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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2688 Original Issue: August 21, 2008 Revision 1: September 19, 2012 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Unpublished Work.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, 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: August 21, 2008 747-53A2688Revision 1: September 19, 2012 1 of 163
6.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 2 of 163 BOEING SERVICE BULLETIN 747-53A2688
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3
1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 8 D. Description .............................................. 1 9 E. Compliance .............................................. 2 0 F . A p p r o v a l ............................................... 2 6 G. Manpower .............................................. 2 7 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J . R e f e r e n c e s .............................................. 2 8
1. Existing Data: ......................................... 2 8
2. Data Supplied with this Service Bulletin: ........................... 2 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 9 K. Publications Affected ........................................ 2 9 L. Interchangeability and Intermixability of Parts ........................... 2 9 M. Software Accomplishment Summary ................................ 2 9
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary for Each Airplane ................................. 3 1 1 . K i t s / P a r t s : ........................................... 3 1
2. Parts and Materials Supplied by the Operator: ........................ 3 1
3. Parts Modified and Reidentified: ............................... 3 5
4. Parts Removed and Not Replaced: .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 8 FIGURE 1: SECTION 41 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 1] ....... 5 0 FIGURE 2: SECTION 41 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 2] ....... 5 1 FIGURE 3: SECTION 41 - OPEN HOLE HFEC INSPECTION AT FLOOR PANEL ATTACHMENT FASTENER LOCATIONS .......................................... 5 2 FIGURE 4: SECTION 41 - CLIPNUT MODIFICATION AND SURFACE HFEC INSPECTION ..... 5 5 FIGURE 5: SECTION 41 - FLOOR PANEL ATTACHMENT HOLE MODIFICATION .......... 5 9 FIGURE 6: SECTION 41 - HOLE MEASUREMENTS AFTER CRACK REMOVAL ........... 6 2 FIGURE 7: SECTION 41 - REPAIR STRAP INSTALLATION ....................... 6 5 FIGURE 8: SECTION 41 - UPPER CHORD TRIM ............................ 6 9 FIGURE 9: SECTION 41 - UPPER CHORD REPAIR WITH STRAP ................... 7 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 3 of 163 BOEING SERVICE BULLETIN 747-53A2688
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FIGURE 10: SECTION 41 - UPPER CHORD REPAIR WITH STRAP AND CLIP ............. 7 6 FIGURE 11: SECTION 41 - AFTER-REPAIR INSPECTION FOR LOCATIONS WITH THE STRAP REPAIR .................................................. 8 1 FIGURE 12: SECTION 41 - AFTER-REPAIR INSPECTIONS FOR LOCATIONS WITH UPPER CHORD TRIM REPAIR WITH STRAP OR ANGLE .............................. 8 4 FIGURE 13: SECTION 41 - UPPER CHORD THICK FLANGE REPAIR WITH STRAP (REPAIR 8) . . 87 FIGURE 14: SECTION 41 - UPPER CHORD THICK FLANGE REPAIR WITH ANGLE (REPAIR 9) . . 92 FIGURE 15: SECTION 41 - UPPER CHORD THIN FLANGE REPAIR WITH STRAP (REPAIR 11) . . . 97 FIGURE 16: SECTION 41 - UPPER CHORD THIN FLANGE REPAIR WITH ANGLE (REPAIR 12) . . 102 FIGURE 17: SECTION 41 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 3] ...... 1 0 7 FIGURE 18: SECTION 44 - UPPER DECK FLOOR BEAM INSPECTION AREA [Group 1] ...... 1 0 8 FIGURE 19: SECTION 44 - OPEN HOLE HFEC INSPECTION AT FLOOR PANEL ATTACHMENT FASTENER LOCATIONS [Group 1] .................................... 1 0 9 FIGURE 20: SECTION 44 - CLIPNUT MODIFICATION AND SURFACE HFEC INSPECTION [Group 1] . 112 FIGURE 21: SECTION 44 - FLOOR PANEL ATTACHMENT HOLE MODIFICATION [Group 1] .... 1 1 6 FIGURE 22: SECTION 44 - HOLE MEASUREMENTS AFTER CRACK REMOVAL [Group 1] ..... 1 1 9 FIGURE 23: SECTION 44 - REPAIR STRAP INSTALLATION [Group 1] ................ 1 2 2 FIGURE 24: SECTION 44 - UPPER CHORD TRIM [Group 1] ...................... 1 2 6 FIGURE 25: SECTION 44 - UPPER CHORD REPAIR WITH STRAP [Group 1] ............ 1 2 9 FIGURE 26: SECTION 44 - UPPER CHORD REPAIR WITH STRAP AND CLIP [Group 1] ...... 1 3 3 FIGURE 27: SECTION 44 - UPPER CHORD THICK FLANGE REPAIR WITH STRAP (REPAIR 8) [Group 1 ] ................................................ 1 3 8 FIGURE 28: SECTION 44 - UPPER CHORD THICK FLANGE REPAIR WITH ANGLE (REPAIR 9) [Group 1 ] ................................................ 1 4 3 FIGURE 29: SECTION 44 - UPPER CHORD THIN FLANGE REPAIR WITH STRAP (REPAIR 11) [Group 1] ................................................. 1 4 8 FIGURE 30: SECTION 44 - UPPER CHORD THIN FLANGE REPAIR WITH ANGLE (REPAIR 12) [Group 1] ................................................. 1 5 3 FIGURE 31: SECTION 44 - AFTER-REPAIR INSPECTION FOR LOCATIONS WITH THE STRAP REPAIR [Group 1] ............................................ 1 5 8 FIGURE 32: SECTION 44 - AFTER-REPAIR INSPECTIONS FOR LOCATIONS WITH UPPER CHORD TRIM REPAIR WITH STRAP OR ANGLE [Group 1] ........................ 1 6 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 4 of 163 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 1: September 19, 2012 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 2009-10-06 and AD 2004-07-22 R1 are related to this service bulletin.
Group 1: More work is necessary on airplane(s) inspected or changed in accordance with the original issue of this service bulletin. Inspection of the Section 44 upper deck floor beam upper chords from Station (STA) 1000 to STA 1100 is necessary. Continue to do inspections of the Section 41 upper deck floor beam upper chords.
No more work is necessary to change any repairs installed in accordance with the original issue of this service bulletin. Replace the upper deck floor beam upper chords at the compliance time given in paragraph 1.E., Compliance.
Group 2-3: No more work is necessary on airplane(s) inspected or changed in accordance with the original issue of this service bulletin. Continue to do inspections of the Section 41 upper deck floor beam upper chords. No more work is necessary to change any repairs installed in accordance with the original issue of this service bulletin. Replace the upper deck floor beam upper chords at the compliance time given in paragraph 1.E., Compliance.
REASON FOR REVISION This revision is sent to add inspections and repair of the Section 44 upper deck floor beam upper chords from STA 1000 to STA 1100 and also to add replacement of the upper deck floor beam upper chords at the time given in paragraph 1.E., Compliance.
These sections were changed:
1. In Summary: Updated Background, Action, Compliance, Manpower, and Summary illustration. Also, added Planning Data table.
2. Paragraph 1.A., Effectivity: Airplanes RT021, RT031, RT032, RT033, RT061, RT161, RT164, RT461, RT519, RT526, RT530, RT576, RT577, RT578, RT579, RT642, RT752 and RT837 are moved from group 1 to group 2. Airplanes RT631, RT632, RT743 and RT876 are moved from group 1 to new group
3. Group 1 configurations are removed.
3. Paragraph 1.C., Reason: Revision information is added.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 5 of 163
4. Paragraph 1.D., Description: Section 44 access information is added and maintenance zone tables are changed for group 1 airplanes.
5. Paragraph 1.E., Compliance: AD information is added. After-modification and after-repair inspection requirements are clarified in compliance tables 1 and 2. Some after repair/modification inspection compliance times are changed. Repairs are numbered. Compliance tables 3 and 4 are added for the inspection, repair and after-repair inspection of Section 44 upper deck floor beam upper chords.
Compliance table 5 has been added for upper deck floor beam upper chord replacement.
6. Paragraph 1.F., Approval: New approval information is added.
7. Paragraph 1.G., Manpower: Manpower estimates are added for Section 44 inspections.
8. Paragraph 1.H., Weight and Balance Changes: Weight and balance information is added.
9. Paragraph 1.J., References: An AD is added to existing data.
10. Paragraph 1.K., Publications Affected: Damage Tolerance Inspection information is added.
11. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Part information is added for Section 44 repairs.
12. Paragraph 3.A., General Information: Notes are added.
13. Paragraph 3.B., Work Instructions: Modification and repair options are clarified. Repairs are added to PART 2 table 2 for upper chords made from BAC1506-2441 extrusion. After repair/modification inspection instructions are clarified. Existing repairs are numbered. Instruction is added for the inspection, repair and after-repair inspection of Section 44 upper deck floor beam upper chords.
14. Figure 8: Instruction is added to measure the depth of the trim.
15. Figures 13 to 16: New figures are added for the repair of upper chords made from BAC1506-2441 extrusion.
16. Figure 17: New figure added to show the inspection area for Large Cargo Freighter (LCF) configuration airplanes.
17. Figures 18 to 32: New figures are added for the inspection, repair and after-repair/modification inspection of Section 44 upper deck floor beam upper chords.
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 August 21, 2008Original Issue:
September 19, 2012Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 6 of 163 BOEING SERVICE BULLETIN 747-53A2688
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2688Original Issue: August 21, 2008 Revision 1: September 19, 2012 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 service bulletin gives instructions to do inspections of the floor panel attachment fastener holes in the Section 41 and Section 44 upper deck floor beam upper chords for fatigue cracks. 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 1: September 19, 2012 7 of 163
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.
Boeing Service Related Problem (SRP) 747-SRP-53-0293 and 747-SRP-53-0353 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.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 8 of 163 BOEING SERVICE BULLETIN 747-53A2688
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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. On Group 3 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 during modification 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.
EFFECTIVITY All 747-400 and 747-400D airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-10-06 is 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 Large Cargo Freighter Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 9 of 163 BOEING SERVICE BULLETIN 747-53A2688
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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 1: September 19, 2012 10 of 163 BOEING SERVICE BULLETIN 747-53A2688
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BOEING SERVICE BULLETIN 747-53A2688
ALERT ALERT STA 1100 STA 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 460
AREA SIMILAR 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 COMMON TO THE UPPER DECK FLOOR BEAM UPPER CHORDS.
> FWD B-B 1454601 (TYPICAL) Original Issue: August 21, 2008 Revision 1: September 19, 2012 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2688 Work - See page 1 for details. 11 of 163
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2008 747-53A2688Revision 1: September 19, 2012 12 of 163 BOEING SERVICE BULLETIN 747-53A2688