Boeing ASB 747-53A2785: Revision 1, text

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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2785 Original Issue: February 12, 2009 Revision 1: July 15, 2010 ATA System: 5310 SUBJECT: FUSELAGE - Nose Section: Station 90 to Station 520 - Main Entry Door 1 Upper Main Sill From STA 440 to STA 480 - Inspection and Repair 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: February 12, 2009 747-53A2785Revision 1: July 15, 2010 1 of 63

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Original Issue: February 12, 2009 747-53A2785Revision 1: July 15, 2010 2 of 63 BOEING SERVICE BULLETIN 747-53A2785

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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 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 2 D. Description .............................................. 2 3 E. Compliance .............................................. 2 4 F. Approval ............................................... 2 8 G. Manpower .............................................. 2 9 H. Weight and Balance Changes .................................... 2 9 I. Electrical Load Data ......................................... 3 0 J. References .............................................. 3 0

1. Existing Data .......................................... 3 0

2. Data supplied with this Service Bulletin ............................ 3 0

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 3 1 K. Publications Affected ........................................ 3 1 L. Interchangeability and Intermixability of Parts ........................... 3 1

2. MATERIAL INFORMATION ........................................ 3 3 A. Material - Price and Availability ................................... 3 3 B. Industry Support Information .................................... 3 4 C. Parts Necessary For Each Airplane ................................. 3 4

1. Kits/Parts ............................................ 3 4

2. Parts and Materials Supplied by the Operator ........................ 4 3

3. Parts Modified and Reidentified ................................ 4 3

4. Parts Removed and Not Replaced .............................. 4 3 D. Parts Necessary to Change Spares ................................. 4 3 E. Special Tooling - Price and Availability ............................... 4 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 3

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5 A. GENERAL INFORMATION ..................................... 4 5 B. WORK INSTRUCTIONS ....................................... 4 6 FIGURE 1: LEFT MAIN ENTRY DOOR 1 MAIN UPPER SILL INSPECTION .............. 5 2 FIGURE 2: RIGHT MAIN ENTRY DOOR 1 MAIN UPPER SILL INSPECTION ............. 5 6 FIGURE 3: REPAIRED LEFT MAIN ENTRY DOOR UPPER SILL AFTER-REPAIR INSPECTION . . 60 FIGURE 4: REPAIRED RIGHT MAIN ENTRY DOOR UPPER SILL AFTER-REPAIR INSPECTION . . 62

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Original Issue: February 12, 2009 747-53A2785Revision 1: July 15, 2010 4 of 63 BOEING SERVICE BULLETIN 747-53A2785

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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2785Original Issue: February 12, 2009 Revision 1: July 15, 2010 ATA System: 5310 SUBJECT: FUSELAGE - Nose Section: Station 90 to Station 520 - Main Entry Door 1 Upper Main Sill From STA 440 to STA 480 - Inspection and Repair This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes inspected or repaired in accordance with the original issue of this service bulletin. Continue to do repeated inspections or after-repair inspections at the times given in this service bulletin.

No airplanes were added to the service bulletin effectivity. However, 747-400 airplanes that have been modified by Boeing to the Large Cargo Freighter (LCF) configuration have been moved from Group 3 to new Group 5.

All other 747-400 and 747-400D airplanes have been moved from Group 3 to new Group 6. All 747-400F airplanes have been moved from Group 4 to new Group 7.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2009-NM-035-AD is related to this service bulletin.

REASON FOR REVISION This Alert revision is sent to include reduced inspection thresholds and repeat inspection intervals for airplanes modified by Boeing to the Large Cargo Freighter (LCF) configuration. LCF airplanes have been removed from Group 3 and included in new Group 5.

In addition, 747-400, 747-400D, and 747-400F airplanes were moved from Groups 3 and 4 and placed in new Groups 6 and 7. This change was made to make it more clear that the actions in Paragraph 3.B., Part 2 and Part 3 related to existing Structural Repair Manual (SRM) outer chord repairs are not applicable to 747-400 airplanes.

Optional repair kits 141U0062-( ) have been created to provide kits of parts that are equivalent to the repairs previously described on repair drawing 691U0145. Drawing 141U0062 Sheets 1 through 4 and Sheet PSDL are sent with this revision. The contents of the 141U0062-( ) repair kits are listed in Paragraph 2.C.1., Parts Necessary For Each Airplane, but operators should refer to Drawing 141U0062, Sheet 1 or Sheet PSDL for kit applicability.

References to FAA NPRM 2009-NM-035-AD have also been added.

Original Issue: February 12, 2009 747-53A2785Revision 1: July 15, 2010 5 of 63

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The data given in Information Notice 747-53A2785 IN 01 and IN 02 is included in this revision. IN 01 was sent to make it clear that it was only necessary to remove existing outer chord repairs before doing the inspection in this service bulletin. IN 02 was sent to clarify that the escape rope and retainer assembly, which is to be removed for access, is not installed on all airplanes.

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 February 12, 2009Original Issue:

July 15, 2010Revision 1:

Original Issue: February 12, 2009 747-53A2785Revision 1: July 15, 2010 6 of 63 BOEING SERVICE BULLETIN 747-53A2785

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2785Original Issue: February 12, 2009 Revision 1: July 15, 2010 ATA System: 5310 SUBJECT: FUSELAGE - Nose Section: Station 90 to Station 520 - Main Entry Door 1 Upper Main Sill From STA 440 to STA 480 - Inspection and Repair

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 for the inspection for and repair of cracks in the Main Entry Door 1 upper main sill outer chord, web, and frame attach angles or clips. Fatigue cracks in the sill can become large and result in loss of structural integrity, which could result in cracks in adjacent parts.

Multiple operators have reported cracks up to 8 inches long in the Main Entry Door 1 upper main sill outer chord, along the radius, on multiple airplanes. The upper main sill is replaced as part of the Zone 3 modification in Boeing Service Bulletin 747-53-2272, "Fuselage - Nose Section 41 Body Frame Structure Replacement and Reinforcement". The upper main sill installed as part of Service Bulletin 747-53-2272 and in subsequent production airplanes has a thicker outer chord.

One operator has reported a 4.35 inch long crack in the new, thicker upper main sill outer chord, along the radius, at STA 460 on a 747-400 airplane with 11,539 flight-cycles. A 0.5 inch long crack was also found in the STA 460 upper sill to frame attach angle on this airplane. These cracks have been attributed to fatigue.

Accomplishment of the inspections shown in this service bulletin will make sure that fatigue cracks in the Main Entry Door 1 main upper sill outer chord, web, and frame attach angles or clips are found and repaired before they can become large and result in cracks in adjacent parts.

Boeing Service Related Problem (SRP) 747-SRP-53-0325 is related to this service bulletin.

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ACTION (PRR 85672-R) Get access to the Main Entry Door 1 upper main sill. Do a detailed inspection of the upper main sill outer chord, web, and frame attach angles or clips from STA 440 to STA 480 for cracks. If cracks are found, repair before further flight. Replace the cracked parts, repair in accordance with this service bulletin, or ask Boeing for repair data. If no cracks are found, put the airplane back in a serviceable condition. Do the inspections in this service bulletin again at the time given in Paragraph 1.E., Compliance.

EFFECTIVITY All 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, and 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) Notice of Proposed Rule Making NPRM 2009-NM-035-AD is related to this service bulletin.

FAA Airworthiness Directives AD 90-06-06, AD 2005-08-01, AD 2009-18-07 and AD 2010-01-01 are related to the subject of this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection or repair procedures given in this service bulletin.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

8.517.0Group 1, Group 3, Group 5 and Group 6

8.08.0Group 2, Group 4, and Group 7

MATERIAL INFORMATION Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability

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BOEING SERVICE BULLETIN 747-53A2785

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UPPER DECK

FLOOR BEAMS 00000000000 UPPER MAIN SILL

- S-13

• S-14 S-15 -S-16 35-17 S-18

• S-19

- S-20

• S-22 S-23

• S-24

DO A DETAILED INSPECTION / OF THE UPPER MAIN SILL • S-26

OUTER CHORD, WEB, AND FRAME ATTACHMENT CLIPS AND ANGLES FOR CRACKS. ASSEMBLY REVEAL → S-27

• S-28

- S-30 STA 400 LOWER

STA MAIN SILL 420 STA LOWER AUXILLIARY SILL 440 STA 460 STA 480 STA STA 500 1664192 520 MAIN ENTRY DOOR NO. 1 Original Issue: February 12, 2009 Revision 1: July 15, 2010 747-53A2785

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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.

This service bulletin is for the airplanes shown below. Refer to PRR 85672-R for data about this change.

Original Issue: February 12, 2009 747-53A2785Revision 1: July 15, 2010 11 of 63

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DESCRIPTIONCONFIGURATIONGROUP Airplanes line number 1 - 686, 688, and 690 - 695, except 747-200F airplanes, which are affected by Boeing Service Bulletin 747-53-2272.

-1 Not converted by Boeing to the Special Freighter or Boeing Converted Freighter configuration, with the Zone 3 modification in Boeing Service Bulletin 747-53-2272 previously accomplished. Zone 3 includes replacement of the Main Entry Door 1 main upper sill.

1 Converted by Boeing to the Special Freighter or Boeing Converted Freighter configuration, with the Zone 3 modification in Boeing Service Bulletin 747-53-2272 previously accomplished. Zone 3 includes replacement of the Main Entry Door 1 main upper sill.

2 Not converted by Boeing to the Special Freighter or Boeing Converted Freighter configuration, with the Zone 3 modification in Boeing Service Bulletin 747-53-2272 not previously accomplished.

3 Converted by Boeing to the Special Freighter or Boeing Converted Freighter configuration, with the Zone 3 modification in Boeing Service Bulletin 747-53-2272 not previously accomplished.

4 747-200F airplanes through line number 686, which are affected by Boeing Service Bulletin 747-53-2272.

-2 With the Zone 3 modification in Boeing Service Bulletin 747-53-2272 previously accomplished. Zone 3 includes replacement of the Main Entry Door 1 main upper sill.

1 With the Zone 3 modification in Boeing Service Bulletin 747-53-2272 not previously accomplished.

2 747 Classic airplanes line number 696 - 810, except 747-200F airplanes.

-3 Not converted by Boeing to the Special Freighter configuration.1 Converted by Boeing to the Special Freighter configuration.2 747-200F airplanes line number 687 and on.-4 747-400 airplanes modified by Boeing to the Large Cargo Freighter (LCF) configuration.

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