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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2688 Original Issue: August 21, 2008 Revision 2: August 21, 2014 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Section 41 and Section 44 Upper Deck Floor Beam Upper Chord Inspection and Repair at Floor Panel Attachment Fastener Holes 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Unpublished Work.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, 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 21, 2008 747-53A2688Revision 2: August 21, 2014 1 of 177
6.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 2 of 177 BOEING SERVICE BULLETIN 747-53A2688
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 8 D. Description .............................................. 1 9 E. Compliance .............................................. 2 1 F. Approval ............................................... 2 7 G. Manpower .............................................. 2 8 H. Weight and Balance Changes .................................... 3 1 I. Electrical Load Data ......................................... 3 1 J. References .............................................. 3 1
1. Existing Data: ......................................... 3 1
2. Data Supplied with this Service Bulletin: ........................... 3 1
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 2 K. Publications Affected ........................................ 3 2 L. Interchangeability and Intermixability of Parts ........................... 3 2 M. Software Accomplishment Summary ................................ 3 2
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 7
4. Parts Removed and Not Replaced: .............................. 3 7 D. Parts Necessary to Change Spares ................................. 3 7 E. Special Tooling - Price and Availability ............................... 3 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 0 FIGURE 1: SECTION 41 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 1] ....... 5 3 FIGURE 2: SECTION 41 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 2] ....... 5 4 FIGURE 3: SECTION 41 - OPEN HOLE HFEC INSPECTION AT FLOOR PANEL ATTACHMENT FASTENER LOCATIONS .......................................... 5 5 FIGURE 4: SECTION 41 - CLIPNUT MODIFICATION AND SURFACE HFEC INSPECTION ..... 5 8 FIGURE 5: SECTION 41 - FLOOR PANEL ATTACHMENT HOLE MODIFICATION .......... 6 2 FIGURE 6: SECTION 41 - HOLE MEASUREMENTS AFTER CRACK REMOVAL ........... 6 5 FIGURE 7: SECTION 41 - REPAIR STRAP INSTALLATION ....................... 6 8 FIGURE 8: SECTION 41 - UPPER CHORD TRIM ............................ 7 2 FIGURE 9: SECTION 41 - UPPER CHORD REPAIR WITH STRAP ................... 7 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 3 of 177 BOEING SERVICE BULLETIN 747-53A2688
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FIGURE 10: SECTION 41 - UPPER CHORD REPAIR WITH STRAP AND CLIP ............. 7 9 FIGURE 11: SECTION 41 - AFTER-REPAIR INSPECTION FOR LOCATIONS WITH THE STRAP REPAIR .................................................. 8 4 FIGURE 12: SECTION 41 - AFTER-REPAIR INSPECTIONS FOR LOCATIONS WITH UPPER CHORD TRIM REPAIR WITH STRAP OR ANGLE .............................. 8 7 FIGURE 13: SECTION 41 - UPPER CHORD THICK FLANGE REPAIR WITH STRAP (REPAIR 8) . . 90 FIGURE 14: SECTION 41 - UPPER CHORD THICK FLANGE REPAIR WITH ANGLE (REPAIR 9) . . 95 FIGURE 15: SECTION 41 - UPPER CHORD THIN FLANGE REPAIR WITH STRAP (REPAIR 11) . . 100 FIGURE 16: SECTION 41 - UPPER CHORD THIN FLANGE REPAIR WITH ANGLE (REPAIR 12) . . 105 FIGURE 17: SECTION 41 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 3] ...... 1 1 0 FIGURE 18: SECTION 44 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 1] ...... 1 1 1 FIGURE 19: SECTION 44 - OPEN HOLE HFEC INSPECTION AT FLOOR PANEL ATTACHMENT FASTENER LOCATIONS [Group 1] .................................... 1 1 2 FIGURE 20: SECTION 44 - CLIPNUT MODIFICATION AND SURFACE HFEC INSPECTION [Group 1] . 115 FIGURE 21: SECTION 44 - FLOOR PANEL ATTACHMENT HOLE MODIFICATION [Group 1] .... 1 1 9 FIGURE 22: SECTION 44 - HOLE MEASUREMENTS AFTER CRACK REMOVAL [Group 1] ..... 1 2 2 FIGURE 23: SECTION 44 - REPAIR STRAP INSTALLATION [Group 1] ................ 1 2 5 FIGURE 24: SECTION 44 - UPPER CHORD TRIM [Group 1] ...................... 1 2 9 FIGURE 25: SECTION 44 - UPPER CHORD REPAIR WITH STRAP [Group 1] ............ 1 3 2 FIGURE 26: SECTION 44 - UPPER CHORD REPAIR WITH STRAP AND CLIP [Group 1] ...... 1 3 6 FIGURE 27: SECTION 44 - UPPER CHORD THICK FLANGE REPAIR WITH STRAP (REPAIR 8) [Group 1 ] ................................................ 1 4 1 FIGURE 28: SECTION 44 - UPPER CHORD THICK FLANGE REPAIR WITH ANGLE (REPAIR 9) [Group 1 ] ................................................ 1 4 6 FIGURE 29: SECTION 44 - UPPER CHORD THIN FLANGE REPAIR WITH STRAP (REPAIR 11) [Group 1] ................................................. 1 5 1 FIGURE 30: SECTION 44 - UPPER CHORD THIN FLANGE REPAIR WITH ANGLE (REPAIR 12) [Group 1] ................................................. 1 5 6 FIGURE 31: SECTION 44 - AFTER-REPAIR INSPECTION FOR LOCATIONS WITH THE STRAP REPAIR [Group 1] ............................................ 1 6 1 FIGURE 32: SECTION 44 - AFTER-REPAIR INSPECTIONS FOR LOCATIONS WITH UPPER CHORD TRIM REPAIR WITH STRAP OR ANGLE [Group 1] ........................ 1 6 4 FIGURE 33: SECTION 41 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 4] ...... 1 6 7 FIGURE 34: SECTION 41 - HFEC INSPECTION OF UPPER CHORD AT PLUGGED OR RE-USED FLOOR PANEL ATTACHMENT HOLES [Group 2] .......................... 1 6 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 4 of 177 BOEING SERVICE BULLETIN 747-53A2688
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2688Original Issue: August 21, 2008 Revision 2: August 21, 2014 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Section 41 and Section 44 Upper Deck Floor Beam Upper Chord Inspection and Repair at Floor Panel Attachment Fastener Holes This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directives AD 2013-22-11 and AD 2004-07-22 R1 are related to this service bulletin. AD 2013-22-11 superseded AD 2009-10-06.
Group 1, 3-4:
No more work is necessary on the airplane(s) changed or inspected in accordance with Revision 1 of this service bulletin.
Group 2:
More work is necessary on the airplane(s) changed or inspected in accordance with Revision 1 of this service bulletin. Do a High Frequency Eddy Current (HFEC) inspection for any cracks in the upper deck floor beam upper chords and a detailed visual inspection of the upper deck floor beam vertical flanges.
REASON FOR REVISION This revision is sent to add a High Frequency Eddy Current (HFEC) inspection for cracks in the upper deck floor beam upper chords, at floor panel and floor structure attachment holes, that were plugged or re-used during the conversion to Boeing Converted Freighter (BCF).
These sections were changed:
1. Background and Reason Sections in the Summary have been updated to describe the reason for the new revision.
2. Action and Description Sections in the Summary, updated to include additional work and new groups.
3. Updated the Summary illustration to include new work.
4. In Paragraph 1.C Reason, added new work and updated the information to include the reason for the new revision.
5. In Paragraph 1.D Description, added new Group 4 and revised work summaries.
6. In Paragraph 1.E Compliance, revised tables to include new work and groups.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 5 of 177
7. In Paragraph 1.F Approval, included alternative method of compliance (AMOC) paragraphs.
8. In Paragraph 1.G Manpower, revised to include new work and groups.
9. In Paragraph 1.J References, added new SRP reference.
10. In Paragraph 3.A., General Information, revised and added general notes.
11. In Paragraph 3.B., Work Instructions, Part 7 updated to include new work.
12. In Paragraph 3.B., Work Instructions, Part 8 added to include new work.
13. Figure 2, changed group information.
14. Figure 3, changed note for revised STA information.
15. Added Figure 33 and Figure 34 to include additional work for the new revision.
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 changes.
REVISION HISTORY August 21, 2008Original Issue:
September 19, 2012Revision 1:
August 21, 2014Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 6 of 177 BOEING SERVICE BULLETIN 747-53A2688
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2688Original Issue: August 21, 2008 Revision 2: August 21, 2014 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Section 41 and Section 44 Upper Deck Floor Beam Upper Chord Inspection and Repair at Floor Panel Attachment Fastener Holes
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 SB gives instructions to do inspections for fatigue cracks of the upper deck floor beam upper chords at the floor panel attachment holes. Also, additional inspections are provided at the floor panel attachment holes that have been plugged or re-used during the BCF modification in Section 41. Cracks in these chords that are not found and repaired could become large and cause the floor beam to become severed. This can lead to large deflection or deformation of the floor and of the body skin, frames, and stringers. This deflection or deformation could result in damage to wire bundles and unintended inputs to the flight control cables which could affect airplane controllability. Multiple adjacent severed floor beams could result in rapid decompression of the airplane.
Flight critical wire bundles and control cables are routed through cutouts in the upper deck floor beams.
Cracks have been found at open floor panel attach fastener holes in the upper chord of two Section 41 upper deck floor beam on three different 747-400D airplanes, which had flown 24,053, 24,783, and 25,631 flight-cycles.
Boeing believes that these 747-400D airplanes were operated at reduced cabin differential pressures. Similar cracks were also found on the 747-400 Fatigue Test airplane.
Accomplishment of the inspections given in this service bulletin will ensure the structural integrity of the upper chords of the Section 41 upper deck floor beams.
A structural reassessment of the 747 airplane was conducted under the requirements of Federal Aviation Administration (FAA) Advisory Circular 91-56, in accordance with Federal Aviation Regulation (FAR) 25.571 as amended in 1978, to ensure safe operation of 747 airplanes throughout their operational life. From this requirement, the Section 41 upper deck floor beam upper chords were determined to be significant, in that they are critical to airplane structural integrity. Therefore, a flight safety inspection program which will continue throughout the operational life of the airplane is specified in this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 7 of 177
Between the original issue and Revision 1 of this service bulletin, Boeing has received two reports of cracking in upper deck floor beam upper chords in Section 44. The cracks were at STA 1000 and STA 1100. Due to these crack reports Boeing has determined that inspection of all upper deck floor beam upper chords in Section 44 (from STA 1000 to STA 1100) is required.
Since the release of Revision 1 of this service bulletin, Boeing has found that certain fastener holes in the upper deck floor beam upper chords in Section 41, that were plugged or re-used during the conversion to BCF may not have been inspected in accordance with the instructions provided in Revision 1 of this service bulletin, because these locations may be hidden and not recognized as inspection locations. Boeing has determined that inspection of the upper deck floor beam upper chords in all locations containing plugged or re-used fastener holes is required.
Boeing Service Related Problem (SRP) 747-SRP-53-0293, 747-SRP-53-0353 and 747-SRP-53-0428 are related to this service bulletin.
The upper deck floor beam upper chords have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.
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., ComplianceYesAD 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/PartsNoKits/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 Group 1:
Get access from above or below to the upper chords of the Section 41 upper deck floor beams from Station (STA) 340 to STA 520 and to the upper chords of the Section 44 upper deck floor beams from STA 1000 to STA 1100.
Group 2:
Get access from above or below to the upper chords of the Section 41 upper deck floor beams from STA 340 to STA 440.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 8 of 177 BOEING SERVICE BULLETIN 747-53A2688
ALERTALERT
NOTE: On Group 2 airplanes, upper deck floor beams from STA 460 to STA 520 do not require inspection as given in this service bulletin because they were replaced with new floor beams during modification to Boeing Converted Freighter (BCF). The new floor beams have floor panel attachment fastener holes that have been cold-worked. Also, on Group 2 airplanes, inspection as given in this service bulletin are not necessary in Section 44 because all floor beams in Section 44 were replaced with tension ties during modification to BCF.
Group 3:
Get access from above or below to the upper chords of the Section 41 upper deck floor beams from STA 340 to STA 380.
NOTE: On Group 3 airplanes, upper deck floor beams from STA 400 to STA 500 do not require inspection as given in this service bulletin because they were replaced with new floor beams during modification to Large Cargo Freighter (LCF). The new floor beams have floor panel attachment fastener holes that have been cold-worked.
Group 4:
Get access from above or below to the upper chords of the Section 41 upper deck floor beams from STA 340 to STA 420.
NOTE: On Group 4 airplanes, upper deck floor beams from STA 440 to STA 500 do not require inspection as given in this service bulletin because they were replaced with new floor beams, or modified, during conversion to Large Cargo Freighter (LCF). The new floor beams have floor panel attachment fastener holes that have been cold-worked.
If access was gained from above, do open hole HFEC inspections of the floor panel attachment fastener holes in the upper chords for cracks. If access was gained from below, modify the clipnuts for the floor panel attachment fasteners as given in this service bulletin. Do surface HFEC inspections of the forward and aft horizontal flanges of the upper chord at floor panel attachment fastener holes.
If cracks are found, repair before any more flights. Repair as given in this service bulletin, or ask Boeing for repair data. For areas repaired as given in this service bulletin, start to do repeat inspections at repaired locations as given in this service bulletin at the times given in Paragraph 1.E., Compliance. For any locations that have a repair that is different from those shown in this service bulletin, contact Boeing for an after-repair inspection plan.
If no cracks are found, do the inspection again at the time given in Paragraph 1.E., Compliance.
Group 2:
Do edge or surface HFEC inspections of the forward and aft horizontal flanges of the upper chord and a detailed inspection of the vertical flanges of the upper chord at all plugged or re-used floor panel attachment holes. If cracks are found in any plugged holes, contact Boeing for repair instructions and do the repair. If no cracks are found, do the inspection again at the time given in Paragraph 1.E., Compliance.
Group 3-4:
Replace all affected upper deck floor beam upper chords at the time given in Paragraph 1.E., Compliance.
EFFECTIVITY All 747-400 and 747-400D airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 9 of 177 BOEING SERVICE BULLETIN 747-53A2688
ALERTALERT
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 2013-22-11 and AD 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 and repair procedures given in this service bulletin.
MANPOWER Section 41 Inspections Elapsed Time (Hours) Total Man- Hours Airplanes
77.25259Passenger
72.25241Boeing Converted Freighter 36120Large Cargo Freighter Section 44 Inspections Elapsed Time (Hours) Total Man- Hours Airplanes
24.0066.00Passenger
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 10 of 177 BOEING SERVICE BULLETIN 747-53A2688
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2688
ALERT ALERT STA STA 1100 SECTION 44 1000 INSPECTION AREA SECTION 41
INSPECTION AREA STA 340 STA 360
STA STA STA 520 380 340 STA 400 STA 420 SECTION 41 INSPECTION STA 440
AREA SHOWN, SECTION 44 INSPECTION STA AREA SIMILAR 460 B • STA 480 _ STA 500
FLOOR PANEL ATTACH STA FASTENER HOLE 520
A-A FWD
UPPER CHORD TYPICAL SECTION 41
INSPECTION AREA
WEB OR STRAP FLOOR PANEL
DO OPEN-HOLE OR SURFACE HFEC INSPECTIONS AT ALL FLOOR PANEL ATTACH FASTENER HOLES.
ON BCF AIRPLANES ALSO INSPECT ALL PLUGGED OR > FWD B-B REUSED FLOOR PANEL ATTACH FASTENER HOLES, COMMON TO THE UPPER DECK FLOOR BEAM. 1454601 (TYPICAL) Original Issue: August 21, 2008 Revision 2: August 21, 2014 Export Controlled ECCN: 9E991 - BOEING 747-53A2688 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 177
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 2: August 21, 2014 12 of 177 BOEING SERVICE BULLETIN 747-53A2688