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Commercial Airplane Group 747 Service Bulletin ALERT Number: 747-53A2751 Date: October 09, 2008 ATA System: 5312 SUBJECT: FUSELAGE - Section 42 - Inspection of Non-Stretched Upper Deck Airplanes for Installation of Fasteners at the Stringer to Stringer Clip Joint.
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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, MD-10, MD-11, MD-80, MD-88, MD-90, 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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 1 of 111
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 2 of 111 BOEING SERVICE BULLETIN 747-53A2751
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F . Approval ............................................... 1 9 G. Manpower .............................................. 1 9 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1
1. Existing Data .......................................... 2 1
2. Data supplied with this Service Bulletin ............................ 2 1
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 1 K. Publications Affected ......................................... 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 2
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary For Each Airplane ................................. 2 3
1. Kits/Parts ............................................ 2 3
2. Parts and Materials Supplied by the Operator ........................ 2 3
3. Parts Modified and Reidentified ................................ 2 3
4. Parts Removed and Not Replaced .............................. 2 3 D. Parts Necessary to Change Spares ................................. 2 3 E. Special Tooling - Price and Availability ............................... 2 3 F . Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: INSPECTION FOR MISSING FASTENERS AT STRINGER TO STRINGER CLIP JOINTS (LEFT SIDE) .............................................. 3 2 FIGURE 2: INSPECTION FOR MISSING FASTENERS AT STRINGER TO STRINGER CLIP JOINTS (RIGHT SIDE) ......................................... 3 5 FIGURE 3: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO FRAME SPLICE ON TYPICAL FRAME (LEFT SIDE) ................................ 3 8 FIGURE 4: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO FRAME SPLICE ON TYPICAL FRAME (RIGHT SIDE) ............................... 4 2 FIGURE 5: INSPECTION OF FRAME AND SKIN STRUCTURE - END OF FRAME SPLICE (LEFT SIDE) .................................................. 4 6 FIGURE 6: INSPECTION OF FRAME AND SKIN STRUCTURE - END OF FRAME SPLICE (RIGHT SIDE) .................................................. 5 1 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 3 of 111 BOEING SERVICE BULLETIN 747-53A2751
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FIGURE 7: INSPECTION OF FRAME AND SKIN STRUCTURE - END OF STEPPED FRAME SPLICE (LEFT SIDE) [Group 4-6] .................................... 5 6 FIGURE 8: INSPECTION OF FRAME AND SKIN STRUCTURE - END OF STEPPED FRAME SPLICE (RIGHT SIDE) [Group 4-6] ................................... 6 1 FIGURE 9: INSPECTION OF FRAME AND SKIN STRUCTURE - MIDDLE OF SHORT FRAME SPLICE (LEFT SIDE) [Group 1-3, 7] .................................. 6 6 FIGURE 10: INSPECTION OF FRAME AND SKIN STRUCTURE - MIDDLE OF SHORT FRAME SPLICE (RIGHT SIDE) [Group 1-3, 7] ................................. 7 0 FIGURE 11: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO END OF LONG FRAME SPLICE - INBOARD (LEFT SIDE) ............................... 7 4 FIGURE 12: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO END OF LONG FRAME SPLICE - INBOARD (RIGHT SIDE) .............................. 7 8 FIGURE 13: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO END OF LONG STEPPED FRAME SPLICE - INBOARD (LEFT SIDE) [Group 4-6] ................... 8 2 FIGURE 14: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO END OF LONG STEPPED FRAME SPLICE - INBOARD (RIGHT SIDE) [Group 4-6] .................. 8 7 FIGURE 15: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO END OF LONG FRAME SPLICE - OUTBOARD (LEFT SIDE) ............................. 9 2 FIGURE 16: INSPECTION OF FRAME AND SKIN STRUCTURE - ADJACENT TO END OF LONG FRAME SPLICE - OUTBOARD (RIGHT SIDE) ............................ 9 6 FIGURE 17: INSPECTION OF FRAME AND SKIN STRUCTURE - TYPICAL FRAME (LEFT SIDE) . . 100 FIGURE 18: INSPECTION OF FRAME AND SKIN STRUCTURE - TYPICAL FRAME (RIGHT SIDE) . 103 FIGURE 19: INSTALLATION OF MISSING FASTENERS AT STRINGER TO STRINGER CLIP JOINTS (LEFT SIDE) .......................................... 1 0 6 FIGURE 20: INSTALLATION OF MISSING FASTENERS AT STRINGER TO STRINGER CLIP JOINTS (RIGHT SIDE) ......................................... 1 0 9 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 4 of 111 BOEING SERVICE BULLETIN 747-53A2751
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Commercial Airplane Group 747 Service Bulletin ALERT SummaryNumber: 747-53A2751Date: October 09, 2008 ATA System: 5312 SUBJECT: FUSELAGE - Section 42 - Inspection of Non-Stretched Upper Deck Airplanes for Installation of Fasteners at the Stringer to Stringer Clip Joint.
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 Accomplishment of work given in this Service Bulletin will make sure that necessary fasteners are installed at stringer to stringer clip joints. These fasteners are located on the left and right side of Stringer (S)-10, S-10A, and S-11 at Body Station (STA) 760 through 940 frames. If the fasteners are not installed, fatigue cracking can occur in the adjacent shear ties. The cracks in the shear ties can cause skin cracks and a rapid in-flight decompression.
The stringers are structurally connected to the body frames by stringer clips. The skin is attached to the frame and stringers and shear ties are installed to the skin and frame. Adjacent to S-10, S-10A, and S-11 at STA 760 through 940 frames, there are tension ties that connect the left and right sides of the body structure aft of the upper deck floor.
During a routine maintenance of 747-200F airplanes, two operators reported findings of broken and cracked shear ties on STA 820 frame between S-10AL and S-11L. Also cracks were found on the frame doubler and frame web near S-11L. More inspection showed missing fasteners at the stringer to stringer clip joint on S-10L at STA 820 frame. The cracks and missing fasteners were found on airplanes that had 16,087 and 16,421 total flight cycles.
Boeing analysis shows that the cracks were caused by increased load on the shear ties because of the missing fasteners in the stringer to stringer clip joint. Boeing investigation shows that a similar cracking could occur in the frames adjacent to the tensions ties if the stringer clip fasteners are not installed.
Accomplishment of the inspection in this Service Bulletin will make sure that the necessary fasteners are installed at the stringer to stringer clip joints at S-10, S-10A, and S-11 at STA 760 through 940 frames.
Boeing Service Related Problem (SRP) 747-SRP-53-0317 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 5 of 111
ACTION Do a General Visual Inspection to make sure that the fasteners are installed at the stringer to stringer clip joints on S-10, S-10A, and S-11 at STA 760 through 940 frames. If the fasteners are installed, then no more work is necessary. If the fasteners are missing, then do Detailed and Surface High Frequency Eddy Current (HFEC) Inspections of the adjacent frame and skin structure for a crack. If no crack is found, then install the missing fasteners. If a crack is found, then do the repair(s) as given in the Structural Repair Manual (SRM) and install the missing fasteners. After the SRM repair(s) do a repetitive Detailed Inspection of the repaired area(s) as given in Paragraph 1.E., Compliance.
EFFECTIVITY Refer to Service Bulletin Paragraph 1.A., Effectivity.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
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 inspection and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Paragraph 2.C.2., Parts and Materials Supplied by the Operator BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 6 of 111 BOEING SERVICE BULLETIN 747-53A2751
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BOEING SERVICE BULLETIN 747-53A2751
ALERT ALERT STA 940 STA 760
SLOPING SHEAR WEB (2 LOCATIONS)
TENSION TIE (TYPICAL) _ FRAME (TYPICAL) S-9R S-9L S-10L S-10R S-10AR S-10AL S-11R S-11L — STA 760 FWD STA 940 HORIZONTAL SHEAR WEB (2 LOCATIONS) 1495226 October 09, 2008 747-53A2751 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 111
BOEING SERVICE BULLETIN 747-53A2751
ALERT ALERT FRAME (TYPICAL)
STRINGER (TYPICAL)
DO A GENERAL VISUAL INSPECTION
FOR MISSING FASTENERS (4 LOCATIONS) AT EACH STRINGER TO
STRINGER CLIP JOINTS ON LEFT AND RIGHT SIDES OF S-10, S-10A AND S-11 AT STA 760 THROUGH 940.
STRINGER CLIP (TYPICAL) 1495231 October 09, 2008 747-53A2751 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 111
Commercial Airplane Group 747 Service Bulletin ALERT Number: 747-53A2751 Date: October 09, 2008 ATA System: 5312 SUBJECT: FUSELAGE - Section 42 - Inspection of Non-Stretched Upper Deck Airplanes for Installation of Fasteners at the Stringer to Stringer Clip Joint.
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.
DESCRIPTIONCONFIGURATIONGROUP 747-100/-200B airplanes with a short splice frame at STA 760 and STA 780. This excludes Boeing-Modified Special Freighter and Boeing-Modified CRAF airplanes.
-1 Boeing-Modified Special Freighter airplanes with a short splice frame at STA 760 and STA 780.
-2 Boeing-Modified CRAF airplanes with a short splice frame at STA 760 and STA 780.
-3 In passenger configuration1 In freighter configuration2 747-100/-100B/-200B/-SR airplanes with a long splice frame at STA 760 and STA 780. This excludes Boeing-Modified Special Freighter and Boeing-Modified Special CRAF airplanes.
-4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 9 of 111
DESCRIPTIONCONFIGURATIONGROUP Boeing-Modified Special Freighter airplanes with a long splice frame at STA 760 and STA 780.
-5 747-200C (Convertible) and Boeing-Modified CRAF airplanes with a long splice frame at STA 760 and STA 780.
-6 In passenger configuration1 In freighter configuration2 747-200F airplanes with a long splice frame at STA 760 and short splice frame at STA 780.
-7 Airplane Models:
747-100, 747-100B, 747-200B, 747-200C, 747-200F , 747SR GroupVariable Number 1RA001 3RA002 1RA003 - RA005 3RA006 1RA007 - RA010 3RA011 1RA012 - RA014 3RA015 1RA016 - RA025 2RA026 1RA027 3RA028 2RA029 3RA030 1RA031 - RA032 2RA033 1RA034 2RA101 - RA103 1RA104 - RA110 2RA111 - RA112 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1RA113 - RA115 2RA161 - RA162 5RA163 4RA164 1RA201 - RA203 1RA216 4RA217 1RA245 4RA246 1RA251 - RA255 4RA256 - RA266 1RA301 - RA306 4RA307 - RA318 1RA351 - RA360 1RA369 - RA371 4RA372 - RA373 6RA401 - RA405 4RA406 - RA418 1RA501 - RA502 1RA521 - RA523 5RA524 4RA525 - RA528 1RA532 - RA534 4RA535 - RA548 1RA551 - RA552 1RA559 - RA560 4RA561 1RA581 - RA582 4RA585 1RA601 - RA602 3RA631 2RA632 3RA633 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 5RA634 - RA635 1RA651 - RA652 1RA671 - RA674 4RA675 - RA677 1RA701 4RA702 1RA721 - RA722 4RA723 - RA731 1RA741 - RA743 4RA744 - RA745 4RA749 - RA750 1RA761 - RA762 1RA781 4RA782 - RA783 6RA784 5RA901 - RA902 4RA903 - RA909 5RA910 - RA916 4RB001 - RB016 2RB041 1RB042 2RB043 1RB044 4RB071 - RB075 1RB101 - RB102 4RB411 - RB413 4RB421 4RB601 - RB603 5RB604 - RB605 4RB606 5RB607 4RB681 - RB695 5RB696 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
October 09, 2008 747-53A2751 12 of 111 BOEING SERVICE BULLETIN 747-53A2751