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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2837 Original Issue: July 13, 2012 ATA System: 5313 SUBJECT: FUSELAGE - Section 48 - Body Station 2598 Bulkhead - Horizontal Stabilizer Hinge Support Frame Cracking - Modification and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 2 1 B. Concurrent Requirements ...................................... 2 1 C. Reason ................................................ 2 2 D. Description .............................................. 2 2 E. Compliance .............................................. 2 4 F. Approval ............................................... 3 5 G. Manpower .............................................. 3 6 H. Weight and Balance Changes .................................... 3 7 I. Electrical Load Data ......................................... 3 7 J. References .............................................. 3 7
1. Existing Data .......................................... 3 7
2. Data supplied with this Service Bulletin ............................ 3 7
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 3 8 K. Publications Affected ........................................ 3 8 L. Interchangeability and Intermixability of Parts ........................... 3 9
2. MATERIAL INFORMATION ........................................ 4 1 A. Material - Price and Availability ................................... 4 1 B. Industry Support Information .................................... 4 1 C. Parts Necessary For Each Airplane ................................. 4 1
1. Kits/Parts ............................................ 4 1
2. Parts and Materials Supplied by the Operator ........................ 6 0
3. Parts Modified and Reidentified ................................ 6 0
4. Parts Removed and Not Replaced .............................. 6 0 D. Parts Necessary to Change Spares ................................. 6 0 E. Special Tooling - Price and Availability ............................... 6 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 1 A. GENERAL INFORMATION ..................................... 6 1 B. WORK INSTRUCTIONS ....................................... 6 2 FIGURE 1: ACCESS FOR MODIFICATION OF THE LEFT SIDE OF THE STA 2598 BULKHEAD . . 72 FIGURE 2: ACCESS FOR MODIFICATION OF THE RIGHT SIDE OF THE STA 2598 BULKHEAD . 74 FIGURE 3: REMOVAL OF EXISTING MODIFICATION - LEFT SIDE [Group 1-7, Configuration 1] . . 76 FIGURE 4: REMOVAL OF EXISTING MODIFICATION - RIGHT SIDE [Group 1, 4, 6, Configuration 1] . 78 FIGURE 5: REMOVAL OF EXISTING MODIFICATION - RIGHT SIDE [Group 2, Configuration 1] . . . 80 FIGURE 6: REMOVAL OF EXISTING MODIFICATION - RIGHT SIDE [Group 3, 5, 7, Configuration 1] . 82 FIGURE 7: LEFT SIDE MODIFICATION ON PREVIOUSLY MODIFIED AIRPLANES [Group 1-3, 7, Configuration 1] ......................................... 8 4 FIGURE 8: RIGHT SIDE MODIFICATION ON PREVIOUSLY MODIFIED AIRPLANES [Group 1, Configuration 1 ] ................................................ 8 9 FIGURE 9: RIGHT SIDE MODIFICATION ON PREVIOUSLY MODIFIED AIRPLANES [Group 2, Configuration 1 ] ................................................ 9 5
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FIGURE 10: RIGHT SIDE MODIFICATION ON PREVIOUSLY MODIFIED AIRPLANES [Group 3, 7, Configuration 1] ........................................ 1 0 1 FIGURE 11: EXISTING PARTS REMOVAL - LEFT SIDE [Group 4-6, Configuration 1] ......... 1 0 7 FIGURE 12: LEFT SIDE MODIFICATION [Group 4-6, Configuration 1] ................. 1 1 0 FIGURE 13: EXISTING PARTS REMOVAL - RIGHT SIDE [Group 4-6, Configuration 1] ........ 1 1 5 FIGURE 14: RIGHT SIDE MODIFICATION [Group 4, 6, Configuration 1] ................ 1 1 7 FIGURE 15: RIGHT SIDE MODIFICATION [Group 5, Configuration 1] ................. 1 2 2 FIGURE 16: EXISTING PARTS REMOVAL - LEFT SIDE [Group 1-3, 7, Configuration 2] ....... 1 2 8 FIGURE 17: LEFT SIDE MODIFICATION [Group 1-3, 7, Configuration 2] ................ 1 3 0 FIGURE 18: EXISTING PARTS REMOVAL - RIGHT SIDE [Group 1, Configuration 2] ......... 1 3 5 FIGURE 19: RIGHT SIDE MODIFICATION [Group 1, Configuration 2] ................. 1 3 7 FIGURE 20: EXISTING PARTS REMOVAL - RIGHT SIDE [Group 2, Configuration 2] ......... 1 4 3 FIGURE 21: RIGHT SIDE MODIFICATION [Group 2, Configuration 2] ................. 1 4 5 FIGURE 22: EXISTING PARTS REMOVAL - RIGHT SIDE [Group 3, 7, Configuration 2] ........ 1 5 1 FIGURE 23: RIGHT SIDE MODIFICATION [Group 3, 7, Configuration 2] ................ 1 5 3 FIGURE 24: EXISTING PARTS REMOVAL - LEFT SIDE [Group 4-6, Configuration 2] ......... 1 5 9 FIGURE 25: LEFT SIDE MODIFICATION [Group 4-6, Configuration 2] ................. 1 6 1 FIGURE 26: EXISTING PARTS REMOVAL - RIGHT SIDE [Group 4, 6, Configuration 2] ........ 1 6 6 FIGURE 27: RIGHT SIDE MODIFICATION [Group 4, 6, Configuration 2] ................ 1 6 8 FIGURE 28: EXISTING PARTS REMOVAL - RIGHT SIDE [Group 5, Configuration 2] ......... 1 7 3 FIGURE 29: RIGHT SIDE MODIFICATION [Group 5, Configuration 2] ................. 1 7 5 FIGURE 30: MODIFICATION FASTENER DIFFERENCES IF A PREVIOUSLY ACCOMPLISHED LOCAL
WEB REPAIR OR INTERIM MODIFICATION EXISTS AT THE UPPER CORNER OF THE STA 2598 BULKHEAD ....................................... 1 8 0 FIGURE 31: MODIFICATION FASTENER DIFFERENCES IF PREVIOUSLY ACCOMPLISHED LOCAL WEB
REPAIR OR INTERIM MODIFICATION AND CHORD REPAIR EXISTS AT THE UPPER CORNER OF THE STA 2598 BULKHEAD [Group 1-7, Configuration 2] .......... 1 8 4 FIGURE 32: RESTORATION AFTER MODIFICATION OF THE LEFT SIDE OF THE STA 2598 BULKHEAD ................................................. 1 8 8 FIGURE 33: RESTORATION AFTER MODIFICATION OF THE RIGHT SIDE OF THE STA 2598 BULKHEAD ................................................. 1 9 1 FIGURE 34: WEB TRIM AND FILLER FABRICATION AT THE UPPER LEFT AND RIGHT CORNERS OF THE STA 2598 BULKHEAD [Group 1-3, 7] ......................... 1 9 4 FIGURE 35: WEB TRIM AND FILLER FABRICATION AT THE LOWER LEFT CORNER OF THE STA 2598 BULKHEAD .......................................... 1 9 8 FIGURE 36: WEB TRIM AND FILLER FABRICATION AT THE UPPER LEFT AND RIGHT CORNERS OF THE STA 2598 BULKHEAD [Group 4-6] ........................... 2 0 1 FIGURE 37: MODIFICATION OF AN EXISTING REPAIR AT THE LOWER LEFT CORNER OF THE STA 2598 BULKHEAD [Group 1-5, 7, Configuration 1] ...................... 2 0 5 FIGURE 38: MODIFICATION OF AN EXISTING REPAIR AT THE LOWER LEFT CORNER OF THE STA 2598 BULKHEAD [Group 6, Configuration 1] ........................ 2 0 9 FIGURE 39: POST-MODIFICATION INSPECTION - SUPPORT FRAME AND ACCESS CUT-OUT DETAILED INSPECTION ......................................... 2 1 3 FIGURE 40: POST-MODIFICATION INSPECTION - LOWER FLOOR SUPPORT CHORD SURFACE HFEC INSPECTION ......................................... 2 1 5 FIGURE 41: POST-MODIFICATION INSPECTION - OUTER CHORD LFEC INSPECTION ...... 2 2 0 FIGURE 42: POST-MODIFICATION INSPECTION - SUPPORT FRAME OUTER CHORD AND FRAME SUPPORT FITTING INSPECTION ............................. 2 2 4
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FIGURE 43: POST-MODIFICATION INSPECTION - HINGE SUPPORT OPEN-HOLE HFEC INSPECTION ................................................. 2 2 6 FIGURE 44: POST-MODIFICATION INSPECTION - SUPPORT FRAME INSPECTIONS [Group 1-6] . 232 FIGURE 45: POST-MODIFICATION INSPECTION - SUPPORT FRAME INSPECTIONS ....... 2 3 5 FIGURE 46: POST-MODIFICATION INSPECTION - SUPPORT FRAME INSPECTIONS [Group 7] . . 239 FIGURE 47: POST-MODIFICATION INSPECTION - SUPPORT FRAME INSPECTIONS [Group 7] . . 243 APPENDIX A: ................................................. 2 4 6
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2837Original Issue: July 13, 2012 ATA System: 5313 SUBJECT: FUSELAGE - Section 48 - Body Station 2598 Bulkhead - Horizontal Stabilizer Hinge Support Frame Cracking - Modification 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 instruction for a modification to the bulkhead at Body Station 2598. This modification makes the bulkhead more resistant to fatigue cracks in the areas that must be inspected to satisfy requirements given in the FAA Airworthiness Directives and Boeing service bulletins identified below. This modification can be done to address safety issues related to Airworthiness Directive AD 2010-14-07 and Service Bulletins 747-53A2427, 747-53A2449, 747-53A2467 and 747-53A2473. However, after this modification is done inspections of the Body Station 2598 diagonal braces, bulkhead outer chord, and diagonal brace fittings and flanges continue in accordance with 747-53A2467.
NoteFAA Airworthiness DirectiveBoeing Service Bulletin
(a)AD 2010-14-07747-53A2427
(a)AD 2010-14-07747-53A2449
(b)AD 2010-14-07747-53A2467
(c)AD 2010-14-07747-53A2473
(a) All inspection requirements terminated - no more work necessary after this modification.
(b) Inspection of the support frame aft inner chord in accordance with 747-53A2467 is not necessary after the modification; however inspection of the upper aft outer chords and the diagonal brace attachment fittings, flanges and rods in accordance with 747-53A2467 is necessary after this modification.
(c) All inspection requirements terminated - no more Service Bulletin 747-53A2473 work is necessary after this modification. Post-modification inspections in accordance with this service bulletin are required.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
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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/PartsYesKits/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 YesSpecial Tooling Required Boeing Service Related Problem (SRP) 747-SRP-53-0343 is related to this service bulletin.
ACTION (PRR 85901-103RS) Externally support the horizontal stabilizer to remove the load on the hinge pins. Get access to the STA 2598 bulkhead. If a modification in accordance with Boeing Service Bulletin 747-53A2473 was previously installed, remove that modification. If repairs were previously installed in accordance with Boeing Service Bulletin 747-53A2427 or the Structural Repair Manual, remove the repair parts. Remove existing parts and install a reinforcing modification in accordance with this service bulletin.
EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, and 747SR Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits.
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BOEING SERVICE BULLETIN 747-53A2837
ALERT ALERT Refer to Paragraph 2.A., Material - Price and Availability.
STA 2598 STA 2598
REINFORCE THE LEFT
AND RIGHT SIDES OF THE STA 2598 BULKHEAD 2049779 Original Issue: July 13, 2012 BOEING PROPRIETARY - 747-53A2837 Copyright © Unpublished Work - See page 1 for details. 9 of 250
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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2837 Original Issue: July 13, 2012 ATA System: 5313 SUBJECT: FUSELAGE - Section 48 - Body Station 2598 Bulkhead - Horizontal Stabilizer Hinge Support Frame Cracking - Modification 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 Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. Refer to PRR 85901-103RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP All 747 airplanes through line number 695, except Group 2, Group 3 and Group 7 airplanes.
-1 Previously modified in accordance with SB 747-53A2473.1 Not previously modified in accordance with SB 747-53A2473.2 Certain 747 airplanes line number 46 through line number 380 with a variable fastener installation at the lower right inboard corner of the STA 2598 bulkhead, between RBL 30 and RBL 35.
-2 Previously modified in accordance with SB 747-53A2473.1 Not previously modified in accordance with SB 747-53A2473.2
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DESCRIPTIONCONFIGURATIONGROUP Certain 747 airplanes line number 116 through line number 695, except 747SP airplanes (Group 7), with a variable fastener installation, different than Group 2, at the lower right inboard corner of the STA 2598 bulkhead, between RBL 30 and RBL 35.
-3 Previously modified in accordance with SB 747-53A2473.1 Not previously modified in accordance with SB 747-53A2473.2 747 airplanes line number 696 - 1101, except Group 5 airplanes and 747 Large Cargo Freighter airplanes.
-4 Previously modified in accordance with SB 747-53A2473.1 Not previously modified in accordance with SB 747-53A2473.2 Certain 747 airplanes line number 697 through line number 886, with a variable fastener installation, different than Group 4, at the lower right inboard corner of the STA 2598 bulkhead, between RBL 30 and RBL 35.
-5 Previously modified in accordance with SB 747-53A2473.1 Not previously modified in accordance with SB 747-53A2473.2 747 airplanes line number 1102 - 1307.-6 Previously modified in accordance with SB 747-53A2473.1 Not previously modified in accordance with SB 747-53A2473.2 All 747SP airplanes.-7 Previously modified in accordance with SB 747-53A2473.1 Not previously modified in accordance with SB 747-53A2473.2 Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA164
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