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Commercial Airplanes 747 Service Bulletin Number: 747-53A2747 Original Issue: July 08, 2010 Revision 2: February 22, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspection, Repair and Modification of Section 41 Skin Panels 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 1 of 284
3.0
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 2 of 284 BOEING SERVICE BULLETIN 747-53A2747
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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 0 B. Concurrent Requirements ...................................... 2 1 C. Reason ................................................ 2 1 D. Description .............................................. 2 2 E. Compliance .............................................. 2 4 F. Approval ............................................... 5 3 G. Manpower .............................................. 5 4 H. Weight and Balance Changes .................................... 5 5 I. Electrical Load Data ......................................... 5 5 J. References .............................................. 5 5
1. Existing Data .......................................... 5 5
2. Data supplied with this Service Bulletin ............................ 5 6
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 5 6 K. Publications Affected ........................................ 5 6 L. Interchangeability and Intermixability of Parts ........................... 5 6
2. MATERIAL INFORMATION ........................................ 5 7 A. Material - Price and Availability ................................... 5 7 B. Industry Support Information .................................... 5 7 C. Parts Necessary For Each Airplane ................................. 5 7
1. Kits/Parts ............................................ 5 7
2. Parts and Materials Supplied by the Operator ........................ 5 7
3. Parts Modified and Reidentified ................................ 5 7
4. Parts Removed and Not Replaced .............................. 5 7 D. Parts Necessary to Change Spares ................................. 5 7 E. Special Tooling - Price and Availability ............................... 5 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 9 A. GENERAL INFORMATION ..................................... 5 9 B. WORK INSTRUCTIONS ....................................... 6 0 FIGURE 1: INSPECTION FOR SKIN CRACKS AND DISCREPANT FASTENERS - LEFT SIDE PLUS CENTER LOWER LOBE [Group 1-4, 12] ........................... 6 6 FIGURE 2: INSPECTION FOR SKIN CRACKS AND DISCREPANT FASTENERS - RIGHT SIDE [Group 1-4, 12] ............................................. 7 4 FIGURE 3: INSPECTION FOR SKIN CRACKS AND DISCREPANT FASTENERS - LEFT SIDE PLUS CENTER LOWER LOBE [Group 5-7, 13] ........................... 8 0 FIGURE 4: INSPECTION FOR SKIN CRACKS AND DISCREPANT FASTENERS - RIGHT SIDE [Group 5-7, 13] ............................................. 8 8 FIGURE 5: INSPECTION FOR SKIN CRACKS AND DISCREPANT FASTENERS - LEFT SIDE PLUS CENTER LOWER LOBE [Group 8-11, 14] .......................... 9 4 FIGURE 6: INSPECTION FOR SKIN CRACKS AND DISCREPANT FASTENERS - RIGHT SIDE [Group 8-11, 14] ............................................ 1 0 2
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FIGURE 7: INSPECTION FOR DOUBLER DISBOND - LEFT SIDE PLUS CENTER LOWER LOBE [Group 1-4, 12] ............................................ 1 0 8 FIGURE 8: INSPECTION FOR DOUBLER DISBOND - RIGHT SIDE [Group 1-4, 12] ......... 1 4 0 FIGURE 9: INSPECTION FOR DOUBLER DISBOND - LEFT SIDE PLUS CENTER LOWER LOBE [Group 5-7, 13] ............................................ 1 6 4 FIGURE 10: INSPECTION FOR DOUBLER DISBOND - RIGHT SIDE [Group 5-7, 13] ......... 1 9 0 FIGURE 11: INSPECTION FOR DOUBLER DISBOND - LEFT SIDE PLUS CENTER LOWER LOBE [Group 8-11, 14] ............................................ 2 1 3 FIGURE 12: INSPECTION FOR DOUBLER DISBOND - RIGHT SIDE [Group 8-11, 14] ........ 2 4 5 FIGURE 13: TERMINATING MODIFICATION FOR EXISTING REPAIR DOUBLERS ......... 2 7 5 FIGURE 14: LOCATION OF INSPECTION ZONES ............................ 2 7 6 FIGURE 15: SUPPLEMENTAL INSPECTION FOR DISBONDED DOUBLER [Group 1-7, 12-13] . . . 278 FIGURE 16: SUPPLEMENTAL INSPECTION FOR DISBONDED DOUBLERS [Group 8-11, 14] . . . 282
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 4 of 284 BOEING SERVICE BULLETIN 747-53A2747
Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2747Original Issue: July 08, 2010 Revision 2: February 22, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspection, Repair and Modification of Section 41 Skin Panels This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplanes changed in accordance with Revision 1 of this service bulletin.
NOTE: With Revision 1 to this service bulletin, a supplemental inspection for disbonds was added as a more work requirement for airplanes inspected in accordance with the initial release of this service bulletin.
The compliance time for the supplemental disbond inspection added with Revision 1 to this service bulletin is changed with this revision.
Federal Aviation Administration (FAA) Airworthiness Directives AD 2006-20-02, AD 2006-24-02, and AD 2006-24-05 are related to this service bulletin.
REASON FOR REVISION This revision is sent to give a revised (later) compliance time for the disbond inspection given in this service bulletin. Boeing has conducted additional analysis which shows that the initial disbond inspection can be delayed if crack inspections are accomplished at the intervals specified in this revision.
Also, this revision is sent to give an exemption from the inspections given in this service bulletin to areas where external modification doublers have been installed in accordance with Boeing Service Bulletin 747-53A2367 .
These areas were inadvertantly omitted from the list of exempt areas given in previous releases of this service bulletin.
These sections were changed:
1. Paragraph 1.E., Compliance: Changes have been made to the compliance tables as follows:
Table 1: Changed compliance time for initial disbond inspection from 8,000 to 14,000 flight-cycles and added note (f).
Table 2: Changed compliance time for initial disbond inspection from 8,000 to 14,000 flight-cycles and added note (h).
Table 3: Changed compliance time for initial disbond inspection from 10,000 to 16,000 flight-cycles and added note (h).
Tables 4, 5: Removed the action of a disbond inspection so that it is now not a necessary action for any condition given in these tables.
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 5 of 284
Tables 6, 8: Changed compliance time for the supplemental disbond inspection from 8,000 to 14,000 flight-cycles.
Tables 7, 9: Changed compliance time for the supplemental disbond inspection from 10,000 to 16,000 flight-cycles.
2. Paragraph 3.B., Work Instructions:
Step 1: Areas where external modification doublers have been installed in accordance with Boeing Service Bulletin 747-53A2367 have been added to the list of areas that are exempt from the crack and fastener inspections given in this service bulletin.
Step 2: Areas where external modification doublers have been installed in accordance with Boeing Service Bulletin 747-53A2367 have been added to the list of areas that are exempt from the disbond inspections given in this service bulletin. Also, instruction to inspect for disbonds in areas common to external repair doublers was removed.
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 July 08, 2010Original Issue:
October 12, 2011Revision 1:
February 22, 2012Revision 2:
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 6 of 284 BOEING SERVICE BULLETIN 747-53A2747
Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2747Original Issue: July 08, 2010 Revision 2: February 22, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspection, Repair and Modification of Section 41 Skin Panels
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin tells about the possibility of fatigue cracks in the section 41 body skins caused by disbond of the internal doublers. Fatigue cracks can start in the body skin at fastener holes where internal doublers have disbonded from the skin panel. This service bulletin tells how to find and repair disbonded doublers and fatigue cracks before they can affect flight safety. This service bulletin also tells about the possibility of cracked, deformed, or missing fastener heads in section 41 and it tells how to find and repair this condition which could cause fatigue cracking at adjacent fastener holes. Lastly, this service bulletin tells how the structure in section 41 can be changed so that the inspections given in this service bulletin will not be necessary. Fatigue cracks that are not found and repaired could extend with continued use of the airplane and cause a rapid decompression and loss of structural integrity.
The section 41 skin panels to be inspected have internal bonded doublers which reinforce the skin where it is connected by fasteners to the stringers, frames, intercostals, sills, and shear ties. The function of the internal bonded doublers is to reduce bending stresses in the skin. If an internal doubler becomes disbonded, the bending stresses in the skin will increase in the area of the disbond and this can cause fatigue cracks to start at the fastener holes common to the disbonded doubler.
Boeing Service Bulletins 747-53A2321, 747-53A2409, 747-53A2675 and 747-53A2406 each give instruction to inspect for skin cracks over some of the inspection area given in this service bulletin. Boeing Service Bulletin 747-53A2409 also gives instruction to inspect some section 41 skin panels for disbonded doublers. Boeing Service Bulletin 747-53A2409 instructs to do repeat inspections only if/where disbonded doublers were found with the initial inspection. Based on a report of a disbonded doubler and 10 inch crack found at 21,800 flight-cycles on an airplane that had been inspected as given in Boeing Service Bulletin 747-53A2409, it is now believed that certain section 41 skin panels should be inspected for doubler disbond and cracks over the operational life of the airplane, or until a replacement skin panel is installed.
Boeing has also received two reports of cracked or missing fastener heads found on four airplanes. Cracked and/or missing fastener heads were found at STA 480 and STA 520 between stringers S-8 and S-10 on airplanes with 10,529 and 10,531 flight-cycles. Also, missing fastener heads were found between STA 400 and 420 at stringer S-24AL on airplanes with 28,153 and 28,319 flight-cycles. As a result of these findings, this service bulletin also includes an inspection for cracked, deformed or missing fastener heads.
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 7 of 284
The inspections given in this service bulletin supersede those given in Boeing Service Bulletins 747-53A2321, 747-53A2409, and 747-53A2675. The inspections given in this service bulletin also supersede the section 41 (only) inspections given in Boeing Service Bulletin 747-53A2406. Inspection in accordance with these service bulletins is to be continued until inspection in accordance with this service bulletin is started.
Boeing Service Related Problem (SRP) 747-SRP-53-0297 is related to this service bulletin (SB).
ACTION Specified skin panels in section 41 are to be inspected for cracks and disbonded doublers. The skin panels are to be inspected for cracks at the fasteners common to the frames, stringers, intercostals and shear ties. The inspection for cracks is to be done from outside the airplane using a specified surface HFEC procedure. Also, a Detailed inspection for cracked, deformed or missing countersunk fastener heads is to be made in the same areas inspected for cracks.
The skin panels are also to be inspected for disbonds at the doublers that reinforce the skin where it is fastened to the frames, stringers, intercostals, shear ties and sills. The disbond inspection is to be done from outside the airplane using a specified ultrasonic or thermographic procedure, or alternatively, a Detailed inspection for disbonds can be done from inside the airplane.
Skin panels that have a crack or damaged fastener are to be repaired in accordance with the SRM. Skin panels that have missing fasteners or fasteners with deformed or missing heads are to be repaired in accordance with this service bulletin. Where there is a disbond finding and the disbonded area is crack-free, a disbond repair can be accomplished in accordance with the SRM, or alternatively, only repeat inspections for cracks can be accomplished. Skin panels that have more than a specified amount of disbond are to be replaced within a specified number of flight-cycles.
EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directives FAA AD 2006-24-02, FAA AD 2006-20-02, and FAA AD 2006-24-05 are related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 8 of 284 BOEING SERVICE BULLETIN 747-53A2747
BOEING SERVICE BULLETIN 747-53A2747
MATERIAL INFORMATION None.
INSPECT THE SKIN PANELS IN THE SHADED AREA FOR CRACKS, DISBONDED DOUBLERS, AND CRACKED, MISSHAPED OR MISSING FASTE JER HEADS. INSPECT FOR CRACKS AT THE FASTENERS
COMMON TO THE FRAMES, STRINGERS, INTERCOSTALS AND SHEAR TIES FROM OUTSIDE THE AIRPLANE USING A SPECIFIED HFEC PROCEDURE. • FOR DISBONDS AT THE INTERNAL
DOUBLERS THAT REINFORCE THE SKIN WHERE IT NED TO THE FRAMES, STRINGERS, INTERCOSTALS, SHEAR TIES AND SILLS. INSPEC T FOR DISBONDS FROM OUTSIDE THE AIRPLANE
USING A SPECIFIED ULTRASONIC OR THEMOGRAPHIC PROCEDURE, OR ALTERNATIVELY, DO A DETAILED INSPECTION FOR DISBONDS FROM INSIDE THE AIRPLANE. REPAIR SKIN PANEL CRACKS, DISBONDS, AND DAMAGED FASTENERS IN ACCORDANCE WITH THE SRM. REPLACE SKIN PANELS
WITHIN A SPECIFIED NUMBER OF FLIGHT-CYCLES IF MORE THAN A SPECIFIED AMOUNT OF DISBOND IS FOUND ON THE PANELS.
STA 520 STA 340 _S-6 STA 260 _ S-14 STA 220 STA 520 S-10A 000000000 STA 400 S-34 STA 340 ~ S-6 S-19- • 0 STA 260 S-23- STA 400 STA 460 STA 300 - S-14
PASSENGER AIRPLANE
LEFT SIDE SHOWN, RIGHT SIDE SIMILAR
- S-34 S-19 - S-23 - STA STA 460 400 AIRPLANE WITH NOSE CARGO DOOR 1843133
LEFT SIDE SHOWN, RIGHT SIDE SIMILAR Original Issue: July 08, 2010 Revision 2: February 22, 2012 747-53A2747
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Commercial Airplanes 747 Service Bulletin Number: 747-53A2747 Original Issue: July 08, 2010 Revision 2: February 22, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspection, Repair and Modification of Section 41 Skin Panels
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP Line number 1-200 airplanes that do not have a nose cargo door or Stretched Upper Deck -1 Line number 201-430 airplanes that do not have a nose cargo door or Stretched Upper Deck -2 Line number 431-628 airplanes that do not have a nose cargo door or stretched upper deck -3 Line number 686-1075 airplanes that do not have a nose cargo door or stretched upper deck -4 Line number 201-430 airplanes that have a stretched upper deck-5 Line number 431-628 airplanes that have a stretched upper deck-6 Line number 686-1075 airplanes that have a stretched upper deck-7 Line number 1-200 airplanes that have a nose cargo door-8 Line number 201-430 airplanes that have a nose cargo door-9 Line number 431-628 airplanes that have a nose cargo door-10 Line number 686-1075 airplanes that have a nose cargo door-11
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DESCRIPTIONCONFIGURATIONGROUP Line number 629-685 airplanes that do not have a nose cargo door or stretched upper deck -12 Line number 629-685 airplanes that have a stretched upper deck-13 Line number 629-685 airplanes that have a nose cargo door-14 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 - RA034 1RA101 - RA115 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA259 2RA260 - RA266 1RA301 - RA312 2RA313 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA414 2RA415 - RA418 1RA501 - RA502 1RA521 - RA527 2RA528 1RA532 - RA540 2RA541 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585
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Original Issue: July 08, 2010 747-53A2747Revision 2: February 22, 2012 12 of 284 BOEING SERVICE BULLETIN 747-53A2747