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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2839 Original Issue: November 06, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin and Bear Strap Crack at the Aft Upper Corner of the Main Entry Door 5 Cutout - Inspection, Repair and Modification 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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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Original Issue: November 06, 2012 747-53A2839 1 of 76
4.0
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 1 9 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 5 G. Manpower .............................................. 2 6 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 9 J. References .............................................. 2 9
1. Existing Data .......................................... 2 9
2. Data supplied with this Service Bulletin ............................ 2 9
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 3 0 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 0
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 2 C. Parts Necessary For Each Airplane ................................. 3 2
1. Kits/Parts ............................................ 3 2
2. Parts and Materials Supplied by the Operator ........................ 4 5
3. Parts Modified and Reidentified ................................ 4 6
4. Parts Removed and Not Replaced .............................. 4 6 D. Parts Necessary to Change Spares ................................. 4 6 E. Special Tooling - Price and Availability ............................... 4 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 7 A. GENERAL INFORMATION ..................................... 4 7 B. WORK INSTRUCTIONS ....................................... 4 8 FIGURE 1: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY DOOR 5 CUTOUT .................................. 5 3 FIGURE 2: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY DOOR 5 CUTOUT ....................................... 5 6 FIGURE 3: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY DOOR 5 CUTOUT [Group 1-2, 4] .......................... 5 9 FIGURE 4: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY DOOR 5 CUTOUT [Group 1-2, 4] ............................... 6 2 FIGURE 5: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY DOOR 5 CUTOUT ....................................... 6 5 FIGURE 6: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY DOOR 5 CUTOUT [Group 1-2, 4] .......................... 6 8
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FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF THE MAIN ENTRY DOOR 5 CUTOUT ............................ 7 1
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2839Original Issue: November 06, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin and Bear Strap Crack at the Aft Upper Corner of the Main Entry Door 5 Cutout - Inspection, Repair and Modification
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 do inspections of the fuselage skin and internal bear strap at the aft upper corner of the cutout for Main Entry Door (MED) 5. Skin and bear strap cracks that are not found and repaired can become large and result in in-flight depressurization of the airplane.
An operator has told Boeing that a 3.65 inch long crack was found at the aft upper corner of the right MED 5 cutout on an airplane with 11,047 flight-cycles. The skin (including the bonded doubler and tripler) and bear strap were found to be cracked. This is the first reported crack to extend up to the door edge frame.
Boeing has received several reports of cracks that did not extend up to the door edge frame on more than thirty airplanes. The affected airplanes had flown between 10,042 and 31,410 total flight-cycles at the time the cracks were found.
Accomplishment of the inspections in this service bulletin and installation of a repair or modification will help prevent in-flight depressurization of the airplane and ensure the structural integrity of the aft upper corner of the MED 5 cutout.
Boeing Service Related Problem (SRP) 747-SRP-53-0361 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
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ReferenceAffectedPlanning Data 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 NoSpecial Tooling Required ACTION (PRR 85901-110RS) Do a detailed inspection for existing repairs at the aft upper corner of the main entry door 5 cutout. If any repair is found, contact Boeing for instructions.
Measure the edge margin at certain fastener locations around the corner of the door cutout. The threshold of the subsequent inspection is dependent on the measured edge margin. At the applicable times given in Paragraph
1.E., Compliance, do detailed and High Frequency Eddy Current (HFEC) inspections of the skin and bear strap for cracks at the aft upper corner of the door cutout. If any crack is found, repair in accordance with this service bulletin. If no cracks are found, put the airplane back to a serviceable condition and do the inspections again and install the preventive modification at the applicable times given in Paragraph 1.E., Compliance. As an alternative to repeat inspections, install a preventive modification in accordance with this service bulletin.
Do post-repair or post-modification detailed and Low Frequency Eddy Current (LFEC) inspections at the times given in Paragraph 1.E., Compliance, Table 3.
EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, and 747SR Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 2009-18-07 and AD 2010-01-01 are related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of September 2, 1997. Please refer to Paragraph 2.B., Industry Support Information.
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MANPOWER Group 1-2, 4:
Elapsed HoursTotal Task HoursAirplanes
1.001.00Inspection for previous repairs and edge margin measurement
23.1035.70Inspection and preventive modification installed on both sides
16.7033.20Post repair/post modification inspection Group 3, 5:
Elapsed HoursTotal Task HoursAirplanes
0.500.50Inspection for previous repairs and edge margin measurement
13.0520.85Inspection and preventive modification installed on the left side
8.4516.70Post repair/post modification inspection Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 747-53A2839
ALERT ALERT ~ DO AN INSPECTION FOR EXISTING REPAIRS AT
THE UPPER CORNER OF THE LEFT AND RIGHT (IF INSTALLED) MAIN ENTRY DOOR 5 CUTOUT. ALSO
MEASURE THE EDGE MARGIN AT CERTAIN
FASTENER LOCATIONS AT THE AFT UPPER
CORNER OF THE DOOR CUTOUT
DO DETAILED AND HFEC INSPECTIONS OF THE
SKIN AT THE AFT UPPER CORNER OF THE CUTOUT
FOR THE LEFT AND RIGHT (IF INSTALLED) MAIN ENTRY DOOR 5 FOR CRACKS. IF CRACKS ARE
FOUND, INSTALL A REPAIR IN ACCORDANCE WITH THIS SERVICE BULLETIN. 2118198 Original Issue: November 06, 2012 747-53A2839
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 76
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2839 Original Issue: November 06, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin and Bear Strap Crack at the Aft Upper Corner of the Main Entry Door 5 Cutout - Inspection, Repair and Modification
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 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 PRR85901-110RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP All 747 airplanes line number 1 through 85.-1 All 747SR, 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400 and 747-400D airplanes line number 86 through 1235, except 747 Large Cargo Freighter (LCF) airplanes. Door 5 does not exist on LCF airplanes.
-2 All 747-200F and 747-400F airplanes line number 86 through 1235.
These airplanes do not have a Door 5 on the right side.
-3 All 747-400 airplanes line number 1236 through 1419.-4 All 747-400F airplanes line number 1236 through 1419. These airplanes do not have a Door 5 on the right side.
-5 Airplane Models:
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747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR GroupVariable Number 1RA001 - RA026 2RA027 - RA034 1RA101 - RA112 2RA113 - RA115 1RA161 - RA162 2RA163 - RA164 1RA201 - RA203 2RA216 - RA217 2RA245 - RA246 1RA251 - RA254 2RA255 - RA266 1RA301 - RA303 2RA304 - RA318 1RA351 - RA359 2RA360 2RA369 - RA373 1RA401 - RA405 2RA406 - RA418 1RA501 2RA502 1RA521 - RA523 2RA524 - RA528 2RA532 - RA548 1RA551 - RA552 2RA559 - RA561 1RA581 2RA582 2RA585 1RA601 - RA602 1RA631 - RA632 2RA633 - RA635
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GroupVariable Number 2RA651 - RA652 2RA671 - RA677 2RA701 - RA702 2RA721 - RA731 2RA741 - RA745 2RA749 - RA750 2RA761 - RA762 2RA781 - RA784 1RA901 - RA907 2RA908 - RA916 2RB001 - RB016 1RB041 - RB043 2RB044 2RB071 - RB075 2RB101 - RB102 2RB411 - RB413 2RB421 2RB601 - RB607 2RB681 - RB697 2RB711 2RB721 - RB723 2RB741 - RB748 2RD001 - RD004 2RD021 - RD022 2RD041 - RD059 2RD071 - RD072 2RD081 - RD083 2RD091 - RD092 2RD101 - RD104 2RD121 - RD127 2RD131 - RD144 2RD166 - RD167 2RD171 - RD172
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GroupVariable Number 2RD181 - RD183 2RD201 - RD204 2RD221 - RD227 2RD231 - RD235 2RD241 - RD243 2RD251 - RD262 2RD271 - RD272 2RD291 - RD292 2RD301 - RD302 2RD311 2RD351 - RD358 2RD361 - RD366 2RD381 - RD383 2RD411 - RD414 2RD421 - RD426 2RD431 - RD435 2RD441 - RD442 2RD451 - RD456 2RD461 2RD471 - RD475 2RD513 - RD519 2RD531 - RD533 2RD551 2RD561 2RD571 2RD581 - RD583 2RD591 - RD593 2RD601 - RD607 2RD621 - RD623 2RD641 - RD649 2RD651 - RD659 2RD661 2RD671
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