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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2815 Original Issue: November 08, 2012 ATA System: 5313 SUBJECT: FUSELAGE - Tail Section - Body Station 2598 Bulkhead Inner Chord and Web Cracking
- Inspection and Repair 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 © 2012 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Unpublished Work.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: November 08, 2012 747-53A2815 1 of 74
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 2 of 74 BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT
BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 1 D. Description .............................................. 1 1 E. Compliance .............................................. 1 2 F. Approval ............................................... 1 7 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 1 9 J. References .............................................. 1 9
1. Existing Data: ......................................... 1 9
2. Data Supplied with this Service Bulletin: ........................... 1 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 0 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 0 M. Software Accomplishment Summary ................................ 2 0
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 1 C. Parts Necessary for Each Airplane ................................. 2 1
1. Kits/Parts: ........................................... 2 1
2. Parts and Materials Supplied by the Operator: ........................ 2 1
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: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER LEFT SIDE ......... 2 9 FIGURE 2: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER RIGHT SIDE ........ 3 4 FIGURE 3: STA 2598 BULKHEAD - BULKHEAD LOWER LEFT SIDE - INSPECTION ......... 3 9 FIGURE 4: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - LEFT SIDE ......... 4 4 FIGURE 5: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - RIGHT SIDE ........ 5 0 FIGURE 6: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - UNREPAIRED STRUCTURE - LEFT SIDE .............................................. 5 6 FIGURE 7: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - UNREPAIRED STRUCTURE - RIGHT SIDE .............................................. 6 1 FIGURE 8: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - REPAIRED STRUCTURE - LEFT SIDE .................................................. 6 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 3 of 74 BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT
FIGURE 9: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - REPAIRED STRUCTURE - RIGHT SIDE .............................................. 6 9 APPENDIX A: MASTER FASTENER CODE TABLE ............................. 7 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 4 of 74 BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2815Original Issue: November 08, 2012 ATA System: 5313 SUBJECT: FUSELAGE - Tail Section - Body Station 2598 Bulkhead Inner Chord and Web Cracking
- 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 to inspect for cracks in the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead upper and lower webs of the Body Station (STA) 2598 bulkhead.
The horizontal stabilizer hinge fittings are attached to the STA 2598 bulkhead. Cracks in the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead upper and lower webs of the STA 2598 bulkhead that are not found and repaired could extend with continued use of the airplane and adversely affect the structural integrity of the bulkhead and the horizontal stabilizer support structure.
Airplanes prior to line number 1308 all have a similar design of the STA 2598 bulkhead. On these airplanes many operators have told Boeing about cracks that were found in the forward and aft inner chords of the STA 2598 bulkhead. In addition, many operators have reported crack findings in the bulkhead upper and lower webs near the inner chord to shear deck connection in the STA 2598 bulkhead. The forward and aft inner chords and bulkhead upper web cracks were found in the upper corners of the cutout for the horizontal stabilizer rear spar.
The aft inner chord and lower bulkhead web cracks were found only in the lower left corner of the cutout for the horizontal stabilizer rear spar. For more details, refer to Boeing Service Bulletin 747-53A2427, which addresses cracks that were found in the STA 2598 bulkhead on airplanes prior to line number 1308.
On airplanes line number 1308 through 1419, there was a production change to the STA 2598 bulkhead, which was a part of an overall structural design improvement for increased gross takeoff weight. On these airplanes, Boeing has done an analysis of the STA 2598 bulkhead subsequent to receiving crack reports on the previous airplanes. Although there was a production change to strengthen the STA 2598 bulkhead, the analysis showed that cracks can still occur in the STA 2598 bulkhead for airplanes line number 1308 through 1419; similar to cracks found in the STA 2598 bulkhead on airplanes prior to line number 1308.
This service bulletin gives instructions to inspect the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead upper and lower webs of the STA 2598 bulkhead on airplanes line number 1308 through 1419.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 5 of 74
NOTE: A future service bulletin will be released to give instructions for a modification to the STA 2598 bulkhead for airplane line number 1308 through 1419, which will terminate the repeat inspection requirements given in this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-53-0343 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 747 FTD 53-09004 is related to this service bulletin.
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/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-103RS) For the STA 2598 Upper Bulkhead:
– Do surface high frequency eddy current (HFEC) and low frequency eddy current (LFEC) inspections for cracks in the splice fitting, support frame, forward and aft inner chords, and bulkhead upper web on the upper left and right sides of the bulkhead.
– If no crack is found, repeat the inspections.
– If any crack is found in the bulkhead upper web that is within the maximum allowable cutout area, do a bulkhead upper web repair. After the installation of the bulkhead upper web repair, do a post-repair inspection.
– If any crack is found in the splice fitting, support frame, forward and aft inner chords, or bulkhead upper web that is outside the maximum allowable cutout area, contact Boeing for repair instructions and do the repair.
For the STA 2598 Lower Bulkhead:
– Do open hole and surface HFEC inspections for cracks in the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead lower web on the lower left side of the bulkhead. For the open hole HFEC inspection locations, fastener hole diameter can be increased up to a maximum of 1/32 inch oversize from its orignal fastener hole size to remove a crack.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 6 of 74 BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT
NOTE: This inspection only applies to the lower left side of the bulkhead.
– If no crack is found or crack was removed by oversizing the fastener hole, repeat the inspections.
– If any crack is found in the splice fitting, support frame, floor support, forward and aft inner chords, or bulkhead lower web except for cracks removed by oversizing the fastener hole, contact Boeing for repair instructions and do the repair.
NOTE: A future service bulletin will be released to give instructions for a modification to the STA 2598 bulkhead for airplane line numbers 1308 through 1419, which will terminate the repeat inspection requirements given in this service bulletin.
EFFECTIVITY 747-400 and 747-400F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-07-22 R1 is related to this service bulletin.
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
29.4553.60Group 1(a)
(a) The total hours include access, inspection, bulkhead upper web repair on both sides, and restoration.
Refer to Paragraph 1.G., Manpower.
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: November 08, 2012 747-53A2815 7 of 74 BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2815
ALERT ALERT STA 2598 DO SURFACE HFEC AND LFEC
INSPECTIONS FOR CRACKS IN THE
SPLICE FITTING, SUPPORT FRAME
FORWARD AND AFT INNER CHORDS AND BULKHEAD UPPER WEB. IF ANY
CRACK IS FOUND, DO A REPAIR IN
ACCORDANCE WITH THIS SERVICE
BULLETIN OR CONTACT BOEING FOR
STA REPAIR INSTRUCTIONS AND DO THE 2598 REPAIR. CONTINUE TO DO REPEAT
INSPECTIONS OR POST-REPAIR INSPECTION AS APPLICABLE.
HORIZONTAL
STABILIZER
SUPPORT FRAME
AFT INNER CHORD
DO OPEN HOLE AND SURFACE HFEC
INSPECTIONS FOR CRACKS IN THE
SPLICE FITTING, SUPPORT FRAME, FLOOR
SUPPORT, FORWARD AND AFT INNER CHORDS, AND BULKHEAD LOWER WEB. IF
ANY CRACK IS FOUND, OR THERE IS ANY
CRACK AFTER OVERSIZING THE FASTENER
HOLES IN ACCORDANCE WITH THIS SERVICE
BULLETIN, CONTACT BOEING FOR REPAIR INSTRUCTIONS AND DO THE REPAIR. CONTINUE TO DO REPEAT INSPECTIONS. 2161023 Original Issue: November 08, 2012 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 74
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2815 Original Issue: November 08, 2012 ATA System: 5313 SUBJECT: FUSELAGE - Tail Section - Body Station 2598 Bulkhead Inner Chord and Web Cracking
- 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplane(s) shown below. Refer to PRR 85901-103RS for data about this change.
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP Airplanes line number 1308 to 1419.-1 Airplane Models:
747-400, 747-400F GroupVariable Number 1RF001 - RF006 1RL403 1RL420 - RL436 1RL451 - RL456 1RL461 - RL462 1RL471 - RL481 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 9 of 74
GroupVariable Number 1RL491 - RL492 1RL501 - RL502 1RL511 - RL516 1RL521 - RL522 1RL531 - RL534 1RL551 1RL561 - RL568 1RL571 - RL572 1RL576 - RL577 1RL579 1RL581 - RL586 1RL655 1RL671 - RL675 1RL681 - RL684 1RL752 1RM030 1RM053 1RM401 - RM403 1RM426 1RM431 1RM441 - RM443 1RM445 1RM859 1RM863 1RM877 - RM880 1RM887 - RM890 1RM906
2. Spares Affected None.
B. Concurrent Requirements None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 10 of 74 BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT
C. Reason This service bulletin gives instructions to inspect for cracks in the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead upper and lower webs of the Body Station (STA) 2598 bulkhead. The horizontal stabilizer hinge fittings are attached to the STA 2598 bulkhead. Cracks in the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead upper and lower webs of the STA 2598 bulkhead that are not found and repaired could extend with continued use of the airplane and adversely affect the structural integrity of the bulkhead and the horizontal stabilizer support structure.
Airplanes prior to line number 1308 all have a similar design of the STA 2598 bulkhead. On these airplanes many operators have told Boeing about cracks that were found in the forward and aft inner chords of the STA 2598 bulkhead. In addition, many operators have reported crack findings in the bulkhead upper and lower webs near the inner chord to shear deck connection in the STA 2598 bulkhead. The forward and aft inner chords and bulkhead upper web cracks were found in the upper corners of the cutout for the horizontal stabilizer rear spar. The aft inner chord and lower bulkhead web cracks were found only in the lower left corner of the cutout for the horizontal stabilizer rear spar. For more details, refer to Boeing Service Bulletin 747-53A2427, which addresses cracks that were found in the STA 2598 bulkhead on airplanes prior to line number 1308.
On airplanes line number 1308 through 1419, there was a production change to the STA 2598 bulkhead, which was a part of an overall structural design improvement for increased gross takeoff weight. On these airplanes, Boeing has done an analysis of the STA 2598 bulkhead subsequent to receiving crack reports on the previous airplanes. Although there was a production change to strengthen the STA 2598 bulkhead, the analysis showed that cracks can still occur in the STA 2598 bulkhead for airplanes line number 1308 through 1419; similar to cracks found in the STA 2598 bulkhead on airplanes prior to line number 1308.
This service bulletin gives instructions to inspect the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead upper and lower webs of the STA 2598 bulkhead on airplanes line number 1308 through 1419.
NOTE: A future service bulletin will be released to give instructions for a modification to the STA 2598 bulkhead for airplanes line number 1308 through 1419, which will terminate the repeat inspection requirements given in this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-53-0343 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 747 FTD 53-09004 is related to this service bulletin.
D. Description For the STA 2598 Upper Bulkhead:
– Do surface high frequency eddy current (HFEC) and low frequency eddy current (LFEC) inspections for cracks in the splice fitting, support frame, forward and aft inner chords, and bulkhead upper web on the upper left and right sides of the bulkhead.
– If no crack is found, repeat the inspections.
– If any crack is found in the bulkhead upper web that is within the maximum allowable cutout area, do a bulkhead upper web repair. After the installation of the bulkhead upper web repair, do a post-repair inspection.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 11 of 74 BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT
– If any crack is found in the splice fitting, support frame, forward and aft inner chords, or bulkhead upper web that is outside the maximum allowable cutout area, contact Boeing for repair instructions and do the repair.
For the STA 2598 Lower Bulkhead:
– Do open hole and surface HFEC inspections for cracks in the splice fitting, support frame, floor support, forward and aft inner chords, and bulkhead lower web on the lower left side of the bulkhead.
For the open hole HFEC inspection locations, fastener hole diameter can be increased up to a maximum of 1/32 inch oversize from its orignal fastener hole size to remove a crack.
NOTE: This inspection only applies to the lower left side of the bulkhead.
– If no crack is found or crack was removed by oversizing the fastener hole, repeat the inspections.
– If any crack is found in the splice fitting, support frame, floor support, forward and aft inner chords, or bulkhead lower web except for cracks removed by oversizing the fastener hole, contact Boeing for repair instructions and do the repair.
NOTE: A future service bulletin will be released to give instructions for a modification to the STA 2598 bulkhead for airplane line numbers 1308 through 1419, which will terminate the repeat inspection requirements given in this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones ZoneModel 315, 316747-400, 747-400F E. Compliance Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-07-22 R1 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2012 747-53A2815 12 of 74 BOEING SERVICE BULLETIN 747-53A2815