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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2682 Original Issue: May 08, 2008 Revision 1: May 24, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 42 Fuselage Frame Shear Tie End Fasteners - External Skin Crack Inspection 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 © 2008 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Unpublished Work.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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management Company.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 1 of 83
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 2 of 83 BOEING SERVICE BULLETIN 747-53A2682
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 1 D. Description .............................................. 2 1 E. Compliance .............................................. 2 2 F. Approval ............................................... 2 8 G. Manpower .............................................. 2 9 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 0 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 3 C. Parts Necessary for Each Airplane ................................. 3 3
1. Kits/Parts: ........................................... 3 3
2. Parts and Materials Supplied by the Operator: ........................ 3 3
3. Parts Modified and Reidentified: ............................... 3 3
4. Parts Removed and Not Replaced: .............................. 3 3 D. Parts Necessary to Change Spares ................................. 3 3 E. Special Tooling - Price and Availability ............................... 3 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: STATION 540 TO 980, BELOW STRINGER 23 TO ABOVE STRINGER 26 - LEFT SIDE - EXTERNAL SKIN INSPECTION [Group 1-2, 4] ........................ 4 0 FIGURE 2: STATION 540 TO 980, BELOW STRINGER 23 TO ABOVE STRINGER 26 - RIGHT SIDE - EXTERNAL SKIN INSPECTION ................................ 4 5 FIGURE 3: STATION 540 TO 980, BELOW STRINGER 26 TO ABOVE STRINGER 39 - LEFT SIDE - EXTERNAL SKIN INSPECTION [Group 1-2, 4] ........................ 5 0 FIGURE 4: STATION 540 TO 980, BELOW STRINGER 26 TO ABOVE STRINGER 39 - RIGHT SIDE - EXTERNAL SKIN INSPECTION ................................ 5 5 FIGURE 5: STATION 540 TO 980, BELOW STRINGER 39 LEFT TO BELOW STRINGER 39 RIGHT - EXTERNAL SKIN INSPECTION ................................ 6 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 3 of 83 BOEING SERVICE BULLETIN 747-53A2682
ALERTALERT
FIGURE 6: STATION 540 TO 980, BELOW STRINGER 23 TO ABOVE STRINGER 28 - LEFT SIDE - EXTERNAL SKIN INSPECTION [Group 3] .......................... 6 5 FIGURE 7: STATION 540 TO 980, BELOW STRINGER 26 TO ABOVE STRINGER 39 - LEFT SIDE - EXTERNAL SKIN INSPECTION [Group 3] .......................... 6 9 FIGURE 8: INSPECTION OF SKIN AT DOUBLER LOCATIONS WHERE THE UPPER OR LOWER FASTENER ROW OF THE DOUBLER IS COMMON TO A SHEAR TIE END FASTENER . 72 FIGURE 9: INSPECTION OF SKIN AT DOUBLER LOCATIONS WHERE THE UPPER OR LOWER FASTENER ROW OF THE DOUBLER IS COMMON TO A SHEAR TIE END FASTENER [Group 3 ] ................................................ 7 6 APPENDIX A: DOUBLER EXAMPLES THAT REQUIRE INSPECTION OF SKIN NEXT TO THE SHEAR TIE END FASTENER ....................................... 8 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 4 of 83 BOEING SERVICE BULLETIN 747-53A2682
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2682Original Issue: May 08, 2008 Revision 1: May 24, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 42 Fuselage Frame Shear Tie End Fasteners - External Skin Crack Inspection This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) inspected or repaired in accordance with the original issue of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-06-02 is related to this service bulletin.
Airplane line numbers 758 through 1419 (except Large Cargo Freighter airplanes) were added to this Service Bulletin effectivity as new Groups 3 and 4.
REASON FOR REVISION This Alert revision is sent to add airplane line numbers 758 through 1419 to the service bulletin effectivity (except Large Cargo Freighter airplanes).
These sections were changed:
1. In the Summary: Updated Background and Action information, added reference to Service Related Problem 747-SRP-53-0352 and Fleet Team Digest article 747-FTD-53-09006, added reference to FAA AD 2009-06-02, and added new Groups 3 and 4 to Manpower table.
2. In Paragraph 1.A.1., Airplanes: Revised description for Group 1 and added description for new Groups 3 and 4.
3. In Paragraph 1.C., Reason: Updated Reason information, added references to Service Related Problem 747-SRP-53-0352 and Fleet Team Digest article 747-FTD-53-09006.
4. In Paragraph 1.D., Description: Inspection area description changed, "No more work" statement is added, and Affected Maintenance Zones are added.
5. In Paragraph 1.E., Compliance: Related AD statement is added. Compliance information in Table 1 is updated, and footnote (b) was deleted. Table 2 is added for Group 2 airplanes. Table 3 is added for new Groups 3 and 4. Tables 4 and 5 are added for inspection at shear tie end fasteners that are common to an upper or lower fastener row of a repair doubler.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 5 of 83
6. In Paragraph 1.F., Approval: Alternative Method of Compliance (AMOC) statement is added relating to FAA AD 2009-06-02.
7. In Paragraph 1.K.2., Publication Affected: "Damage Tolerance Structural Inspections" statement is added.
8. In Paragraph 1.J.1., References: Document references and installation drawings are updated.
9. In Paragraph 3.B., Work Instructions: Group applicability is updated. Instructions for inspection of Group 3 and 4 airplanes is added. PART 3 - Skin Crack Repair steps are clarified. New PART 4 is added for inspection at shear tie end fasteners that are common to an upper or lower fastener row of a repair doubler.
10. In Figures 1 through 5: Previous flag note 1 is now footnote (a), and the flag note table was deleted.
Section view A-A is corrected. L-shaped shear tie is identified. Group applicability is also updated for Group 4.
11. In Figure 2: Stringer identifications are corrected.
12. In Figures 3, 4, and 5: Added footnote (b).
13. Figures 6 and 7: These new figures have been added for Group 3.
14. Figures 8 and 9: These new figures have been added for inspection of the skin at repair doublers where the upper or lower fastener row of the repair doubler is common to a shear tie end fastener.
15. Appendix A: This new appendix has been added to identify external repair doubler configurations where the skin should be inspected next to the shear tie end fastener.
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 May 08, 2008Original Issue:
May 24, 2012Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 6 of 83 BOEING SERVICE BULLETIN 747-53A2682
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2682Original Issue: May 08, 2008 Revision 1: May 24, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 42 Fuselage Frame Shear Tie End Fasteners - External Skin Crack Inspection
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 instructions to do external inspections of the Section 42 skin for cracks at fuselage frame shear tie end fastener locations. Cracks in the fuselage skin can propagate and become large, resulting in a loss of structural integrity and a sudden decompression of the airplane in-flight.
Fuselage frame shear ties are an integral part of the load bearing airframe structure, and are located between longitudinal stringers.
The inspection for skin cracks at fuselage frame shear tie end fastener locations as given in this service bulletin is between Station 540 to 980 (STA 780 on 747SP airplanes), Stringer 23 to 47 left and right side. This issue is a part of the wide-spread fatigue damage (WFD) assessment for the model 747 airplanes. It is one of the structural details that have been determined by analysis and fleet history to be susceptible to WFD and requires service action in the form of inspections and/or modification.
Since the release of the original issue of this service bulletin, one operator has reported finding three skin cracks at fastener holes common to STA 540 frame shear tie between S-23L and S-25L. The affected airplane had T-shaped shear ties in the inspection area and was not in the effectivity of the original issue of this service bulletin. Based on these reports of cracks in T-shaped shear ties, airplane line numbers 758 through 1419 (except Large Cargo Freighter airplanes) have been added to the bulletin effectivity.
Boeing Service Related Problems (SRP) 747-SRP-53-0299 and 747-SRP-53-0352 are related to this service bulletin.
Boeing Fleet Team Digest (FTD) 747-FTD-53-09006 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 7 of 83
ACTION Station 540 to 980 (STA 780 on 747SP series airplanes), Stringers 23 to 47, left and right sides, do an external detailed inspection or external high frequency eddy current (HFEC) inspection for skin cracks at fuselage frame shear tie end fastener locations. If an external repair doubler exists in the inspection area and the upper or lower fastener row of the doubler is common to a shear tie end fastener, do an internal HFEC inspection of the skin next to the shear tie.
If no cracks are found, repeat inspections are required. See Paragraph 1.E., Compliance. If cracks are found, repair as given in the applicable 747 Structural Repair Manual (SRM).
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 2009-06-02 is related to this service bulletin.
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.
Refer to Paragraph 1.E., Compliance.
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
25.7591.00Group 1, 2, 3, and 4 Refer to Paragraph 1.G., Manpower .
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 8 of 83 BOEING SERVICE BULLETIN 747-53A2682
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2682
ALERT ALERT SECTION 42 1000 000 • 0 0 0 0 0 000000 0000 0000000 00000
DO AN EXTERNAL DETAILED INSPECTION
OR HIGH FREQUENCY EDDY CURRENT (HFEC)
INSPECTION FOR SKIN CRACKS AT FUSELAGE FRAME SHEAR TIE END FASTENER LOCATIONS.
STRETCHED UPPER DECK 747 SHOWN 1371677
OTHER AFFECTED AIRPLANES SIMILAR Original Issue: May 08, 2008 Revision 1: May 24, 2012 Export Controlled ECCN: 9E991 - BOEING 747-53A2682 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 83
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 10 of 83 BOEING SERVICE BULLETIN 747-53A2682
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2682 Original Issue: May 08, 2008 Revision 1: May 24, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 42 Fuselage Frame Shear Tie End Fasteners - External Skin Crack Inspection
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 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.
DESCRIPTIONCONFIGURATIONGROUP 747 airplanes, line numbers 1 through 757, except 747SP airplanes.
This Group includes airplanes modified to Boeing Special Freighter.
-1 747SP airplanes.-2 747-300/-400/-400D, airplanes, line numbers 758 through 1419, except Large Cargo Freighter airplanes. This Group includes airplanes modified to Boeing Converted Freighter.
-3 747-200F/400F airplanes, line numbers 758 through 1419.-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: May 08, 2008 747-53A2682Revision 1: May 24, 2012 11 of 83
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 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 - RA635 1RA651 - RA652 1RA671 - RA677 1RA701 - RA702 1RA721 - RA731 1RA741 - RA745 1RA749 - RA750 1RA761 - RA762 1RA781 - RA784 1RA901 - RA916 1RB001 - RB016 1RB041 - RB044 1RB071 - RB075 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 08, 2008 747-53A2682Revision 1: May 24, 2012 12 of 83 BOEING SERVICE BULLETIN 747-53A2682