# Boeing Alert Service Bulletin 747-53A2815: No revision named

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### Page 1

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Unpublished Work.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.
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Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
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
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FIGURE 9: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - REPAIRED STRUCTURE - RIGHT
SIDE .............................................. 6 9
APPENDIX A: MASTER FASTENER CODE TABLE ............................. 7 2
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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.
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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 Air-
plane 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.
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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.
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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
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### Page 9

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
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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.
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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.
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### Page 12

– 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.
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Table 1: STA 2598 Bulkhead Inspection and Repair
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Within 1,500
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Before 16,000
total flight cy-
cles.
Do surface HFEC and
LFEC inspections for
cracks in the splice fitting,
support frame, forward
and aft inner chords, and
bulkhead upper web on
the upper left side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 2,
All airplanes.
and
do surface HFEC and
LFEC inspections for
cracks in the splice fitting,
support frame, forward
and aft inner chords, and
bulkhead upper web on
the upper right side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 2,
and
do open hole and surface
HFEC inspections for
cracks in the splice fitting,
support frame, floor sup-
port, forward and aft inner
chords, and bulkhead
lower web on the lower
left side of the bulkhead
in accordance with Para-
graph 3.B., Work Instruc-
tions, Part 2.
1,500 flight cycles.Within 1,500 flight cycles after the
initial inspection.
Repeat the surface HFEC
and LFEC inspections for
cracks in the splice fitting,
support frame, forward
and aft inner chords, and
bulkhead upper web on
the upper left side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 2.
No crack found on the up-
per left side of the bulk-
head.
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### Page 14

Table 1: STA 2598 Bulkhead Inspection and Repair
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
1,500 flight cycles.Within 1,500 flight cycles after the
initial inspection.
Repeat the surface HFEC
and LFEC inspections for
cracks in the splice fitting,
support frame, forward
and aft inner chords, and
bulkhead upper web on
the upper right side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 2.
No crack found on the up-
per right side of the bulk-
head.
3,000 flight cycles.Within 3,000 flight cycles after the
initial inspection.
Repeat the open hole and
surface HFEC inspec-
tions for cracks in the
splice fitting, support
frame, floor support, for-
ward and aft inner
chords, and bulkhead
lower web on the lower
left side of the bulkhead
in accordance with Para-
graph 3.B., Work Instruc-
tions, Part 2.
No crack found or crack
was removed by oversizing
the fastener hole on the
lower left side of the bulk-
head.
-Before further flight.Do a bulkhead upper web
repair on the left side of
the bulkhead in accor-
dance with Paragraph
3.B., Work Instructions,
Part 3.
Any crack found in the
bulkhead upper web that is
within the maximum allow-
able cutout area on the left
side of the bulkhead.
-Before further flight.Do a bulkhead upper web
repair on the right side of
the bulkhead in accor-
dance with Paragraph
3.B., Work Instructions,
Part 3.
Any crack found in the
bulkhead upper web that is
within the maximum allow-
able cutout area on the
right side of the bulkhead.
-Before further flight.Contact Boeing for repair
instructions and do the
repair.
Any crack found in the
splice fitting, support frame,
forward and aft inner
chords, or bulkhead upper
web that is outside the
maximum allowable cutout
area on the upper left or
upper right side of the
bulkhead.
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### Page 15

Table 1: STA 2598 Bulkhead Inspection and Repair
Repeat Interval
(Not to Exceed)
Compliance Time
(Whichever Occurs Later)
ActionCondition
-Before further flight.Contact Boeing for repair
instructions and do the
repair.
Any crack found in the
splice fitting, support frame,
floor support, forward and
aft inner chords, or bulk-
head lower web on the
lower left side of the bulk-
head except for cracks re-
moved by oversizing the
fastener hole.
--Refer to Table 2.Installed bulkhead upper
web repair.
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### Page 16

Table 2: STA 2598 Bulkhead Post-Repair Inspection
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
-Within 1,500 flight cycles after the
bulkhead upper web repair.
Do surface HFEC and
LFEC inspections for
cracks in the unrepaired
structure on the upper left
side of the bulkhead in
accordance with Para-
graph 3.B., Work Instruc-
tions, Part 4.
Installed bulkhead upper
web repair on the left side
of the bulkhead.
and
-Within 6,000 flight cycles after the
bulkhead upper web repair.
Do a surface HFEC in-
spection for cracks in the
repaired structure on the
upper left side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 4.
-Within 1,500 flight cycles after the
bulkhead upper web repair.
Do surface HFEC and
LFEC inspections for
cracks in the unrepaired
structure on the upper
right side of the bulkhead
in accordance with Para-
graph 3.B., Work Instruc-
tions, Part 4.
Installed bulkhead upper
web repair on the right side
of the bulkhead.
and
-Within 6,000 flight cycles after the
bulkhead upper web repair.
Do a surface HFEC in-
spection for cracks in the
repaired structure on the
upper right side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 4.
1,500 flight cycles.Within 1,500 flight cycles after the
initial post-repair inspection.
Repeat the surface HFEC
and LFEC inspections for
cracks in the unrepaired
structure on the upper left
side of the bulkhead in
accordance with Para-
graph 3.B., Work Instruc-
tions, Part 4.
No crack found on the up-
per left side of the bulk-
head.
and
1,500 flight cycles.Within 1,500 flight cycles after the
initial post-repair inspection.
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Table 2: STA 2598 Bulkhead Post-Repair Inspection
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
Repeat the surface HFEC
inspection for cracks in
the repaired structure on
the upper left side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 4.
1,500 flight cycles.Within 1,500 flight cycles after the
initial post-repair inspection.
Repeat the surface HFEC
and LFEC inspections for
cracks in the unrepaired
structure on the upper
right side of the bulkhead
in accordance with Para-
graph 3.B., Work Instruc-
tions, Part 4.
No crack found on the up-
per right side of the bulk-
head.
and
1,500 flight cycles.Within 1,500 flight cycles after the
initial post-repair inspection.
Repeat the surface HFEC
inspection for cracks in
the repaired structure on
the upper right side of the
bulkhead in accordance
with Paragraph 3.B.,
Work Instructions, Part 4.
-Before further flight.Contact Boeing for repair
instructions and do the
repair.
Any crack found.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
In addition, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the
accomplishment of the inspections and repairs with the corresponding compliance times specified in
Tables 1 and 2, under paragraph 1.E., "Compliance," of SB 747-53A2815, Original Issue as an AMOC
to the inspections and repairs at the STA 2598 bulkhead required by paragraphs (h), and (i) of AD
2004-07-22 R1 for the areas inspected by Boeing 747 Supplemental Structural Inspection Document
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(SSID) D6-35022, Revision G, Significant Structural Items 747 SSID F-49B. This AMOC only applies
to the areas that are inspected as given in this SB. When this SB specifies contacting Boeing for repair
or modification data, the data must be approved by the FAA in accordance with paragraph (l) of the
AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph remain
fully applicable and must be complied with accordingly.
G. Manpower
The table below shows an estimate of the task hours necessary to do this inspection and repair for
each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate
with operator task hour data if necessary. The estimate does not include lost time. These are some
examples of lost time:
 Time to adjust to the workplace
 Time to schedule the work
 Time to inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
Elapsed HoursTask HoursNumber of Per-
sons
Task
0.750.751Open Access
2.635.252FIGURE 1
2.635.252FIGURE 2
2.505.002FIGURE 3
4.1012.303FIGURE 4
4.1012.303FIGURE 5
5.255.251FIGURE 6
5.255.251FIGURE 7
0.750.751FIGURE 8
0.750.751FIGURE 9
0.750.751Restoration
29.45(a)53.60(a)TOTAL FOR EACH AIRPLANE
(a) The total hours include bulkhead upper web repair on both sides of the
STA 2598 bulkhead.
H. Weight and Balance Changes
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
+3160.5+1.2747-400 and 747-
400F(a)
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Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
(a) Weight and balance changes are for the bulkhead upper web
repair in accordance with Paragraph 3.B., Work Instructions,
Part 3, on one side only.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 85901-103RS
b. Boeing Service Bulletin 747-53A2427
c. Boeing Service Letter 747-SL-51-048
d. Boeing Service Related Problem (SRP) 747-SRP-53-0343
e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1
f. Service Bulletin Index D6-30300
g. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-42-05, 20-43-03,
20-50-19, 20-50-20
h. 747 Fleet Team Digest (FTD) 53-09004
i. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Figure 1, 11, or 16, Part 6,
51-00-00, Figure 4 or 23, Part 6, 51-00-26
j. 747 Supplemental Structural Inspection Document (SSID) Vol 1F-49B
k. 747-400 Aircraft Maintenance Manual (AMM) 06-09-05, 24-22-00, 29-11-00
2. Data Supplied with this Service Bulletin:
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
-A1TAIL SECTION - BODY STATION 2598
BULKHEAD - BULKHEAD UPPER WEB
REPAIR
624U0075
--2
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3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
BULKHEAD INSTL - LOWER LOBE, STA 2598148U3360
BULKHEAD INSTL HORIZONTAL HINGE STA 2598148U3365
BULKHEAD, UPPER LOBE, STA 259865B02502
PANEL INSTL - SHEAR, UPPER STA 2484 - 259865B02597
The table above lists applicable drawings used to prepare this service bulletin. The drawings are
not necessary to make the specified changes, and are not supplied with this service bulletin. The
drawings may not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected
are contained in Paragraph 1.E., Compliance of this service bulletin.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each
Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin
does not show the Boeing price and supply data.
B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes, inspection and/or repairs
given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts:
None.
2. Parts and Materials Supplied by the Operator:
NotesNameQTY(h)Part Number /
Specification
(a)PART A (REPAIR DOUBLER)215-5PH CRES
SHEET PER BMS
7-240, TYPE I OR
AMS 5659.
THICKNESS =
0.050. HEAT
TREAT TO 180 -
200 KSI PER BAC
5619.
(a) (b)PART B (CUTOUT FILLER)2BACF3F030L035AN
(b)PART C (TAPERED FILLER)2BACF3T01C087-
25
(a) (b)PART D (UPPER FILLER)2BACF3F042G230AN
(a) (b)PART E (SHIM)2BACS40R022A022F
(b)PART F (TAPERED FILLER)4BACF3T01H10-08
(b)PART G (RADIUS FILLER)2BACF3H07LP008HN
(c)BOLT4BACB30NX10K11X
(c)BOLT4BACB30NX10K12X
(c) (d)BOLT1BACB30NX10K13
(c)BOLT8BACB30NX10K14X
(c)BOLT52BACB30NX6K3
(c)BOLT8BACB30NX6K5X
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NotesNameQTY(h)Part Number /
Specification
(c)BOLT16BACB30NX6K6X
(c)BOLT30BACB30NX6K8X
(c)BOLT2BACB30NX6K9X
(c)BOLT10BACB30NX8K10X
(c)BOLT8BACB30NX8K11X
(c)BOLT8BACB30NX8K6X
(c) (d)BOLT2BACB30NX8K8
(c)BOLT64BACB30NX8K8X
(c)BOLT4BACB30NX8K9X
(c)COLLAR17BACC30BH10
(c)COLLAR108BACC30BH6
(c)COLLAR96BACC30BH8
(e)WASHER, COUNTERSUNK36BACW10EG61C
(e)WASHER, COUNTERSUNK36BACW10EG61CU
(e)WASHER, COUNTERSUNK52BACW10EG6C
(e)WASHER, COUNTERSUNK52BACW10EG6CU
(f)CHEMICAL CONVERSION COAT-
ING
2 Oz-
(g)PRIMER2 OzBMS 10-11, TYPE
1
(g)SEALANT4 OzBMS 5-95
(a) Fabricate from the specified part.
(b) Make the part if the part is not available from Boeing. Refer to SOPM 20-50-20 as an
accepted procedure for making laminated shims and solid fillers.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternate fasteners.
(d) There are other fastener options for this part. Refer to FIGURE 3 for additional fastener
options.
(e) Available washer options based on the plating/finish of the repair doubler. Refer to FIGURE
4 and FIGURE 5 for details.
(f) Refer to SOPM 20-43-03 for material information.
(g) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)
for supplier data.
(h) The quantity given is for repair parts necessary for each airplane.
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3. Parts Modified and Reidentified:
None.
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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### Page 25

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque limits to tighten nuts and bolts are in SRM Chapter 51
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
6. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
7. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
8. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
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9. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
10. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
11. Unless otherwise noted, all fasteners to be installed with the bolt head on the near
side at fastener symbol locations.
12. Refer to APPENDIX A for a Master Fastener Code Table.
B. WORK INSTRUCTIONS
Part 1 - Access
1. Remove electrical and hydraulic power. Refer to 747-400 AMM 24-22-00 and 747-400 AMM
29-11-00 as an accepted procedure for the removal of electrical and hydraulic power, respectively.
2. For access to the aft side of the of the STA 2598 bulkhead, open APU Battery Access Door 315A.
Open Horizontal Stabilizer Jackscrew Access Door 312A to get access to the forward side of the
STA 2598 bulkhead through the access holes in the bulkheads at body station (STA) 2484, STA
2502, and STA 2517. Refer to 747-400 AMM 06-09-05 for access door locations.
Part 2 - Inspection
CAUTION: DO NOT USE THE JACK POINT AT BODY STATION 2596 (PRIMARY TAIL JACK
POINT III) DURING OPEN HOLE HFEC INSPECTIONS OR INSTALLATION OF REPAIRS
TO PREVENT ANY DAMAGE AND MISALIGNMENT OF THE BULKHEAD STRUCTURE.
1. 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 side of the bulkhead in accordance with FIGURE 1.
a. If any crack is found, do the applicable corrective action in the following table:
Corrective ActionCrack Description/Location
Do a bulkhead upper web repair in accordance
with Part 3.
Any crack found in the bulkhead upper web that
is within the maximum allowable cutout area as
shown in FIGURE 4.
Contact Boeing for repair instructions and do the
repair.
Any crack found in the splice fitting, support
frame, forward and aft inner chords, or bulkhead
upper web that is outside the maximum allowable
cutout area.
b. If no crack is found, repeat the surface HFEC and LFEC inspections in accordance with
FIGURE 1 at the time given in Paragraph 1.E., Compliance.
2. Do surface HFEC and LFEC inspections for cracks in the splice fitting, support frame, forward and
aft inner chords, and bulkhead upper web on the upper right side of the bulkhead in accordance
with FIGURE 2.
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a. If any crack is found, do the applicable corrective action in the following table:
Corrective ActionCrack Description/Location
Do a bulkhead upper web repair in accordance
with Part 3.
Any crack found in the bulkhead upper web that
is within the maximum allowable cutout area as
shown in FIGURE 5.
Contact Boeing for repair instructions and do the
repair.
Any crack found in the splice fitting, support
frame, forward and aft inner chords, or bulkhead
upper web that is outside the maximum allowable
cutout area.
b. If no crack is found, repeat the surface HFEC and LFEC inspections in accordance with
FIGURE 2 at the time given in Paragraph 1.E., Compliance.
3. 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
in accordance with FIGURE 3.
NOTE: This inspection only applies to the lower left side of the bulkhead.
a. 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: If any crack is found at a fastener hole with the open hole HFEC inspection, the
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 in accordance with FIGURE 3. If any
crack is found after the maximum 1/32 inch oversize, contact Boeing for repair
instructions and do the repair.
b. If no crack is found or crack was removed by oversizing the fastener hole, repeat the open
hole and surface HFEC inspections in accordance with FIGURE 3 at the time given in
Paragraph 1.E., Compliance.
Part 3 - Bulkhead Upper Web Repair
CAUTION: DO NOT USE THE JACK POINT AT BODY STATION 2596 (PRIMARY TAIL JACK
POINT III) DURING THE BULKHEAD UPPER WEB REPAIR TO PREVENT ANY
DAMAGE AND MISALIGNMENT OF THE BULKHEAD STRUCTURE.
1. If any crack is found in the bulkhead upper web on the left side of the bulkhead, do the following:
a. Install a bulkhead upper web repair in accordance with FIGURE 4. The bulkhead upper web
repair is applicable only if the crack is within the maximum allowable cutout area as shown in
FIGURE 4. If the bulkhead upper web crack is outside the maximum allowable cutout area
as shown in FIGURE 4, contact Boeing for repair instructions and do the repair.
b. After the installation of the bulkhead upper web repair, do the post-repair inspection in
accordance with Part 4 at the time given in Paragraph 1.E., Compliance.
2. If any crack is found in the bulkhead upper web on the right side of the bulkhead, do the following:
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a. Install a bulkhead upper web repair in accordance with FIGURE 5. The bulkhead upper web
repair is applicable only if the crack is within the maximum allowable cutout area as shown in
FIGURE 5. If the bulkhead upper web crack is outside the maximum allowable cutout area
as shown in FIGURE 5, contact Boeing for repair instructions and do the repair.
b. After the installation of the bulkhead upper web repair, do the post-repair inspection in
accordance with Part 4 at the time given in Paragraph 1.E., Compliance.
Part 4 - Post-Repair Inspection
1. After the installation of the bulkhead upper web repair on the left side, do the following:
a. Do surface HFEC and LFEC inspections for cracks in the unrepaired structure, which includes
splice fitting, support frame, aft and forward inner chord, and bulkhead upper web, in
accordance FIGURE 6.
(1) If no crack is found, repeat the surface HFEC and LFEC inspections in accordance with
FIGURE 6 at the time given in Paragraph 1.E., Compliance.
(2) If any crack is found, contact Boeing for repair instructions and do the repair.
b. Do a surface HFEC inspection for cracks in the repaired structure, which is bulkhead upper
web, in accordance FIGURE 8.
(1) If no crack is found, repeat the surface HFEC inspection in accordance with FIGURE 8
at the time given in Paragraph 1.E., Compliance.
(2) If any crack is found, contact Boeing for repair instructions and do the repair.
2. After the installation of the bulkhead upper web repair on the right side, do the following:
a. Do surface HFEC and LFEC inspections for cracks in the unrepaired structure, which includes
splice fitting, support frame, aft and forward inner chord, and bulkhead upper web, in
accordance FIGURE 7.
(1) If no crack is found, repeat the surface HFEC and LFEC inspections in accordance with
FIGURE 7 at the time given in Paragraph 1.E., Compliance.
(2) If any crack is found, contact Boeing for repair instructions and do the repair.
b. Do a surface HFEC inspection for cracks in the repaired structure, which is bulkhead upper
web, in accordance FIGURE 9.
(1) If no crack is found, repeat the surface HFEC inspection in accordance with FIGURE 9
at the time given in Paragraph 1.E., Compliance.
(2) If any crack is found, contact Boeing for repair instructions and do the repair.
Part 5 - Restoration
1. Close all access doors that were opened for access to the STA 2598 bulkhead.
2. Put the airplane back to a serviceable condition.
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### Page 29 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
STA
2598
STA
2598
HORIZONTAL
STABILIZER
SUPPORT
FRAME
AFT INNER
CHORD
2161033
FIGURE 1: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER LEFT SIDE
(SHEET 1 OF 5)
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### Page 30 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
BULKHEAD
UPPER WEB
FORWARD
INNER CHORD
TYPICAL
CRACK
SHEAR
AFT INNER  DECK
CHORD  SPLICE
FITTING
INSPECTION
AREA
FORWARD
INNER CHORD
FORWARD  INNER  BULKHEAD  UPPER
CHORD  WEB
BULKHEAD
UPPER WEB
SPLICE  FITTING 2  SPLICE
FITTING
TYPICAL
CRACK
SHEAR
DECK  INBD
FWD
SHEAR
DECK  2161073
A-A  B-B
FIGURE 1: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER LEFT SIDE
(SHEET 2 OF 5)
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 747-53A2815C
ALERT  ALERT
SHEAR
DECK
SUPPORT
_ FRAME
2) SPLICE
FITTING
STA
2598
FORWARD  SHEAR
INNER  DECK
CHORD
FWD
TYPICAL FRAME
SUPPORT CRACK
SPLICE  SUPPORT
FITTING  C-C  FRAME  2161140
FIGURE 1: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER LEFT SIDE
(SHEET 3 OF 5)
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### Page 32 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
LBL 40
FORWARD
INNER
CHORD
BULKHEAD
UPPER
WEB
SYSTEMS
BRACKET
• BULKHEAD
-- UPPER
SPLICE  WEB
FITTING
2.5
MINIMUM
• FLOOR
SUPPORT  SUPPORT
FRAME
TYPICAL BULKHEAD
UPPER WEB CRACK
AFT INNER
CHORD
AFT INNER CHORD
INSPECTION AREA (AFT SIDE)
BULKHEAD UPPER WEB
INSPECTION AREA (AFT SIDE)
AFT INNER CHORD INSPECTION
AREA (AFT SIDE) AND BULKHEAD
UPPER WEB INSPECTION
INBD  VIEW LOOKING FORWARD  AREA (FORWARD SIDE)
BULKHEAD UPPER WEB  2161217
INSPECTION AREA
(FORWARD SIDE)
FIGURE 1: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER LEFT SIDE
(SHEET 4 OF 5)
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Work - See page 1 for details.  32 of 74

### Page 33

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)--FORWARD INNER
CHORD
Inspect1
(b)--FORWARD INNER
CHORD
Inspect
(a)--SPLICE FITTINGInspect2
(a)--SUPPORT FRAMEInspect3
(b)--SUPPORT FRAMEInspect
(a)--AFT INNER CHORDInspect4
(c)--AFT INNER CHORDInspect5
(a)--BULKHEAD UPPER
WEB
Inspect6
(d)--BULKHEAD UPPER
WEB
Inspect
(a)--BULKHEAD UPPER
WEB
Inspect7
(e)--BULKHEAD UPPER
WEB
Inspect
(a) Do a surface HFEC inspection around fasteners as shown in the figure for cracks in accordance with 747
NDT Part 6, 51-00-00, Figure 4 or 23.
(b) Do a surface HFEC inspection along the edge of splice fitting as shown in the figure for cracks in accor-
dance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.
(c) Do an LFEC inspection around the fastener as shown in the figure for cracks in accordance with 747 NDT
Part 6, 51-00-26. This inspection is for the area where the systems bracket covers up the aft inner chord.
Thickness of the systems bracket is 0.040 inch.
(d) Do a surface HFEC inspection along the edge of aft inner chord as shown in the figure for cracks in ac-
cordance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.
(e) Do a surface HFEC inspection along the edge of floor support as shown in the figure for cracks in accor-
dance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.
FIGURE 1: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER LEFT SIDE
(SHEET 5 OF 5)
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PROPRIETARY - Copyright © Unpublished
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 34 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
STA
2598
STA
2598
HORIZONTAL
STABILIZER
2161393
FIGURE 2: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER RIGHT SIDE
(SHEET 1 OF 5)
Original Issue: November 08, 2012
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.

### Page 35 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
BULKHEAD
UPPER WEB
FORWARD
INNER CHORD
TYPICAL
CRACK
SHEAR
DECK
SPLICE  AFT INNER
FITTING  CHORD
INSPECTION
AREA
FORWARD
INNER CHORD
FORWARD
INNER
BULKHEAD  CHORD
BULKHEAD  UPPER WEB
UPPER WEB
SPLICE  2 FITTING  SPLICE
FITTING
TYPICAL
CRACK
SHEAR
NBD  DECK  FWD
SHEAR
A-A  B-B  DECK  2161399
FIGURE 2: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER RIGHT SIDE
(SHEET 2 OF 5)
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Work - See page 1 for details.  35 of 74

### Page 36 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
SHEAR
DECK
SUPPORT •
FRAME
2) SPLICE
FITTING
STA
2598
SHEAR
DECK
FORWARD
INNER
CHORD
TYPICAL FRAME
SUPPORT CRACK .  FWD
SUPPORT  SPLICE
FRAME  FITTING
C-C  2161419
FIGURE 2: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER RIGHT SIDE
(SHEET 3 OF 5)
Original Issue: November 08, 2012
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Work - See page 1 for details.  36 of 74

### Page 37 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
RBL 40
FORWARD
INNER
CHORD
BULKHEAD
UPPER WEB
SYSTEMS
BULKHEAD  BRACKET
UPPER
WEB
SPLICE
FITTING
2.5
MINIMUM
FLOOR
SUPPORT  SUPPORT
FRAME
TYPICAL BULKHEAD
UPPER WEB CRACK
AFT INNER
CHORD
AFT INNER CHORD
INSPECTION AREA (AFT SIDE)
BULKHEAD UPPER WEB
INSPECTION AREA (AFT SIDE)
AFT INNER CHORD INSPECTION
AREA (AFT SIDE) AND BULKHEAD
UPPER WEB INSPECTION
AREA (FORWARD SIDE)
INBD
BULKHEAD UPPER WEB
INSPECTION AREA  VIEW LOOKING FORWARD
(FORWARD SIDE)  2161495
FIGURE 2: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER RIGHT SIDE
(SHEET 4 OF 5)
Original Issue: November 08, 2012
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PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  37 of 74

### Page 38

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)--FORWARD INNER
CHORD
Inspect1
(b)--FORWARD INNER
CHORD
Inspect
(a)--SPLICE FITTINGInspect2
(a)--SUPPORT FRAMEInspect3
(b)--SUPPORT FRAMEInspect
(a)--AFT INNER CHORDInspect4
(c)--AFT INNER CHORDInspect5
(a)--BULKHEAD UPPER
WEB
Inspect6
(d)--BULKHEAD UPPER
WEB
Inspect
(a)--BULKHEAD UPPER
WEB
Inspect7
(e)--BULKHEAD UPPER
WEB
Inspect
(a) Do a surface HFEC inspection around fasteners as shown in the figure for cracks in accordance with 747
NDT Part 6, 51-00-00, Figure 4 or 23.
(b) Do a surface HFEC inspection along the edge of splice fitting as shown in the figure for cracks in accor-
dance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.
(c) Do an LFEC inspection around the fastener as shown in the figure for cracks in accordance with 747 NDT
Part 6, 51-00-26. This inspection is for the area where the systems bracket covers up the aft inner chord.
Thickness of the systems bracket is 0.040 inch.
(d) Do a surface HFEC inspection along the edge of aft inner chord as shown in the figure for cracks in ac-
cordance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.
(e) Do a surface HFEC inspection along the edge of floor support as shown in the figure for cracks in accor-
dance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.
FIGURE 2: STA 2598 BULKHEAD - INSPECTION - BULKHEAD UPPER RIGHT SIDE
(SHEET 5 OF 5)
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PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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38 of 74
BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 39 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
STA
2598
STA
2598
HORIZONTAL
STABILIZER
SUPPORT
FRAME
AFT INNER CHORD
2161517
FIGURE 3: STA 2598 BULKHEAD - BULKHEAD LOWER LEFT SIDE - INSPECTION
(SHEET 1 OF 5)
Original Issue: November 08, 2012
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Work - See page 1 for details.  39 of 74

### Page 40 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
TYPICAL
CRACK
1350  • AFT INNER  CHORD
2000
SPLICE
FITTING
5.0 MINIMUM
(TYPICAL)
BULKHEAD
INBD  LOWER WEB
BULKHEAD LOWER
WEB INSPECTION
AREA
2161583
FIGURE 3: STA 2598 BULKHEAD - BULKHEAD LOWER LEFT SIDE - INSPECTION
(SHEET 2 OF 5)
Original Issue: November 08, 2012
Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-53A2815
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### Page 41

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)--BULKHEAD LOWER
WEB
Inspect1
(b)--BULKHEAD LOWER
WEB
Inspect
-3-FASTENERRemove2
(c) (d)--AFT INNER CHORDInspect3
(c) (d)--BULKHEAD LOWER
WEB
Inspect
(c) (d)--FORWARD INNER
CHORD
Inspect
(c) (d)--SPLICE FITTINGInspect
FIGURE 3: STA 2598 BULKHEAD - BULKHEAD LOWER LEFT SIDE - INSPECTION
(SHEET 3 OF 5)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2012
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41 of 74
BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 42

More DataQtyIdentificationNameTaskStep
(c) (d)--AFT INNER CHORDInspect4
(c) (d)--BULKHEAD LOWER
WEB
Inspect
(c) (d)--FLOOR SUPPORTInspect
See fastener code
table for hole
sizes.(e)
3-FASTENER HOLEDrill / Ream5
-3-FASTENERInstall (New)6
(a) Do a surface HFEC inspection around fasteners as shown in the figure for cracks in accordance with 747
NDT Part 6, 51-00-00, Figure 4 or 23.
(b) Do a surface HFEC inspection along the edge of aft inner chord as shown in the figure for cracks in ac-
cordance with 747 NDT Part 6, 51-00-00, Figure 4 or 23
(c) Do an open hole HFEC inspection for cracks at the identified fastener holes in accordance with 747 NDT
Part 6, 51-00-00, Figure 1, 11, or 16.
(d) If any crack is found, the hole diameter can be increased up to a maximum 1/32 inch oversize from its
original fastener hole size to remove the crack. After the hole diameter is increased, repeat the open hole
HFEC inspection in accordance with 747 NDT Part 6, 51-00-00, Figure 1, 11, or 16. If any crack is found
after the maximum 1/32 inch oversize, more repair work is necessary. Contact Boeing for repair instructions
and do the repair. If no crack is found, go to the next step in this figure.
(e) The fastener holes are close reamed to make the fastener removal easier for the repeat open-hole HFEC
inspection.
FIGURE 3: STA 2598 BULKHEAD - BULKHEAD LOWER LEFT SIDE - INSPECTION
(SHEET 4 OF 5)
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PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 43

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.
A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the
number of fasteners necessary for this figure.
More DataHole DiaQtyIdentificationNameCode
(a) (b) (d) (e) (f)0.2495 -
0.2505
2BACB30NX8K8BOLTI
--2BACC30BH8COLLAR
(a) (c) (g) (h) (i)0.3120 -
0.3130
1BACB30NX10K13BOLTJ
--1BACC30BH10COLLAR
(a) Close ream holes are specified to facilitate subsequent open hole HFEC inspections and prevent contin-
uous oversizing.
(b) If necessary, up to 1/32 oversize is allowed. For 1/64 oversize use BACB30NX8K8X and BACC30BH8 in
0.2651-0.2661 diameter hole. For 1/32 oversize use BACB30NX8K8Y and BACC30AC8 in 0.2807-0.2817
diameter hole.
(c) If necessary, up to 1/32 oversize is allowed. For 1/64 oversize use BACB30NX10K13X and BACC30BH10
in 0.3276-0.3286 diameter hole, and 1/32 oversize use BACB30NX10K13Y and BACC30AC10 in 0.3432-
0.3442 diameter hole.
(d) Alternate fastener: For standard size use BACB30NT4K10 BOLT, BACW10BP4CD WASHER under head,
BACW10BP4DP WASHER under nut and BACN10JC4CD NUT. Torque nut 63 - 67 inch/pounds.
(e) Alternate fastener: For 1/64 oversize use BACB30LK4K10X BOLT, BACW10BP41CD WASHER under
head, BACW10BP41DP WASHER under nut and BACN10JC4CD NUT. Torque nut 63 - 67 inch/pounds.
(f) Alternate fastener: For 1/32 oversize use BACB30LK4K10Y BOLT, BACW10BP42CD WASHER under
head, BACW10BP42DP WASHER under nut and BACN10JC4CD NUT. Torque nut 63 - 67 inch/pounds.
(g) Alternate fastener: For standard size use BACB30NT5K15 BOLT, BACW10BP5CD WASHER under head,
BACW10BP5DP WASHER under nut and BACN10JC5CD NUT. Torque nut 120 - 130 inch/pounds (target
is 125).
(h) Alternate fastener: For 1/64 oversize use BACB30LK5K15X BOLT, BACW10BP51CD WASHER under
head, BACW10BP51DP WASHER under nut and BACN10JC5CD NUT. Torque nut 120 - 130 inch/pounds
(target is 125).
(i) Alternate fastener: For 1/32 oversize use BACB30LK5K15Y BOLT, BACW10BP52CD WASHER under
head, BACW10BP52DP WASHER under nut and BACN10JC5CD NUT. Torque nut 120 - 130 inch/pounds
(target is 125).
FIGURE 3: STA 2598 BULKHEAD - BULKHEAD LOWER LEFT SIDE - INSPECTION
(SHEET 5 OF 5)
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PROPRIETARY - Copyright © Unpublished
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Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 44 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
STA
2598
STA
2598
FOR BULKHEAD
UPPER WEB REPAIR
SEE DRAWING
624U0075 SHEET 1
ZONE C3
HORIZONTAL
STABILIZER
SUPPORT FRAME
AFT INNER CHORD
2161856
FIGURE 4: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - LEFT SIDE
(SHEET 1 OF 6)
Original Issue: November 08, 2012
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PROPRIETARY - Copyright © Unpublished
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### Page 45

The step numbers shown below agree with the numbers shown in the circle symbols on drawing 624U0075,
Sheet 1. The QTY numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)83-FASTENERRemove1
(b)--BULKHEAD UPPER
WEB
Cut2
(c)--BULKHEAD UPPER
WEB
Inspect3
(d)1-PART B (CUTOUT
FILLER)
Make4
-1-PART B (CUTOUT
FILLER)
Put / Hold
(e)1-PART D (UPPER
FILLER)
Make5
-1-PART D (UPPER
FILLER)
Put / Hold
(f) (g) (h)1-PART A (REPAIR
DOUBLER)
Make6
-1-PART A (REPAIR
DOUBLER)
Put / Hold
(j)1BACF3T01C87-25PART C (TAPERED
FILLER)
Make7
-1BACF3T01C87-25PART C (TAPERED
FILLER)
Put / Hold
(i) (j)1BACS40R022A022FPART E (SHIM)Make8
(i) (k)1BACS40R022A022FPART E (SHIM)Put / Hold
(j)2BACF3T01H10-08PART F (TAPERED
FILLER)
Make9
-2BACF3T01H10-08PART F (TAPERED
FILLER)
Put / Hold
(j)1BACF3H07LP008HNPART G (RADIUS
FILLER)
Make10
-1BACF3H07LP008HNPART G (RADIUS
FILLER)
Put / Hold
(l)109-FASTENER HOLEDrill / Ream11
---REPAIR PARTSRemove / Keep12
---REPAIR PARTSClean/Deburr13
FIGURE 4: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - LEFT SIDE
(SHEET 2 OF 6)
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PROPRIETARY - Copyright © Unpublished
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Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 46

More DataQtyIdentificationNameTaskStep
(m)--CHEMICAL CONVER-
SION COATING
Apply14
(n)-BMS 10-11, TYPE 1PRIMERApply
(o)-BMS 5-95SEALANTApply15
-1-PART B (CUTOUT
FILLER)
Install (New)16
-1-PART A (REPAIR
DOUBLER)
Install (New)
-1-PART D (UPPER
FILLER)
Install (New)
-1-PART C (TAPERED
FILLER)
Install (New)
-1-PART E (SHIM)Install (New)
-2-PART F (TAPERED
FILLER)
Install (New)
-1-PART G (RADIUS
FILLER)
Install (New)
(a) Remove existing fasteners common to the repair.
(b) Do a cutout of the bulkhead upper web to remove crack damage within the maximum allowable cut line.
Install a temporary/protective shim between the bulkhead upper web and adjacent structure, or use other
means, to prevent any damage when the bulkhead upper web is cut. The inside radius of the cutout is to
be a minimum of 0.50 inch. Maintain surface roughness of 125 microinches Ra or better.
(c) Do a surface HFEC inspection of the bulkhead upper web cutout edges for cracks in accordance with
747 NDT Part 6, 51-00-00, Figure 4 or 23 to make sure that there is no crack. If no crack is found, make
an insurance cut of an additional 0.030 inch. If any crack is found after the cutout of the bulkhead upper
web, contact Boeing for repair instructions and do the repair.
(d) Make a filler to fit the cutout using BACF3F030L035AN. Maintain a gap of 0.010 - 0.030 inch gap between
the filler and bulkhead upper web cutout. Break sharp edges. Maintain surface roughness of 125 microinch-
es Ra or better. Maintain 0.50 minimum radius.
(e) Make a filler to fit under the after inner chord using BACF3F042G230AN. Break sharp edges. Maintain
surface roughness of 125 microinches Ra or better. Maintain 0.50 minimum radius.
(f) Make a repair doubler to fit the area as shown. Make the repair doubler from 15-5PH CRES sheet per
BMS 7-240, Type I or AMS 5659. Thickness = 0.050 in. Heat treat to 180-200 ksi. Refer to BAC 5619 as
an accepted procedure for heat treatment of steel. Break sharp edges. Maintain surface roughness of
125 microinches Ra or better. Maintain 2D minimum edge margin and 0.50 minimum radius when making
the doubler.
FIGURE 4: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - LEFT SIDE
(SHEET 3 OF 6)
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PROPRIETARY - Copyright © Unpublished
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Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 47

More DataQtyIdentificationNameTaskStep
(g) Option 1: Apply zinc-nickel alloy plate or cadmium plate on the doubler. Refer to BAC5637, Type II, Class
2 or SOPM 20-42-05, Type 2, Class 2 as an accepted procedure for zinc-nickel allow plate or cadmium
plate respectively. After the plating apply BMS 10-11, Type 1 primer. Refer to SOPM 20-41-02 as accepted
procedures for applying the primer.
(h) Option 2: Abrasive clean and apply BMS 10-11, Type 1 primer on the doubler. Refer to SOPM 20-30-03
and SOPM 20-41-02 as an accepted procedure for cleaning and applying primer, respectively.
(i) This part is necessary if the gap is more than 0.010 inch before pull up.
(j) Make the part if the part is not available from Boeing. Refer to SOPM 20-50-20 as an accepted procedure
for making laminated shims and solid fillers.
(k) If the part is required, remove 0.003 laminations to limit the gap to 0.010 before pull up. Maintain 1.7D
minimum edge margin. Apply BMS 10-11, Type 1 primer after delaminating.
(l) Drill/ream existing and new fastener holes as specified in the fastener table. For new fastener locations,
maintain 4D to 6D fastener spacing and 2D minimum edge margin.
(m) Apply a chemical conversion coating to all bare aluminum surfaces. Refer to SOPM 20-43-03, Type 2,
Class A as an accepted procedure.
(n) Apply BMS 10-11, Type 1 primer to all bare aluminum surfaces. Refer to SOPM 20-41-02 as an accepted
procedure.
(o) Apply fay surface sealant on PART A (REPAIR DOUBLER) if no plating has been done. Make sure there
is a squeeze out around the edge of the doubler and fair the squeeze out into a fillet seal. Also apply fay
surface sealant on PART B (CUTOUT FILLER) and fill the gap. Refer to SOPM 20-50-19 as an accepted
procedure.
FIGURE 4: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - LEFT SIDE
(SHEET 4 OF 6)
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PROPRIETARY - Copyright © Unpublished
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Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 48

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols on drawing
624U0075, Sheet 1. A number in the lower right corner gives the grip length of the fastener. The QTY numbers
shown below are the number of fasteners necessary for this figure.
More DataHole DiaQtyIdentificationNameCode
(a)0.1895 -
0.1905
26BACB30NX6K3BOLTA
(b)-26BACW10EG6CUWASHER, COUNTER-
SUNK
(c)-26BACW10EG6CWASHER, COUNTER-
SUNK
--26BACC30BH6COLLAR
(a)0.2026 -
0.2036
18BACB30NX6K( )XBOLTB
(b)-18BACW10EG61CUWASHER, COUNTER-
SUNK
(c)-18BACW10EG61CWASHER, COUNTER-
SUNK
--18BACC30BH6COLLAR
(a)0.2026 -
0.2036
7BACB30NX6K( )XBOLTC
--7BACC30BH6COLLAR
-0.200 - 0.2033BACB30NX6K8XBOLTD
--3BACC30BH6COLLAR
(a)0.2651 -
0.2661
10BACB30NX8K( )XBOLTE
--10BACC30BH8COLLAR
-0.263 - 0.26637BACB30NX8K( )XBOLTF
--37BACC30BH8COLLAR
-0.325 - 0.3284BACB30NX10K( )XBOLTG
--4BACC30BH10COLLAR
(a)0.3276 -
0.3286
4BACB30NX10K( )XBOLTH
--4BACC30BH10COLLAR
(a) Fasteners common to the steel repair doubler, wet install fasteners with BMS 5-95. Refer to SOPM 20-
50-19, Method 2 as an accepted procedure.
FIGURE 4: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - LEFT SIDE
(SHEET 5 OF 6)
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Work - See page 1 for details.
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 49

More DataHole DiaQtyIdentificationNameCode
(b) Option 1 (washer): If no plating has been done on the repair doubler and the bolt head is installed on the
aft side (on the side of the steel repair doubler), install the washer under the bolt head against the repair
doubler.
(c) Option 2 (washer): If a plating has been done on the repair doubler and the bolt head is installed on the
aft side (on the side of the steel repair doubler), install the washer under the bolt head against the repair
doubler.
The flag note numbers shown below agree with the numbers shown in the flag symbols on drawing 624U0075,
Sheet 1.
More DataQtyIdentificationName
Flag
Note
A maximum of 1/64 inch oversize
from the original nominal hole size
is allowed at these fastener hole
locations. If additional oversizing
is necessary, contact Boeing for
more instructions.
10-FASTENER HOLE1
FIGURE 4: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - LEFT SIDE
(SHEET 6 OF 6)
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 50 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
STA
2598
STA
2598
FOR BULKHEAD
UPPER WEB REPAIR
SEE DRAWING
624U0075 SHEET 2
ZONE C3
HORIZONTAL
STABILIZER
SUPPORT
2161858
FIGURE 5: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - RIGHT SIDE
(SHEET 1 OF 6)
Original Issue: November 08, 2012
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  1110 09

### Page 51

The step numbers shown below agree with the numbers shown in the circle symbols on drawing 624U0075,
Sheet 2. The QTY numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)83-FASTENERRemove1
(b)--BULKHEAD UPPER
WEB
Cut2
(c)--BULKHEAD UPPER
WEB
Inspect3
(d)1-PART B (CUTOUT
FILLER)
Make4
-1-PART B (CUTOUT
FILLER)
Put / Hold
(e)1-PART D (UPPER
FILLER)
Make5
-1-PART D (UPPER
FILLER)
Put / Hold
(f) (g) (h)1-PART A (REPAIR
DOUBLER)
Make6
-1-PART A (REPAIR
DOUBLER)
Put / Hold
(j)1BACF3T01C87-25PART C (TAPERED
FILLER)
Make7
-1BACF3T01C87-25PART C (TAPERED
FILLER)
Put / Hold
(i) (j)1BACS40R022A022FPART E (SHIM)Make8
(i) (k)1BACS40R022A022FPART E (SHIM)Put / Hold
(j)2BACF3T01H10-08PART F (TAPERED
FILLER)
Make9
-2BACF3T01H10-08PART F (TAPERED
FILLER)
Put / Hold
(j)1BACF3H07LP008HNPART G (RADIUS
FILLER)
Make10
-1BACF3H07LP008HNPART G (RADIUS
FILLER)
Put / Hold
(l)109-FASTENER HOLEDrill / Ream11
---REPAIR PARTSRemove / Keep12
---REPAIR PARTSClean/Deburr13
FIGURE 5: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - RIGHT SIDE
(SHEET 2 OF 6)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 52

More DataQtyIdentificationNameTaskStep
(m)--CHEMICAL CONVER-
SION COATING
Apply14
(n)-BMS 10-11, TYPE 1PRIMERApply
(o)-BMS 5-95SEALANTApply15
-1-PART B (CUTOUT
FILLER)
Install (New)16
-1-PART A (REPAIR
DOUBLER)
Install (New)
-1-PART D (UPPER
FILLER)
Install (New)
-1-PART C (TAPERED
FILLER)
Install (New)
-1-PART E (SHIM)Install (New)
-2-PART F (TAPERED
FILLER)
Install (New)
-1-PART G (RADIUS
FILLER)
Install (New)
(a) Remove existing fasteners common to the repair.
(b) Do a cutout of the bulkhead upper web to remove crack damage within the maximum allowable cut line.
Install a temporary/protective shim between the bulkhead upper web and adjacent structure, or use other
means, to prevent any damage when the bulkhead upper web is cut. The inside radius of the cutout is to
be a minimum of 0.50 inch. Maintain surface roughness of 125 microinches Ra or better.
(c) Do a surface HFEC inspection of the bulkhead upper web cutout edges for cracks in accordance with
747 NDT Part 6, 51-00-00, Figure 4 or 23 to make sure that there is no crack. If no crack is found, make
an insurance cut of an additional 0.030 inch. If any crack is found after the cutout of the bulkhead upper
web, contact Boeing for repair instructions and do the repair.
(d) Make a filler to fit the cutout using BACF3F030L035AN. Maintain a gap of 0.010 - 0.030 inch gap between
the filler and bulkhead upper web cutout. Break sharp edges. Maintain surface roughness of 125 microinch-
es Ra or better. Maintain 0.50 minimum radius.
(e) Make a filler to fit under the after inner chord using BACF3F042G230AN. Break sharp edges. Maintain
surface roughness of 125 microinches Ra or better. Maintain 0.50 minimum radius.
(f) Make a repair doubler to fit the area as shown. Make the repair doubler from 15-5PH CRES sheet per
BMS 7-240, Type I or AMS 5659. Thickness = 0.050 in. Heat treat to 180-200 ksi. Refer to BAC 5619 as
an accepted procedure for heat treatment of steel. Break sharp edges. Maintain surface roughness of
125 microinches Ra or better. Maintain 2D minimum edge margin and 0.50 minimum radius when making
the doubler.
FIGURE 5: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - RIGHT SIDE
(SHEET 3 OF 6)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 53

More DataQtyIdentificationNameTaskStep
(g) Option 1: Apply zinc-nickel alloy plate or cadmium plate on the doubler. Refer to BAC5637, Type II, Class
2 or SOPM 20-42-05, Type 2, Class 2 as an accepted procedure for zinc-nickel allow plate or cadmium
plate respectively. After the plating apply BMS 10-11, Type 1 primer. Refer to SOPM 20-41-02 as accepted
procedures for applying the primer.
(h) Option 2: Abrasive clean and apply BMS 10-11, Type 1 primer on the doubler. Refer to SOPM 20-30-03
and SOPM 20-41-02 as an accepted procedure for cleaning and applying primer, respectively.
(i) This part is necessary if the gap is more than 0.010 inch before pull up.
(j) Make the part if the part is not available from Boeing. Refer to SOPM 20-50-20 as an accepted procedure
for making laminated shims and solid fillers.
(k) If the part is required, remove 0.003 laminations to limit the gap to 0.010 before pull up. Maintain 1.7D
minimum edge margin. Apply BMS 10-11, Type 1 primer after delaminating.
(l) Drill/ream existing and new fastener holes as specified in the fastener table. For new fastener locations,
maintain 4D to 6D fastener spacing and 2D minimum edge margin.
(m) Apply a chemical conversion coating to all bare aluminum surfaces. Refer to SOPM 20-43-03, Type 2,
Class A as an accepted procedure.
(n) Apply BMS 10-11, Type 1 primer to all bare aluminum surfaces. Refer to SOPM 20-41-02 as an accepted
procedure.
(o) Apply fay surface sealant on PART A (REPAIR DOUBLER) if no plating has been done. Make sure there
is a squeeze out around the edge of the doubler and fair the squeeze out into a fillet seal. Also apply fay
surface sealant on PART B (CUTOUT FILLER) and fill the gap. Refer to SOPM 20-50-19 as an accepted
procedure.
FIGURE 5: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - RIGHT SIDE
(SHEET 4 OF 6)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 54

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols on drawing
624U0075, Sheet 2. A number in the lower right corner gives the grip length of the fastener. The QTY numbers
shown below are the number of fasteners necessary for this figure.
More DataHole DiaQtyIdentificationNameCode
(a)0.1895 -
0.1905
26BACB30NX6K3BOLTA
(b)-26BACW10EG6CUWASHER, COUNTER-
SUNK
(c)-26BACW10EG6CWASHER, COUNTER-
SUNK
--26BACC30BH6COLLAR
(a)0.2026 -
0.2036
18BACB30NX6K( )XBOLTB
(b)-18BACW10EG61CUWASHER, COUNTER-
SUNK
(c)-18BACW10EG61CWASHER, COUNTER-
SUNK
--18BACC30BH6COLLAR
(a)0.2026 -
0.2036
7BACB30NX6K( )XBOLTC
--7BACC30BH6COLLAR
-0.200 - 0.2033BACB30NX6K8XBOLTD
--3BACC30BH6COLLAR
(a)0.2651 -
0.2661
10BACB30NX8K( )XBOLTE
--10BACC30BH8COLLAR
-0.263 - 0.26637BACB30NX8K( )XBOLTF
--37BACC30BH8COLLAR
-0.325 - 0.3284BACB30NX10K( )XBOLTG
--4BACC30BH10COLLAR
(a)0.3276 -
0.3286
4BACB30NX10K( )XBOLTH
--4BACC30BH10COLLAR
(a) Fasteners common to the steel repair doubler, wet install fasteners with BMS 5-95. Refer to SOPM 20-
50-19, Method 2 as an accepted procedure.
FIGURE 5: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - RIGHT SIDE
(SHEET 5 OF 6)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2012
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BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 55

More DataHole DiaQtyIdentificationNameCode
(b) Option 1 (washer): If no plating has been done on the repair doubler and the bolt head is installed on the
aft side (on the side of the steel repair doubler), install the washer under the bolt head against the repair
doubler.
(c) Option 2 (washer): If a plating has been done on the repair doubler and the bolt head is installed on the
aft side (on the side of the steel repair doubler), install the washer under the bolt head against the repair
doubler.
The flag note numbers shown below agree with the numbers shown in the flag symbols on drawing 624U0075,
Sheet 2.
More DataQtyIdentificationName
Flag
Note
A maximum of 1/64 inch oversize
from the original nominal hole size
is allowed at these fastener hole
locations. If additional oversizing
is necessary, contact Boeing for
more instructions.
10-FASTENER HOLE1
FIGURE 5: STA 2598 BULKHEAD - BULKHEAD UPPER WEB REPAIR - RIGHT SIDE
(SHEET 6 OF 6)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2012
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55 of 74
BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

### Page 56 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
STA
2598
STA
2598
HORIZONTAL
STABILIZER
SUPPORT
FRAME
AFT INNER
CHORD
2161620
FIGURE 6: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - UNREPAIRED STRUCTURE - LEFT SIDE
(SHEET 1 OF 5)
Original Issue: November 08, 2012
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  121099

### Page 57 (OCR)

BOEING SERVICE BULLETIN 747-53A2815C
ALERT  ALERT
BULKHEAD
UPPER WEB
FORWARD
INNER CHORD
B
TYPICAL
CRACK
SHEAR
AFT INNER  DECK
CHORD  SPLICE
FITTING
B
INSPECTION
AREA
FORWARD
INNER CHORD
FORWARD  BULKHEAD
INNER  UPPER
CHORD  WEB
• BULKHEAD
UPPER WEB
• SPLICI  FITTING 2)  SPLICE
-ITTING
TYPICAL
CRACK
SHEAR
DECK  INBD
FWD
SHEAR
DECK  2161672
A-A  B-B
FIGURE 6: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - UNREPAIRED STRUCTURE - LEFT SIDE
(SHEET 2 OF 5)
Original Issue: November 08, 2012
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PROPRIETARY - Copyright ® Unpublished
Work - See page 1 for details.  57 of 74

### Page 58 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
SHEAR
DECK
SUPPORT
FRAME
2) SPLICE
FITTING
L c
STA
2598
FORWARD  CHORD -  INNER  SHEAR  DECK
FWD
TYPICAL FRAME
SUPPORT CRACK
SPLICE  SUPPORT
FITTING  C-C  FRAME  2161718
FIGURE 6: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - UNREPAIRED STRUCTURE - LEFT SIDE
(SHEET 3 OF 5)
Original Issue: November 08, 2012
Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-53A2815
Work - See page 1 for details.  58 of 74

### Page 59 (OCR)

BOEING SERVICE BULLETIN 747-53A2815
ALERT  ALERT
LBL 40
FORWARD
INNER CHORD
SYSTEMS
BRACKET
BULKHEAD
UPPER WEB
BULKHEAD
(REPAIR  PART A  UPPER WEB
DOUBLER)
FLOOR
SUPPORT
SUPPORT
FRAME
* AFT INNER
SPLICE FITTING  CHORD
AFT INNER CHORD
INSPECTION AREA (AFT SIDE)
BULKHEAD UPPER WEB
INSPECTION AREA (AFT SIDE)
INBD
VIEW LOOKING FORWARD
2168080
FIGURE 6: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - UNREPAIRED STRUCTURE - LEFT SIDE
(SHEET 4 OF 5)
Original Issue: November 08, 2012
PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  747-53A2815
Work - See page 1 for details.  59 of 74

### Page 60

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)--FORWARD INNER
CHORD
Inspect1
(b)--FORWARD INNER
CHORD
Inspect
(a)--SPLICE FITTINGInspect2
(a)--SUPPORT FRAMEInspect3
(b)--SUPPORT FRAMEInspect
(a)--AFT INNER CHORDInspect4
(c)--AFT INNER CHORDInspect5
(a)--BULKHEAD UPPER
WEB
Inspect6
(a) Do a surface HFEC inspection around fasteners as shown in the figure for cracks in accordance with 747
NDT Part 6, 51-00-00, Figure 4 or 23.
(b) Do a surface HFEC inspection along the edge of splice fitting as shown in the figure for cracks in accor-
dance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.
(c) Do an LFEC inspection around the fastener as shown in the figure for cracks in accordance with 747 NDT
Part 6, 51-00-26. This inspection is for the area where the systems bracket covers up the aft inner chord.
Thickness of the systems bracket is 0.040 inch.
FIGURE 6: STA 2598 BULKHEAD - POST-REPAIR INSPECTION - UNREPAIRED STRUCTURE - LEFT SIDE
(SHEET 5 OF 5)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
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Original Issue: November 08, 2012
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60 of 74
BOEING SERVICE BULLETIN 747-53A2815
ALERTALERT

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