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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2784 Original Issue: August 27, 2009 Revision 2: August 20, 2015 ATA System: 5310 SUBJECT: FUSELAGE - Main Frame - STA 320 Crown Frame - Web Inspection and 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 © 2009 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Unpublished Work.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 27, 2009 747-53A2784Revision 2: August 20, 2015 1 of 248
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 2 of 248 BOEING SERVICE BULLETIN 747-53A2784
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Table of Contents
Revision Transmittal Sheet5
S u m m a r y9
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 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 6 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F . A p p r o v a l ............................................... 2 1 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 3 I. Electrical Load Data ......................................... 2 3 J . R e f e r e n c e s .............................................. 2 3
1. Existing Data: ......................................... 2 3
2. Data Supplied with this Service Bulletin: ........................... 2 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 4 K. Publications Affected ........................................ 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 5 M. Software Accomplishment Summary ................................ 2 5
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 7 1 . K i t s / P a r t s ............................................ 2 7
2. Parts and Materials Supplied by the Operator ........................ 3 8
3. Parts Modified and Reidentified ................................ 3 8
4. Parts Removed and Not Replaced .............................. 3 9 D. Parts Necessary to Change Spares ................................. 3 9 E. Special Tooling - Price and Availability ............................... 3 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 1 A. GENERAL INFORMATION ..................................... 4 1 B. WORK INSTRUCTIONS ....................................... 4 3 FIGURE 1: STA 300 TO STA 340 CROWN - ACCESS .......................... 4 8 FIGURE 2: STA 320 CROWN FRAME - WEB THICKNESS MEASUREMENT [Group 1, Configuration 1, 3] .................................................. 5 1 FIGURE 3: STA 320 CROWN FRAME - INSPECTION [Group 1, Configuration 1, 3] .......... 5 3 F I G U R E 4 : D E L E T E D ............................................ 5 7 FIGURE 5: STA 320 CROWN FRAME - WEB INSPECTION [Group 1, Configuration 1, 3] ....... 5 8 FIGURE 6: STA 300 TO STA 340 CROWN - ACCESS PANEL REMOVAL ............... 6 3 FIGURE 7: STA 320 CROWN FRAME - STRAP, ANGLE, TEE, STIFFENER, CLIP AND BRACKET R E M O V A L........................................... 6 9 FIGURE 8: STA 320 CROWN FRAME - LOWER CHORD REMOVAL .................. 8 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 9: STA 320 TO STA 340 CROWN - LEFT SIDE INTERCOSTAL REMOVAL ........ 1 0 0 FIGURE 10: STA 320 TO STA 340 CROWN - RIGHT SIDE INTERCOSTAL REMOVAL ........ 1 0 6 FIGURE 11: STA 320 CROWN FRAME - WEB REMOVAL ........................ 1 1 2 FIGURE 12: STA 320 CROWN FRAME - LOWER CHORD INSPECTION ............... 1 1 8 FIGURE 13: STA 320 CROWN FRAME - WEB INSTALLATION ..................... 1 2 3 FIGURE 14: STA 320 TO STA 340 CROWN - RIGHT SIDE INTERCOSTAL INSTALLATION ..... 1 3 1 FIGURE 15: STA 320 TO STA 340 CROWN - LEFT SIDE INTERCOSTAL INSTALLATION ...... 1 3 9 FIGURE 16: STA 320 CROWN FRAME - LOWER CHORD AND SPLICE INSTALLATION ...... 1 4 7 FIGURE 17: STA 320 CROWN FRAME - DRIPSHIELD BRACKET MODIFICATION OR FABRICATION . 161 FIGURE 18: STA 320 CROWN FRAME - STRAP, ANGLE, TEE STIFFENER, CLIP AND BRACKET INSTALLATION ........................................ 1 6 4 FIGURE 19: STA 320 TO STA 340 CROWN - INTERCOSTAL, TEE AND STRAP INSTALLATION . . 191 FIGURE 20: STA 300 TO STA 340 CROWN - ACCESS PANEL INSTALLATION ........... 2 0 4 FIGURE 21: STA 300 TO STA 340 CROWN - CLOSE ACCESS ..................... 2 1 1 FIGURE 22: STA 300 TO STA 340 CROWN - ACCESS PANEL REMOVAL .............. 2 1 4 FIGURE 23: STA 320 CROWN FRAME - POST WEB REPLACEMENT INSPECTIONS ........ 2 2 0 FIGURE 24: STA 300 TO STA 340 CROWN - ACCESS PANEL INSTALLATION ........... 2 2 3 FIGURE 25: STA 320 CROWN FRAME - UPPER CHORD AND SKIN FASTENER REMOVAL .... 2 2 9 FIGURE 26: STA 320 CROWN FRAME - UPPER CHORD AND SKIN FASTENER INSTALLATION . 233 FIGURE 27: STA 320 CROWN FRAME - WEB WITH REPAIR DOUBLER - UPPER CHORD AND LOWER CHORD INSPECTION [Group 1, Configuration 1, 3] .................... 2 3 8 FIGURE 28: STA 320 CROWN FRAME - FINISH APPLICATION .................... 2 4 1 APPENDIX A: 015U1848-1 TOP KIT - PARTS LIST AND FIGURE KITS ................. 2 4 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 4 of 248 BOEING SERVICE BULLETIN 747-53A2784
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2784Original Issue: August 27, 2009 Revision 2: August 20, 2015 ATA System: 5310 SUBJECT: FUSELAGE - Main Frame - STA 320 Crown Frame - Web Inspection and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive (AD) AD 2012-22-02 is related to this service bulletin.
Effects of this Revision on airplanes on which the Original Issue or Revision 1 was previously done:
ActionConditionGroup No further action required.Web thickness is greater than 0.145 inch.
Group 1, Configuration 2 Do web replacement at the time given in Paragraph 1.E., Compliance.
Web thickness is less than 0.078 inch, or greater than or equal to
0.084 inch and less than or equal to
0.135 inch.
Group 1, Configuration 2
REASON FOR REVISION This revision is sent to include a greater range of thicknesses of the Body Station (STA) 320 crown frame web for which work is required in accordance with this service bulletin. In previous issues of this bulletin, there was no work included for airplanes with a STA 320 crown frame web thickness less than 0.078 inch or between
0.084 and 0.135 inch. Since the release of Revision 1 of this service bulletin, Operators have reported that their airplanes had STA 320 crown frame web thicknesses that did not fall within the ranges given in Revision 1 of this service bulletin.
These sections were changed:
1. In Background, in the Summary section, the Summary Evaluation Table and a second Boeing Service Related Problem (SRP) were added.
2. In Action, in the Summary section, revised to include revised work and match the Description section.
3. In Compliance, in the Summary section, included a reference to the AD associated with this service bulletin.
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Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 5 of 248
4. In Manpower, in the Summary section, task hours and elapsed hours changed.
5. The Summary Illustration, in the Summary section, the range of STA 320 crown frame web thicknesses and applicable work updated.
6. In Paragraph 1.A.1., Effectivity, added the D6 document paragraph and the effectivity divided into configurations.
7. In Paragraph 1.C., Reason, paragraph added to explain the reason for the revised work in Revision 2.
8. In Paragraph 1.D., Description, the range of STA 320 crown frame web thicknesses and applicable work updated.
9. In Paragraph 1.E., Compliance, included a reference to the AD associated with this service bulletin.
Added statement to refer to Accomplishment Instructions for required actions. The range of STA 320 crown frame web thicknesses and applicable work is updated in Table 1, Table 2 and Table 3. Added new Table 5 for airplanes with STA 320 crown frame web thicknesses that did not fall within the ranges given in the Original Issue or Revision 1.
10. In Paragraph 1.F., Approval, added AMOC statement.
11. In Paragraph 1.G., Manpower, added new task figures.
12. In Paragraph 1.J.1., Existing Data, added a reference to the AD associated with this service bulletin and references to Boeing Service Letters, FAA ADs and Aircraft Maintenance Manuals.
13. In Paragraph 1.K., Publications Affected, added Illustrated Parts Catalog reference.
14. In Paragraph 1.M., Software Accomplishment Summary revised.
15. In Paragraph 2.C.1, Kits/Parts, added a note to clarify a countersunk washer.
16. In Paragraph 2.C.2, Parts and Materials Supplied by the Operator, added two optional parts.
17. In Paragraph 3.B., Work Instructions, revised the general notes in accordance with new requirements.
18. In Paragraph 3.B., Work Instructions, added a range of STA 320 crown frame web thicknesses and applicable work.
19. Figure 8, increased the maximum allowed cut width on the lower chord.
20. Figure 13, added note for replacing missing fasteners.
21. Figures 14 through 16, 18, and 19, added optional nut and washer for the existing collar.
22. Figure 16 and 18 removed the requirement to install fasteners on the near side.
23. In Figure 18 and 19, revised the fastener code tables to clarify a countersunk washer.
24. In Figure 18, sheets 12 and 13, revised fastener codes to specify the direction of installation.
25. Figure 19, revised sheet 2, 3, and 4, to incorporate step number changes.
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26. Figure 27, added figure to show inspection areas specific to STA 320 crown frame webs with repair doubler installed.
27. Figure 28, added figure for paint application.
28. In Appendix A, revised to clarify a countersunk washer.
The data given in Alternative Method of Compliance Notice 747-53A2784 AMOC 01 is included in this 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 27, 2009Original Issue:
September 14, 2011Revision 1:
August 20, 2015Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 7 of 248 BOEING SERVICE BULLETIN 747-53A2784
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 8 of 248 BOEING SERVICE BULLETIN 747-53A2784
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2784Original Issue: August 27, 2009 Revision 2: August 20, 2015 ATA System: 5310 SUBJECT: FUSELAGE - Main Frame - STA 320 Crown Frame - Web Inspection and 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 Boeing has determined that the web of the STA 320 crown frame on some 747-400 airplanes may not be the correct design thickness and the frame assembly could be missing fasteners. If the web is not the correct thickness or if the frame assembly is missing fasteners, cracks could exist. If crown frame cracks exist and are not found, the cracks could grow and lead to complete fracture of the STA 320 crown frame assembly. Complete fracture of the crown frame assembly may result in damage to the skin and in-flight decompression of the airplane.
During production an error was made on early 747-400's affecting the thickness of the STA 320 crown frame web, which is located between Left Buttock Line (LBL) 25 and Right Buttock Line (RBL) 25, Water Line (WL)
380. Records indicate that the drawing was revised in September 1988 to increase the STA 320 crown frame web thickness to 0.14 inch for 747-400 airplanes, however this change was not implemented in production until September 1992. The result of this error was the continued installation of a 0.08 inch thick web instead of a 0.14 inch thick STA 320 crown frame web. If the 0.08 inch thick web is not replaced it could crack due to fatigue.
Boeing has also had a report of missing fasteners common to the web.
Initially, two operators informed Boeing of a crown frame web crack at LBL 15.0, STA 320. The cracks were both 0.65 inches in length and were reported after 9,354 flight cycles on one airplane and 12,851 flight cycles on the other airplane. Further investigation revealed that in both cases the web was made from 0.08 inch thick material and did not conform to production drawings. Also, an operator has reported missing fasteners from locations common to the frame web and lower chord on the first delivered 747-400 after 10,317 flight cycles.
This airplane also had a web made from 0.08 inch thick material and did not conform to production drawings.
Since the Original Issue of this service bulletin, Boeing has received three more reports of STA 320 crown frame web cracking on 747-400 airplanes with a 0.08 inch thick web. The reports were of a crack (length not specified) reported at 9,456 flight cycles, a 0.65 inch crack reported at 29,866 flight cycles and a 0.85 inch crack reported at 29,956 flight cycles.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 9 of 248
Accomplishment of the work given in this service bulletin will determine if the web of the STA 320 crown frame is the correct design thickness and if fasteners are missing from the web. If the web is not the correct thickness, or is missing fasteners, this service bulletin provides inspections to find possible cracks in the STA 320 crown frame. This service bulletin also provides instructions for replacement of the STA 320 crown frame web if it is not the correct design thickness.
747-SRP-53-0319 and 747-SRP-53-0480 are related to this service bulletin.
As a part of a service bulletin validation program, this inspection and change was completed on airplane RT437 by Service Bulletin 747-53A2784 Original Issue before the release of Revision 1 of this service bulletin. The inspection and change completed on airplane RT437 by Service Bulletin 747-53A2784 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane RT437 has the configuration of a Group 1 airplane.
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., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications 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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-93RS) Group 1, Configuration 1:
Airplanes that have been inspected in accordance with the Original Issue or Revision 1 of this service bulletin, have a web of thickness greater than or equal to 0.078 inch and less than or equal to 0.083 inch, which remains installed: do web replacement. For airplanes with a replaced web: do repetitive detailed inspections of the web, upper chord, lower chord and lower chord splice for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair. Airplanes with an original 0.136-0.145 inch thick web: no further action is required.
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Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 10 of 248 BOEING SERVICE BULLETIN 747-53A2784
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Group 1, Configuration 2:
Airplanes that have had the web thickness measured in accordance with the Original Issue or Revision 1 of this service bulletin, have a web thickness less than 0.078 inch, or greater than or equal to 0.084 inch and less than or equal to 0.135 inch, which remains installed: do web replacement. After the web is replaced, do repetitive detailed inspections of the web, upper chord, lower chord and lower chord splice for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair. Airplanes with an original web with thickness greater than 0.145 inch: no further action is required.
Group 1, Configuration 3:
Measure the thickness of the STA 320 crown frame web. Airplanes that have not had the inspection done in accordance with the Original Issue or Revision 1 of this service bulletin with a web thickness less than 0.136 inch and no repair doubler installed on the web: do a detailed inspection for any crack and a general visual inspection for missing fasteners of the STA 320 crown frame from LBL 30.0 to RBL 30.0. If any crack is found in the web, do web replacement. If any crack is found in the upper chord or lower chord, contact The Boeing Company for repair instructions and do the repair. If no crack is found in the web, do web replacement, or, do a High Frequency Eddy Current (HFEC) inspection of the web, and if no crack is found, the web can be replaced at a later time. Install any missing fasteners. After a web is replaced, do repetitive detailed inspections of the web, upper chord, lower chord, and lower chord splice for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair. Airplanes that have not had the inspection done in accordance with the Original Issue or Revision 1 of this service bulletin with a web thickness less than 0.136 inch and a repair doubler installed on the web: do a detailed inspection for any crack in the upper chord and lower chord and a general visual inspection for missing fasteners of the STA 320 crown frame from LBL 30.0 to RBL 30.0.
If any crack is found in the upper chord or lower chord, contact The Boeing Company for repair instructions and do the repair. Install any missing fasteners. Replace the web. After a web is replaced: do repetitive detailed inspections of the web, upper chord, lower chord, and lower chord splice for any crack. If any crack is found, contact The Boeing Company for repair instructions and do the repair. Airplanes with a web thickness greater than or equal to 0.136 inch: no further action is required.
EFFECTIVITY 747-400/-400D/-400F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-22-02 is related to this service bulletin.
The effective date of AD 2012-22-02 is December 26, 2012.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
128.85218.85All airplanes Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 27, 2009 747-53A2784Revision 2: August 20, 2015 11 of 248 BOEING SERVICE BULLETIN 747-53A2784
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BOEING SERVICE BULLETIN 747-53A2784
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MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
MEASURE THE THICKNESS OF THE STA 320 CROWN FRAME WEB. IF WEB THICKNESS IS 0.136 INCH OR GREATER, NO FURTHER ACTION IS REQUIRED.
DO POST STA 320
CROWN FRAME WEB RBL REPLACEMENT INSPECTION 7.5 BL LBL
7.5
IF WEB THICKNESS IS LESS THAN 0.136 INCH,
INSTALL A NEW FRAME WEB. INSTALL ANY
MISSING FASTENERS STA 320
IF ANY CRACK IS FOUND IN THE UPPER
CHORD OR LOWER CHORD, CONTACT THE
BOEING COMPANY FOR REPAIR INSTRUCTIONS AND DO THE REPAIR.
ALBL
15.0 SOME STRUCTURE NOT SHOWN FOR CLARITY 1703583 Original Issue: August 27, 2009 Revision 2: August 20, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2784 Work - See page 1 for details. 12 of 248