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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2852 Original Issue: June 22, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor Beam Upper Chord and Strap Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2012 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner™, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management Company.
Original Issue: June 22, 2012 747-53A2852 1 of 189
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2012 747-53A2852 2 of 189 BOEING SERVICE BULLETIN 747-53A2852
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 6 D. Description .............................................. 1 6 E. Compliance .............................................. 1 7 F. Approval ............................................... 2 2 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 8
1. Existing Data: ......................................... 2 8
2. Data Supplied with this Service Bulletin: ........................... 2 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 9 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 0 M. Software Accomplishment Summary ................................ 3 0
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary for Each Airplane ................................. 3 1
1. Kits/Parts: ........................................... 3 1
2. Parts and Materials Supplied by the Operator: ........................ 3 1
3. Parts Modified and Reidentified: ............................... 1 1 9
4. Parts Removed and Not Replaced: ............................. 1 1 9 D. Parts Necessary to Change Spares ................................ 1 1 9 E. Special Tooling - Price and Availability .............................. 1 1 9 F. Special Tooling Necessary to do this Service Bulletin ...................... 1 1 9
3. ACCOMPLISHMENT INSTRUCTIONS ................................. 1 2 1 A. GENERAL INFORMATION .................................... 1 2 1 B. WORK INSTRUCTIONS ...................................... 1 2 2 FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORD - REPLACEMENT LOCATIONS [Group 1-2] ................................................. 1 2 8 FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD - REPLACEMENT LOCATIONS [Group 3-4] ................................................. 1 3 1 FIGURE 3: UPPER DECK FLOOR BEAM - UPPER CHORD - REPLACEMENT LOCATIONS [Group 5] ................................................. 1 3 4 FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD - REPLACEMENT LOCATIONS [Group 6] ................................................. 1 3 8 Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA .................. 1 4 1 APPENDIX B: FASTENER REPLACEMENT GUIDE ............................ 1 8 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2012 747-53A2852 3 of 189 BOEING SERVICE BULLETIN 747-53A2852
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2012 747-53A2852 4 of 189 BOEING SERVICE BULLETIN 747-53A2852
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2852Original Issue: June 22, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor Beam Upper Chord and Strap Replacement
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 replace the upper chords and reinforcing straps on the upper deck floor beams. The upper deck floor beam upper chords have been determined to be structure that could develop Widespread Fatigue Damage (WFD). WFD of the floor beam upper chords could reduce the structural integrity of the floor beams such that multiple adjacent beams could become severed, resulting in rapid decompression of the airplane.
Analysis by Boeing indicates that accomplishment of the inspections, repairs, and modifications currently in Service Bulletin 747-53A2452 are not adequate to ensure the structural integrity of the affected upper deck floor beam upper chords on airplanes that are operated beyond 30,000 total flight cycles. On these airplanes, Boeing recommends that the upper deck floor beam upper chords and reinforcing straps be replaced in accordance with this service bulletin.
For more information on WFD, refer to Boeing Service Letter 747-SL-53-088A.
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 ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Get access to upper deck floor beams from the upper deck and main deck, as necessary. Remove the floor beam upper chords and reinforcing straps. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and repair any cracks that are found. Fabricate and install new upper chords and reinforcing straps. Re-install any repairs or parts that are not replaced. Install all equipment and panels removed for access.
Upper chord replacement is only required at "full length" upper deck floor beams aft of station (STA) 360 that span the entire width of the airplane from the left side of body frame to the right side of body frame.
EFFECTIVITY All 747-100/-100B/-100B SUD/-200B/-300/SP/SR airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1 and AD 2005-20-29 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
REMOVE AND DISCARD EXISTING UPPER CHORDS FLOOR PANEL AND STRAPS. MAKE AND INSTALL NEW UPPER
CHORDS AND STRAPS
UPPER CHORD
WEB DO HFEC OPEN HOLE INSPECTIONS OF — ALL ACCESSED HOLES IN THE WEB AND FRAMES.
LOWER CHORD
TYPICAL UPPER
DECK FLOOR BEAMS 2155373 Original Issue: June 22, 2012 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2852 Work - See page 1 for details. 7 of 189
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2852 Original Issue: June 22, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor Beam Upper Chord and Strap Replacement
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.
DESCRIPTIONCONFIGURATIONGROUP 747-100, 747-100B, 747-200B, 747-SP, and 747-SR Passenger airplanes with a circular stairway cutout, except those modified by Boeing to the Special Freighter configuration.
-1 747-100, 747-100B, 747-200B, and 747-SR airplanes with a circular stairway cutout that have been modified by Boeing to the Special Freighter configuration.
-2 747-100, 747-100B, 747-200B, 747-SP, and 747-SR Passenger airplanes with a forward straight stairway cutout, except those modified by Boeing to the Special Freighter configuration.
-3 747-100, 747-100B, 747-200B, and 747-SR airplanes with a forward straight stairway cutout that have been modified by Boeing to the Special Freighter configuration.
-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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DESCRIPTIONCONFIGURATIONGROUP Stretched upper deck 747-100 (747-100BSUD), stretched upper deck 747-200B, and 747-300 airplanes except those modified by Boeing to the Special Freighter configuration.
-5 Stretched upper deck 747-100 (747-100BSUD), stretched upper deck 747-200B, and 747-300 airplanes that have been modified by Boeing to the Special Freighter configuration.
-6 Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747SP, 747SR GroupVariable Number 1RA001 - RA025 2RA026 1RA027 - RA028 2RA029 1RA030 - RA032 2RA033 1RA034 2RA101 - RA103 1RA104 - RA110 2RA111 - RA112 1RA113 - RA115 2RA161 - RA163 1RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA266 1RA301 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA418 1RA501 - RA502 1RA521 - RA523 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 2RA524 1RA525 - RA528 1RA532 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 2RA632 1RA633 2RA634 - RA635 1RA651 - RA652 1RA671 - RA677 1RA701 - RA702 1RA721 - RA731 1RA741 - RA745 1RA749 - RA750 1RA761 - RA762 1RA781 - RA784 2RA901 - RA902 1RA903 - RA909 2RA910 - RA916 1RB001 - RB016 2RB041 1RB042 2RB043 1RB044 1RB071 - RB075 1RB101 - RB102 1RB411 - RB413 1RB421 1RB601 - RB603 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 2RB604 - RB605 1RB606 2RB607 1RB681 - RB695 2RB696 1RB697 1RB711 1RB721 - RB723 1RB741 - RB748 1RD001 - RD004 1RD021 - RD022 2RD041 1RD042 2RD043 - RD044 1RD045 - RD054 2RD055 1RD056 - RD059 1RD071 - RD072 1RD081 2RD082 - RD083 1RD091 - RD092 1RD101 - RD104 1RD121 - RD127 1RD131 - RD141 2RD142 1RD143 2RD144 1RD166 - RD167 1RD171 - RD172 1RD181 - RD183 3RD201 - RD204 1RD221 - RD226 2RD227 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2012 747-53A2852 12 of 189 BOEING SERVICE BULLETIN 747-53A2852