FWD
INSIDE NOSE WHEEL WELL LEFT SIDE SHOWN D72410
RIGHT SIDE OPPOSITE Original Issue: June 16, 2005 Revision 3: July 11, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2562 Work - See page 1 for details. 10 of 136
Commercial Airplanes 747 Service Bulletin Number: 747-53A2562 Original Issue: June 16, 2005 Revision 3: July 11, 2013 ATA System: 5311 SUBJECT: FUSELAGE - Main Frame - Nose Wheel Well Side and Top Panel - Web and Stiffener Replacement
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. Refer to PRR 85901-63RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747-400, 747-400D, 747SP, and 747SR airplanes, line numbers 1 through 1303, except line number 952 and airplanes modified by Boeing to Special Freighter or Boeing Converted Freighter. These airplanes do not have a nose cargo door.
-1 747-100, 747-200B, 747-300, 747-400, and 747SR airplanes, line numbers 5 through 1188, that have been modified by Boeing to Special Freighter or Boeing Converted Freighter configuration (prior to December 14, 2012) . These airplanes do not have a nose cargo door.
-2 747-400D airplane, line number 952.-3 747-200C, 747-200F, and 747-400F airplanes, line numbers 168 through 1314. These airplanes have a nose cargo door.
-4 Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 16, 2005 747-53A2562Revision 3: July 11, 2013 11 of 136
GroupVariable Number 1RA001 - RA025 2RA026 1RA027 - RA028 2RA029 1RA030 - RA032 2RA033 1RA034 2RA101 - RA103 1RA104 - RA110 2RA111 - RA112 1RA113 - RA115 2RA161 - RA163 1RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA266 1RA301 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA418 1RA501 - RA502 1RA521 - RA523 2RA524 1RA525 - RA528 1RA532 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 16, 2005 747-53A2562Revision 3: July 11, 2013 12 of 136 BOEING SERVICE BULLETIN 747-53A2562