Boeing ASB 747-53A2563: U.S. DOT/FAA - Service Bulletin, text

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Commercial Airplanes 747 Service Bulletin Number: 747-53A2563 Original Issue: March 29, 2007 Revision 4: May 06, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for Scribe Lines Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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: March 29, 2007 747-53A2563Revision 4: May 06, 2010 1 of 281

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Original Issue: March 29, 2007 747-53A2563Revision 4: May 06, 2010 2 of 281 BOEING SERVICE BULLETIN 747-53A2563

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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 5 E. Compliance .............................................. 2 9 F. Approval ............................................... 7 6 G. Manpower .............................................. 7 7 H. Weight and Balance Changes .................................... 7 8 I. Electrical Load Data ......................................... 7 8 J. References .............................................. 7 8

1. Existing Data: ......................................... 7 8

2. Data supplied with this Service Bulletin: ........................... 7 8

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 7 8 K. Publications Affected ........................................ 7 8 L. Interchangeability and Intermixability of Parts ........................... 7 9

2. MATERIAL INFORMATION ........................................ 8 1 A. Material - Price and Availability ................................... 8 1 B. Industry Support Information .................................... 8 1 C. Parts Necessary For Each Airplane ................................. 8 1

1. Kits/Parts: ........................................... 8 1

2. Parts and Materials Supplied by the Operator: ........................ 8 1

3. Parts Modified and Reidentified: ............................... 8 1

4. Parts Removed and Not Replaced: .............................. 8 1 D. Parts Necessary to Change Spares ................................. 8 1 E. Special Tooling - Price and Availability ............................... 8 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 8 1

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 8 3 A. GENERAL INFORMATION ..................................... 8 3 B. WORK INSTRUCTIONS ....................................... 8 5 FIGURE 1: INSPECTION AREA 1 [Group 1] ............................... 1 1 6 FIGURE 2: INSPECTION AREA 1 [Group 2] ............................... 1 2 1 FIGURE 3: INSPECTION AREA 1 [Group 3, Configuration 1] ...................... 1 2 6 FIGURE 4: INSPECTION AREA 1 [Group 3, Configuration 2; Group 4] ................ 1 3 1 FIGURE 5: INSPECTION AREA 1 [Group 5] ............................... 1 3 6 FIGURE 6: INSPECTION AREA 1 [Group 6] ............................... 1 4 1 FIGURE 7: INSPECTION AREA 1 [Group 7] ............................... 1 4 6 FIGURE 8: INSPECTION AREA 1 [Group 8] ............................... 1 5 1 FIGURE 9: INSPECTION AREA 1 [Group 9] ............................... 1 5 6 FIGURE 10: INSPECTION AREA 2 [Group 1-2] .............................. 1 6 1 FIGURE 11: INSPECTION AREA 2 [Group 3-4] .............................. 1 6 5

Original Issue: March 29, 2007 747-53A2563Revision 4: May 06, 2010 3 of 281 BOEING SERVICE BULLETIN 747-53A2563

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FIGURE 12: INSPECTION AREA 2 [Group 7-8] .............................. 1 6 9 FIGURE 13: INSPECTION AREA 2 [Group 9] ............................... 1 7 3 FIGURE 14: INSPECTION AREA 3 [Group 1] ............................... 1 7 7 FIGURE 15: INSPECTION AREA 3 [Group 2] ............................... 1 8 3 FIGURE 16: INSPECTION AREA 3 [Group 3, Configuration 1] ...................... 1 8 9 FIGURE 17: INSPECTION AREA 3 [Group 3, Configuration 2; Group 4] ................ 1 9 5 FIGURE 18: INSPECTION AREA 3 [Group 5] ............................... 2 0 1 FIGURE 19: INSPECTION AREA 3 [Group 6] ............................... 2 0 7 FIGURE 20: INSPECTION AREA 3 [Group 7] ............................... 2 1 3 FIGURE 21: INSPECTION AREA 3 [Group 8] ............................... 2 1 9 FIGURE 22: INSPECTION AREA 3 [Group 9] ............................... 2 2 5 FIGURE 23: LAP JOINT INSPECTION FOR SCRIBE LINES ...................... 2 3 1 FIGURE 24: BUTT JOINT INSPECTION FOR SCRIBE LINES ...................... 2 3 2 FIGURE 25: DELETED ........................................... 2 3 4 FIGURE 26: INSPECTION OF LAP JOINT SCRIBE LINES FOR CRACKS ............... 2 3 5 FIGURE 27: INSPECTION OF BUTT JOINT SCRIBE LINES FOR CRACKS .............. 2 3 7 FIGURE 28: INSPECTION OF SCRIBE LINES AROUND THE WING-TO-BODY FAIRING FOR CRACKS ................................................. 2 3 8 FIGURE 29: INSPECTION FOR SCRIBE LINES AROUND EXTERNAL DOUBLERS ......... 2 3 9 FIGURE 30: INSPECTION FOR SCRIBE LINES IN SKIN GENERAL INSPECTION AREAS ..... 2 4 0 FIGURE 31: INSPECTION OF SCRIBE LINES AROUND EXTERNAL DOUBLERS FOR CRACKS . . 242 FIGURE 32: INSPECTION OF SCRIBE LINES IN SKIN GENERAL INSPECTION AREAS FOR CRACKS ................................................. 2 4 5 FIGURE 33: INSPECTION AREA 2 [Group 5-6] .............................. 2 4 6 FIGURE 34: INSPECTION FOR SCRIBE LINES AT THE EDGE OF THE DOOR 3 UPPER AFT CORNER LARGE DOUBLER ...................................... 2 5 0 FIGURE 35: INSPECTION OF SCRIBE LINES AROUND THE DOOR 3 UPPER AFT CORNER LARGE DOUBLER FOR CRACKS .................................. 2 5 3 Appendix A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN. 256 Appendix B: REPORTING SYSTEM - LIMITED RETURN TO SERVICE PROCEDURE FOR SCRIBED AIRPLANES .......................................... 2 6 2 Appendix C: AIRPLANE FUSELAGE SCRIBE LINE SUMMARY TABLES ................ 2 6 4 Appendix D: SCRIBE SAMPLE ....................................... 2 6 7 Appendix E: AIRPLANES DELIVERED WITH FILLET SEALED LAP JOINTS .............. 2 6 9 APPENDIX F: LAP JOINT REPAIRS ..................................... 2 7 8

Original Issue: March 29, 2007 747-53A2563Revision 4: May 06, 2010 4 of 281 BOEING SERVICE BULLETIN 747-53A2563

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Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2563Original Issue: March 29, 2007 Revision 4: May 06, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for Scribe Lines This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on Group 5, Group 7, and Group 9 airplanes inspected in accordance with Revision 3 of this service bulletin as a result of Revision 4. If scribe lines were found previously and are being inspected as part of the Limited Return to Service (LRTS) program, do the repeat inspections in accordance with Revision

More work is necessary on Group 1, Group 2, Group 3, Group 4, Group 6, and Group 8 airplanes previously inspected in Area 3 in accordance with the original issue, Revision 2, or Revision 3 of this service bulletin. At the time given in Paragraph 1.E., Compliance, Table 29, inspect certain lap splices in accordance with Paragraph

3.B., Work Instructions, PART 19. At any location where scribe lines were found previously and are being inspected as part of the Limited Return to Service (LRTS) program, do the repeat inspections in accordance with Revision 4.

No airplanes were added to this service bulletin effectivity.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2007-NM-087-AD, is related to this service bulletin.

REASON FOR REVISION This revision is sent to give affected operators improved repeat inspection interval data for lap joint and butt joint areas that have been found to have scribe damage which will be or are being inspected under the Limited Return to Service (LRTS) inspection program.

Inspection of the S-18L lap splice from STA 1780 - STA 1920 (on the Main Deck Side Cargo Door) for scribe lines has been added to inspection Area 3. This change only affects Group 2, Group 3 Configuration 2, Group 4, Group 6, and Group 8 airplanes.

Inspection of the S-34R lap splice from STA 1810 - STA 1920 (on the aft lower lobe cargo door) for scribe lines has been added to inspection Area 3. This change only affects Group 1 and Group 2 airplanes.

Inspection of the S-6L and S-6R lap splice from STA 1000 - STA 1220 for scribe lines has been added to inspection Area 3. This change only affects Group 3 and Group 4 airplanes.

Original Issue: March 29, 2007 747-53A2563Revision 4: May 06, 2010 5 of 281

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In addition, general repair instructions for lap joint locations with scribe lines, but no cracks, have been added.

These instructions are in new PART 17 in Paragraph 3.B., and in new Appendix F. General repair instructions for lap joint locations with scribe lines and cracks have also been added. These instructions are in new PART 18 in Paragraph 3.B., and in new Appendix F.

Analysis by Boeing has also determined that inspections for scribe lines is not necessary at the thresholds for Main Entry Door 1 - 5, the Upper Deck Entry Door (Stretched Upper Deck airplanes only) and the Bulk Cargo Door. In addition, inspections for scribe lines are not necessary at the Bulk Cargo Door corner reinforcement doublers. These areas have been removed from Paragraph 3.B., PART 7. Instructions for the continued inspection of scribe lines in these areas that were found in accordance with earlier versions of this service bulletin have been added to Paragraph 3.B., PART 16 and to new Tables 27 and 28 in Paragraph 1.E., Compliance.

References to Revision 1 have been removed throughout this service bulletin. Revision 1 was released on the MyBoeingFleet website for a short time in 2007, but was permanently removed due to missing illustrations. The FAA considers Revision 1 to be not FAA-approved as published.

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 March 29, 2007Original Issue:

November 08, 2007Revision 1:

January 03, 2008Revision 2:

June 11, 2009Revision 3:

May 06, 2010Revision 4:

Original Issue: March 29, 2007 747-53A2563Revision 4: May 06, 2010 6 of 281 BOEING SERVICE BULLETIN 747-53A2563

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Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2563Original Issue: March 29, 2007 Revision 4: May 06, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for Scribe Lines

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin gives instructions for the inspection and repair of scribe lines in the fuselage skin at lap joints, butt joints, decals, at external doublers and around other external features such as antennas and pitot-static ports. Fatigue cracks can develop in the skin at scribe line locations. Fatigue cracks in the skin that remain undetected could grow large and cause sudden decompression.

A scribe line is a narrow, shallow, distinct line of damage typically between 0.001 to 0.006 inch deep, usually associated with the removal of a fillet or gap seal. A more detailed definition of a scribe line is included in Paragraph 3.A., Accomplishment Instructions.

At the time this service bulletin was originally released, 15 747 airplanes have been found with scribe damage by eight operators. Scribe lines were found at lap joints, butt joints, around external doublers and antennas, and at locations where external decals were cut. Many of the scribe lines appear to have been made when sealant was removed as part of preparation of the airplane for repainting. No cracks have been found at scribe line locations on 747 airplanes.

Accomplishment of the inspections shown in this service bulletin will help make sure that fatigue cracks that can form in the fuselage at scribe lines are found and repaired before they can become large and cause sudden loss of cabin pressure.

Boeing Service Related Problem (SRP) 747/747OP-SRP-53-0242 is related to this service bulletin.

ACTION (PRR 85901-66RS) At the time shown in this service bulletin, do detailed inspections of the fuselage skin at certain lap joints, butt joints, and at certain external doubler locations and other external features for scribe lines.

If no scribe lines are found, no more work is required as a result of this service bulletin.

If scribe lines are found, the scribe lines must be inspected for cracks in accordance with this service bulletin.

If cracks are found, repair the cracks before any more flight-cycles in accordance with this service bulletin. If no cracks are found, repair the scribe lines before any more flight-cycles in accordance with this service bulletin.

As an alternative to scribe line repair, if no cracks are found the scribe lines can be reinspected in accordance with the Limited Return to Service (LRTS) Plan shown in the service bulletin.

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Refer to Paragraph 1.D., Description for details.

EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, and 747SR airplanes. Refer to Paragraph 1.A.1. Airplanes, for the list of affected airplanes.

COMPLIANCE See Service Bulletin Paragraph 1.E. for compliance information.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2007-NM-087-AD is related to this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.

MANPOWER Elapsed HoursTotal Task HoursAirplanes 1021020747SP 1141140All other 747 NOTE: More time will be required for repairs or additional inspections if scribe lines or cracks are found.

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION None.

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BOEING SERVICE BULLETIN 747-53A2563

DO A DETAILED INSPECTION FOR SCRIBE

LINES IN THE SKIN ALONG LAP JOINTS,

BUTT JOINTS, AROUND EXTERNAL REPAIR

AND CUTOUT REINFORCEMENT DOUBLERS,

AND AROUND OTHER FEATURES ON THE PRESSURIZED SKIN.

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Original Issue: March 29, 2007 747-53A2563Revision 4: May 06, 2010 10 of 281 BOEING SERVICE BULLETIN 747-53A2563

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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. Refer to PRR85901-66RS for data about this change.

DESCRIPTIONCONFIGURATIONGROUP All 747-100, 747-100B, 747-200B, and 747SR airplanes without a Stretched Upper Deck or a Main Deck Side Cargo Door.

-1 All 747-100, 747-100B, 747-200B, and 747SR airplanes without a Stretched Upper Deck but with a Main Deck Side Cargo Door.

-2 All 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes with a Stretched Upper Deck, but no Main Deck Side Cargo Door, except 747-400ER airplanes.

-3 Not modified to the BCF (Boeing Converted Freighter) configuration.1 Modified to the BCF (Boeing Converted Freighter) configuration.2 All 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes with a Stretched Upper Deck, and a Main Deck Side Cargo Door.

-4 All 747-200F airplanes with a nose cargo door, but no Main Deck Side Cargo Door.

-5 All 747-200F and 747-400F airplanes with a nose cargo door and a Main Deck Side Cargo Door, except 747-400ER Freighter airplanes.

-6

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DESCRIPTIONCONFIGURATIONGROUP All 747-200C airplanes with a nose cargo door, but no Main Deck Side Cargo Door.

-7 All 747-200C airplanes with a nose cargo door and a Main Deck Side Cargo Door.

-8 All 747SP airplanes.-9 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 GroupVariable Number 1RA001 2RA002 1RA003 - RA005 2RA006 1RA007 - RA010 2RA011 1RA012 - RA014 2RA015 1RA016 - RA025 2RA026 1RA027 2RA028 - RA030 1RA031 - RA032 2RA033 1RA034 2RA101 - RA103 1RA104 - RA110 2RA111 - RA112 1RA113 - RA115 2RA161 - RA163 1RA164 1RA201 - RA203

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