TextPartly OCR
Some pages are OCR from a scan. OCR can misread letters and numbers.
Query with SQL
duckdb -csv -c "SELECT p.page, p.text_source, p.text, f.rights_holder, f.license FROM 'https://openairdocs.org/data/latest/service_document_file_page.parquet' p JOIN 'https://openairdocs.org/data/latest/service_document_file.parquet' f USING (file_sha256) WHERE p.file_sha256 = '7252b3b3a690b0c873244eebb7fbf01593b98d1654c71032c834284a9bcbff4e' ORDER BY p.page"
Prints the whole list as CSV. It reads the release’s Parquet files over HTTPS, so there’s nothing to download first. Install DuckDB to run it.
SELECT p.page, p.text_source, p.text, f.rights_holder, f.license FROM 'https://openairdocs.org/data/latest/service_document_file_page.parquet' p JOIN 'https://openairdocs.org/data/latest/service_document_file.parquet' f USING (file_sha256) WHERE p.file_sha256 = '7252b3b3a690b0c873244eebb7fbf01593b98d1654c71032c834284a9bcbff4e' ORDER BY p.page
Run it at the DuckDB prompt, or in any tool that reads Parquet over HTTPS. More ways to query the release are on Use the data.
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2696 Original Issue: October 16, 2008 Revision 1: April 12, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor Beam Upper Chord and Strap 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 © 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Unpublished Work.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: October 16, 2008 747-53A2696Revision 1: April 12, 2012 1 of 101
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 2 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 1 9 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data Supplied with this Service Bulletin: ........................... 2 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ........................................ 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 4 M. Software Accomplishment Summary ................................ 2 4
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary for Each Airplane ................................. 2 5
1. Kits/Parts: ........................................... 2 5
2. Parts and Materials Supplied by the Operator: ........................ 2 5
3. Parts Modified and Reidentified: ............................... 5 8
4. Parts Removed and Not Replaced: .............................. 5 8 D. Parts Necessary to Change Spares ................................. 5 8 E. Special Tooling - Price and Availability ............................... 5 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 9 A. GENERAL INFORMATION ..................................... 5 9 B. WORK INSTRUCTIONS ....................................... 6 0 FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS (STA 340 - STA 440, STA 500, STA 520) ............................................ 6 5 FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA 520) ............................................ 6 7 FIGURE 3: INSPECTION OF HOLES IN STRUCTURE WHERE UPPER CHORDS WERE REMOVED (STA 340 - STA 440, STA 500, STA 520) ............................. 7 2 FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA 500, STA 520) ......................................... 7 4 FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA 500, STA 520) ......................................... 7 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 3 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS (STA 340 - STA 440, STA 500, STA 520) ...................................... 8 1 FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780) . . 83 FIGURE 8: UPPER DECK FLOOR BEAMS - HOLE INSPECTION ................... 8 6 FIGURE 9: UPPER DECK FLOOR BEAM - UPPER CHORDS - FABRICATION (STA 540 - STA 780) . 88 FIGURE 10: UPPER DECK FLOOR BEAM - UPPER CHORDS - INSTALLATION (STA 540 - STA 780) . 90 Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA
520) ............................................... 9 2 APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780) ...... 9 6 APPENDIX C: SECTION 42 - FASTENER REPLACEMENT GUIDE .................... 1 0 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 4 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2696Original Issue: October 16, 2008 Revision 1: April 12, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor Beam Upper Chord and Strap Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Do the upper chord replacement at body stations 540 through 780 at the compliance time specified in Paragraph
1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2005-07-21, AD 2010-03-05 and AD 2010-07-03 are related to this service bulletin.
REASON FOR REVISION This revision is sent to add replacement instructions for upper deck floor beam upper chords at body stations 540 through 780. Several other changes have also been made.
These sections were changed:
1. Throughout the service bulletin, the words "as given in" have been changed to "in accordance with".
However, this is not considered an important change, therefore, vertical lines have not been added to the left side of the page at locations where only this change was made.
2. In Summary: Updated the Background and Action sections to reflect new work requirements. Also, updated Compliance section with new AD numbers, updated Manpower estimates, and updated Summary illustration.
3. In Paragraph 1.C., Reason: Added reason for new replacement requirements aft of station (STA) 520, and added reference to service letter for Widespread Fatigue Damage (WFD).
4. In Paragraph 1.D., Description: Added summary of new replacement requirements aft of STA 520.
5. In Paragraph 1.E., Compliance: Updated titles of Tables 1 and 2. In Table 2, corrected the "Part" callout in the "Action" column for the "no crack found" condition, and clarified repetitive post-replacement inspection action. Added compliance Tables 3, 4, and 5 for replacement and post-replacement requirements of STA 540 through STA 780. Revised grace period for the initial action in compliance Table 1 to match the grace period given in AD 2010-03-05.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 5 of 101
6. In Paragraph 1.F., Approval: Removed Alternative Method of Compliance (AMOC) statement for Airworthiness Directive (AD) 2006-08-02 that has been superseded. Added AMOC statements for AD 2010-07-03 and AD 2010-03-05. Updated AMOC statements for AD 2005-07-21 and AD 2004-07-22 R1.
7. In Paragraph 1.G., Manpower: Added manpower estimates for replacement of upper deck floor beam upper chords for STA 540 through STA 780.
8. In Paragraph 1.H., Weight and Balance Changes: Removed previous weight and balance information that was entered for Section 41 upper chord replacement. Although the previous revision specified weight and balance changes, it has been determined that accomplishment of this service bulletin will not result in a significant change to the airplane weight and balance.
9. In Paragraph 1.J., References: Updated existing data references and added Section 42 drawings used to prepare the service bulletin.
10. In Paragraph 1.K., Damage Tolerance Based Structural Inspections: Added damage tolerance statement appropriate for this service bulletin.
11. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added parts and materials needed for replacement of upper deck floor beam upper chords at STA 540 through STA 780. Also, revised the upper chord, radius filler, and strap part numbers for stations 340 through 520. Also, removed original size bolt part numbers for stations 340 through 520. Boeing recommends installation of oversize fasteners at all bolt locations.
12. In Paragraph 3.A., General Information: Updated existing general notes and added new general notes.
13. In Paragraph 3.B., Work Instructions: Added "Section 41" to Part 1 through Part 5 and designated these Parts as "Work Package 1: Section 41 Replacement". Clarified post replacement inspection actions and repetitive requirement in Part 4. Added new Part 6 through Part 10 as "Work Package 2: Section 42 Replacement".
14. In Figures 1 through 6: Updated figure titles to reflect the stations where each figure is applicable. Also, clarified/corrected the illustrations in these figures and clarified the instructions and footnotes where necessary.
15. In Figure 2: Upper chord part number for STA 520 has been corrected. Footnote (a) has been revised to clarify to remove/discard any repair, modification, or splice parts that were previously installed on the upper chord as part of a Service Bulletin 747-53A2429 repair or modification. Footnote (d) has been added.
16. In Figure 3: Added step 2 and footnote (b) to clarify requirement to inspect frame where fasteners were removed.
17. In Figure 5: Revised footnote (a) to clarify requirements at existing fastener locations in frames that were previously oversized during accomplishment of Section 41 modification Service Bulletin 747-53-2272. Revised footnote (g) to clarify oversize allowances, and revised footnote (i) to clarify requirement for wet installation of bolts.
18. Figures 7 through 10: Added these new figures for replacement of upper deck floor beam upper chords at STA 540 through STA 780.
19. In Appendix A: Revised the title to reflect the stations where this appendix is applicable.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 6 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
20. Appendix B: Added this new appendix to identify the parts to be replaced and the material used to make replacement parts for STA 540 through STA 780.
21. Appendix C: Added this new appendix as a cross-reference between the production drawing fastener codes and the replacement fasteners shown for Section 42 in Paragraph 2.C.2., Parts and Materials Supplied by the Operator.
The data given in Information Notice 747-53A2696 IN01 is included in this revision. Information Notice 747-53A2696 IN01 was issued to inform operators that the upper chord, radius filler, and strap part numbers shown in "Part Number / Specification" column of the material tables in paragraph 2.C.2., Parts Necessary For Each Airplane of the original issue of the service bulletin are incorrect. The part numbers have been corrected in this revision.
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 October 16, 2008Original Issue:
April 12, 2012Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 7 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 8 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2696Original Issue: October 16, 2008 Revision 1: April 12, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor Beam Upper Chord and Strap Replacement
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 replace the upper chords and straps on the upper deck floor beams at STA 340, STA 360, STA 380, STA 400, STA 420, STA 440, STA 500, and STA 520. Analysis by Boeing indicates that accomplishment of the inspections, repairs, and modifications currently in Service Bulletins 747-53A2420, 747-53A2429, and 747-53A2439 are not adequate to ensure the structural integrity of the affected 7075 aluminum upper deck floor beam upper chords on airplanes that are operated beyond 21,000 total flight-cycles. On these airplanes, Boeing recommends that the affected upper deck floor beam upper chords be replaced as shown in this service bulletin. Cracks in the floor beam upper chords that are not found and repaired could become large and fully sever the floor beam. A severed floor beam can lead to large deflection or deformation of the floor and of the body skin, frames, and stringers and could result in damage to the wire bundles and unintended inputs to the flight control cables which could affect airplane controllability. Adjacent severed floor beams could result in rapid decompression of the airplane, and the loss of structural integrity.
Flight critical wire bundles and control cables are routed through cut outs in the upper deck floor beams.
The affected upper deck floor beam upper chords are made from 7075 aluminum. Boeing has received many reports from operators of upper chord cracks that have been found on the affected upper deck floor beams.
Cracks were found in the floor beam upper chords and straps common to floor panel fastener locations. The airplanes had flown between 16,264 and 23,561 total flight cycles. As a result of these crack reports, Boeing issued Service Bulletin 747-53A2439, "Fuselage Floors Upper Deck Floor Beam Upper Chord Inspection at Floor Panel Attachment Fastener Holes". In addition, Boeing has received many reports of cracks in the affected floor beam upper chords at the fastener locations where the upper chords attach to the body frames. As a result of these crack reports, Boeing issued Service Bulletins 747-53A2420, "Fuselage Floors Upper Deck Floor Beam Web and Chord Crack Inspection" and 747-53A2429, "Fuselage Floors Upper Deck Floor Beam Modification and Repair".
Boeing Service Related Problem (SRP) 747OP-SRP-53-0238 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 9 of 101
Subsequent to the original issue of this service bulletin, Boeing has determined that upper deck floor beam upper chord replacement is required at body stations aft of station (STA) 520. Upper deck floor beam upper chords aft of STA 520 are made from 2024 aluminum. These upper chords have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). Ongoing inspection of this structure is not sufficient to maintain an acceptable level of safety, and replacement of the structure is required.
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/PartsNoBoeing supplied Kits/Parts Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts and Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Get access to upper deck floor beams from STA 340 to STA 440, and at STA 500 and STA 520 from the upper deck. Remove the floor beam upper chords, angles, straps and radius fillers. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and repair if any crack is found. Fabricate new upper chords, straps, angles and radius fillers. Install the new floor beam upper chords, angles, straps and radius fillers. Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install all equipment and panels removed for access.
Group 1:
Get access to upper deck floor beams from STA 540 to STA 740 from the upper deck. Remove the floor beam upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and do a repair if any crack is found. Fabricate and install new floor beam upper chords. Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install all equipment and panels removed for access.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 10 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
Group 2:
Get access to upper deck floor beams from STA 540 to STA 780 from the upper deck. Remove the floor beam upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and do a repair if any crack is found. Fabricate and install new floor beam upper chords. Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install all equipment and panels removed for access.
EFFECTIVITY All 747-200C/200F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives 2004-07-22 R1, 2005-07-21, 2010-03-05 and 2010-07-03 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Work Package 1 Elapsed HoursTotal Task HoursAirplanes
135.25541.00Group 1 and 2 Work Package 2 Elapsed HoursTotal Task HoursAirplanes
100.00400.00Group 1
115.81463.25Group 2
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 16, 2008 747-53A2696Revision 1: April 12, 2012 11 of 101 BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2696
ALERT ALERT SEE GROUP1 AND 2: REMOVE AND DISCARD
EXISTING UPPER CHORDS AND STRAPS AT STATION 340 THRU 440, AND AT STATIONS 500 AND 520. MAKE AND
INSTALL NEW UPPER CHORDS AND STRAPS GROUP1: REMOVE AND DISCARD EXISTING UPPER CHORDS AT STATION 540 THRU
740. MAKE AND INSTALL NEW UPPER CHORDS FLOOR PANEL GROUP2: REMOVE AND DISCARD EXISTING UPPER CHORDS AT STATION 540 THRU
780. MAKE AND INSTALL NEW UPPER CHORDS
UPPER CHORD
WEB - DO HFEC OPEN HOLE INSPECTIONS
OF ALL ACCESSED HOLES IN THE WEB AND FRAMES.
LOWER CHORD UP
TYPICAL UPPER
DECK FLOOR BEAMS DINBD 1423286 Original Issue: October 16, 2008 Revision 1: April 12, 2012 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2696 Work - See page 1 for details. 12 of 101