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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2854 Original Issue: September 17, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin Panel Chem-Milled Pocket Inspection and Repair at Locations Adjacent to Lap Splices 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Unpublished Work.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: September 17, 2012 747-53A2854 1 of 33
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 2 of 33 BOEING SERVICE BULLETIN 747-53A2854
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 1 E. Compliance .............................................. 1 1 F. Approval ............................................... 1 2 G. Manpower .............................................. 1 3 H. Weight and Balance Changes .................................... 1 3 I. Electrical Load Data ......................................... 1 3 J. References .............................................. 1 3
1. Existing Data: ......................................... 1 3
2. Data Supplied with this Service Bulletin: ........................... 1 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 4 K. Publications Affected ........................................ 1 4 L. Interchangeability and Intermixability of Parts ........................... 1 4 M. Software Accomplishment Summary ................................ 1 4
2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 5 C. Parts Necessary for Each Airplane ................................. 1 5
1. Kits/Parts ............................................ 1 5
2. Parts and Materials Supplied by the Operator ........................ 1 5
3. Parts Modified and Reidentified ................................ 1 5
4. Parts Removed and Not Replaced .............................. 1 5 D. Parts Necessary to Change Spares ................................. 1 5 E. Special Tooling - Price and Availability ............................... 1 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 7 A. GENERAL INFORMATION ..................................... 1 7 B. WORK INSTRUCTIONS ....................................... 1 7 FIGURE 1: SKIN INSPECTION IN SECTION 42, 44 AND 46 [Group 1] ................. 1 9 FIGURE 2: SKIN INSPECTION IN SECTION 42 [Group 2] ........................ 3 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 3 of 33 BOEING SERVICE BULLETIN 747-53A2854
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 4 of 33 BOEING SERVICE BULLETIN 747-53A2854
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2854Original Issue: September 17, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin Panel Chem-Milled Pocket Inspection and Repair at Locations Adjacent to Lap Splices
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 for cracks just above certain lap splice locations. Skin cracks that are not found and repaired can become large and cause sudden loss of cabin pressure and loss of structural integrity..
Two operators of Boeing 757 airplanes have reported cracking, on two airplanes, that initiated at multiple locations on the inboard surface of the skin, along the edge of the chem-milled step just above the skin lap splice. No cracking of this kind has been reported on 747 airplanes, but analysis by Boeing indicates that the 747 fuselage skin in the areas shown in this service bulletin may be susceptible to similar cracking.
The related Boeing 757 service bulletin is 757-53-0097, "FUSELAGE - Skin - Crown Skin Panel - Station 297 to Station 439, Chem-Milled Step Above Stringer 4 Left and Stringer 4 Right Lap Joint - Inspection".
Accomplishment of the inspections in this service bulletin and installation of a repair will help prevent in-flight depressurization of the airplane and ensure the structural integrity of the fuselage skin at certain chem-milled skin locations.
The skin at the edge of chem-milled steps above certain skin lap splices has been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to 747-SL-53-088A.
Boeing Service Related Problem (SRP) 747-SRP-53-0396 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 5 of 33
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., ComplianceNoAD 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 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 NoOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Get external access to the fuselage skin just above certain lap splice locations. Do external sliding probe eddy current inspections at the affected locations for cracks. If no crack indications are found, put the airplane back to a serviceable condition, and do the inspection again at the times given in this service bulletin. If crack indications are found, contact Boeing for repair data and do the repair. After repair, put the airplane back to a serviceable condition, and do the inspection again at the times given in this service bulletin.
EFFECTIVITY 747-100B SUD, 747-300 and 747SP 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 inspection and repair procedures given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
28.5056.50Group 1
5.2510.00Group 2 Refer to Paragraph 1.G., Manpower.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 6 of 33 BOEING SERVICE BULLETIN 747-53A2854
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BOEING SERVICE BULLETIN 747-53A2854
ALERT ALERT
MATERIAL INFORMATION None.
EDGE OF INTERNAL
CHEM-MILLED STEP
IN OVERLAPPING SKIN
- STRINGER A —
OVERLAPPING SKIN
FWD OVERLAPPED SKIN
LAP SPLICE (TYPICAL)
CHEM-MILLED STEP
TYPICAL CRACK
DO EXTERNAL SLIDING PROBE EDDY
CURRENT INSPECTIONS FOR CRACKS AT THE CHEM-MILLED STEP. IF CRACK
INDICATIONS ARE FOUND, INSTALL A REPAIR.
OVERLAPPED / SKIN
SKERLAPPING- A-A 2148046 Original Issue: September 17, 2012 Export Controlled ECCN: 9E991 - BOEING 747-53A2854 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 33
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 8 of 33 BOEING SERVICE BULLETIN 747-53A2854
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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2854 Original Issue: September 17, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Skin Panel Chem-Milled Pocket Inspection and Repair at Locations Adjacent to Lap Splices
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.
DESCRIPTIONCONFIGURATIONGROUP All 747SP airplanes.-1 747-100B SUD airplanes line number 636 and 655, and 747-300 airplanes line number 692 through 695.
-2 Airplane Models:
747-100B SUD, 747-300, 747SP GroupVariable Number 1RG001 - RG009 1RG091 1RG095 1RG101 - RG104 1RG121 - RG126 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 9 of 33
GroupVariable Number 1RG141 - RG142 1RG161 - RG164 1RG171 - RG174 1RG191 - RG193 1RG211 - RG213 1RG221 - RG222 1RH101 - RH102 1RH111 - RH112 1RH121 - RH122 2RS001 - RS002 2RS265 - RS268
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason This service bulletin gives instructions to do inspections of the fuselage skin for cracks just above certain lap splice locations. Skin cracks that are not found and repaired can become large and cause sudden loss of cabin pressure and loss of structural integrity..
Two operators of Boeing 757 airplanes have reported cracking, on two airplanes, that initiated at multiple locations on the inboard surface of the skin, along the edge of the chem-milled step just above the skin lap splice. No cracking of this kind has been reported on 747 airplanes, but analysis by Boeing indicates that the 747 fuselage skin in the areas shown in this service bulletin may be susceptible to similar cracking.
The related Boeing 757 service bulletin is 757-53-0097, "FUSELAGE - Skin - Crown Skin Panel - Station 297 to Station 439, Chem-Milled Step Above Stringer 4 Left and Stringer 4 Right Lap Joint - Inspection".
Accomplishment of the inspections in this service bulletin and installation of a repair will help prevent in-flight depressurization of the airplane and ensure the structural integrity of the fuselage skin at certain chem-milled skin locations.
The skin at the edge of chem-milled steps above certain skin lap splices has been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to 747-SL-53-088A.
Boeing Service Related Problem (SRP) 747-SRP-53-0396 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 10 of 33 BOEING SERVICE BULLETIN 747-53A2854
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D. Description Get external access to the fuselage skin just above certain lap splice locations. Do external sliding probe eddy current inspections at the affected locations for cracks. If no crack indications are found, put the airplane back to a serviceable condition, and do the inspection again at the times given in this service bulletin. If crack indications are found, contact Boeing for repair data and do the repair. After repair, put the airplane back to a serviceable condition, and do the inspection again at the times given in this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 122, 147, 148, 241, 242747SP Group 2:
Affected Maintenance Zones ZoneModel 225, 226747-100B SUD, 747-300 E. Compliance Accomplish the required actions, based on the applicable conditions in Table 1, in accordance with Paragraph 3. Accomplishment Instructions.
Group 1:
Table 1: Skin Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 500 flight-cycles or one year after the original issue date of this service bulletin, whichever occurs later.
Before 18,500 total flight-cycles Do an external sliding probe eddy current inspections for cracking in accordance with Paragraph 3.B., Work Instructions.
All airplanes -Before further flightContact Boeing for repair data and do the repair.
Any cracking found Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 11 of 33 BOEING SERVICE BULLETIN 747-53A2854
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Group 1:
Table 1: Skin Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 500 flight-cyclesWithin 500 flight-cycles after the previous inspection.
Do external sliding probe eddy current inspections for cracking in unrepaired areas in accordance with Paragraph 3.B., Work Instructions.
No cracking found Group 2:
Table 2: Skin Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 800 flight-cycles or one year after the original issue date of this service bulletin, whichever occurs later.
Before 18,500 total flight-cycles Do an external sliding probe eddy current inspections for cracking in accordance with Paragraph 3.B., Work Instructions.
All airplanes -Before further flightContact Boeing for repair data and do the repair.
Any cracking found 800 flight-cyclesWithin 800 flight-cycles after the previous inspection.
Do external sliding probe eddy current inspections for cracking in unrepaired areas in accordance with Paragraph 3.B., Work Instructions.
No cracking 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 17, 2012 747-53A2854 12 of 33 BOEING SERVICE BULLETIN 747-53A2854