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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2860 Original Issue: December 04, 2012 Revision 1: March 18, 2014 ATA System: 5312 SUBJECT: FUSELAGE - Main Frame - Center Section - Longeron Extension Fitting Inspection, Repairs and Modification - Body Station 1480 to Body Station 1540 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Unpublished Work.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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, 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.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 1 of 107
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 2 of 107 BOEING SERVICE BULLETIN 747-53A2860
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 8 F. Approval ............................................... 2 2 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 4 I. Electrical Load Data ......................................... 2 4 J. References .............................................. 2 4
1. Existing Data: ......................................... 2 4
2. Data Supplied with this Service Bulletin: ........................... 2 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 5 K. Publications Affected ........................................ 2 5 L. Interchangeability and Intermixability of Parts ........................... 2 5 M. Software Accomplishment Summary ................................ 2 5
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 7
1. Kits/Parts ............................................ 2 7
2. Parts and Materials Supplied by the Operator ........................ 3 1
3. Parts Modified and Reidentified ................................ 3 1
4. Parts Removed and Not Replaced .............................. 3 1 D. Parts Necessary to Change Spares ................................. 3 1 E. Special Tooling - Price and Availability ............................... 3 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 4 FIGURE 1: LONGERON EXTENSION FITTING INSPECTION ..................... 3 9 FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY REPAIR) .... 4 1 FIGURE 3: JACKING THE AIRPLANE FOR THE REPAIR, REPLACEMENT OR THE MODIFICATION .................................................. 4 7 FIGURE 4: INSPECTION OF LONGERON EXTENSION FITTINGS WITH THE TEMPORARY REPAIR PREVIOUSLY ACCOMPLISHED ............................... 5 0 FIGURE 5: LONGERON EXTENSION FITTING TEMPORARY REPAIR TRIM PRIOR TO REPAIR ACCOMPLISHMENT ...................................... 5 2 FIGURE 6: INSPECTION OF THE LONGERON EXTENSION FITTING FOR THE REPAIR OR MODIFICATION ........................................ 5 7 FIGURE 7: LONGERON EXTENSION FITTING REMOVAL ....................... 5 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 8: LONGERON EXTENSION FITTING INSTALLATION [Group 1] ............... 6 6 FIGURE 9: LONGERON EXTENSION FITTING INSTALLATION [Group 2] ............... 7 7 FIGURE 10: LONGERON EXTENSION FITTING INSTALLATION [Group 3] ............... 8 8 FIGURE 11: LONGERON EXTENSION FITTING INSURANCE TRIM PRIOR TO THE MODIFICATION . 99 APPENDIX A: MASTER FASTENER CODE TABLE ............................ 1 0 1 APPENDIX B: 675U0006-( ) SPLICE FITTING MODIFICATION ...................... 1 0 4 APPENDIX C: LOGIC DIAGRAM ....................................... 1 0 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 4 of 107 BOEING SERVICE BULLETIN 747-53A2860
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2860Original Issue: December 04, 2012 Revision 1: March 18, 2014 ATA System: 5312 SUBJECT: FUSELAGE - Main Frame - Center Section - Longeron Extension Fitting Inspection, Repairs and Modification - Body Station 1480 to Body Station 1540 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on any airplanes modified or repaired in accordance with the original issue of this service bulletin. On airplanes temporarily repaired in accordance with the original issue of this service bulletin, do inspections of the temporary repair and do a repair or fitting replacement in accordance with this revision. On airplanes modified or repaired in accordance with the original issue of this service bulletin, do post-modification, post-replacement or post-repair inspections in accordance with this revision.
No more work is necessary on any airplanes that have only been inspected in accordance with the original issue of this service bulletin. Continue to do repeat inspections in accordance with this revision.
Airplanes line number 1097 through 1198 were added to Group 1 of the service bulletin effectivity.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2013-14-05 is related to this service bulletin.
REASON FOR REVISION This Alert revision is sent to include airplanes line number 1097 through 1198 in Group 1 of the service bulletin effectivity. Also, Top Kits 015U1931-1 and 015U1931-2 have been added to replace the previous lists of operator-furnished parts. Throughout the service bulletin, references to the "Preventive Modification" were changed to "Modification" and references to the "Permanent Repair" were changed to "Repair". References to new FAA AD 2013-14-05 have been added. References to Boeing Service Related Problem (SRP) 747-SRP-53-0444 have been added.
These sections were changed:
1. The Background section of the Summary and Paragraph 1.C., Reason, were updated to address airplanes line number 1097 through 1198.
2. The Manpower section of the Summary and Paragraph 1.G., Manpower, were updated to include updated estimates.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 5 of 107
3. In Paragraph 1.E., Compliance, Table 1, the Compliance time was changed to count from the effective date of FAA AD 2013-14-05, not the original issue date of the service bulletin. References to new Table 3 were added. Three footnotes were deleted. In Table 2, two footnotes were deleted and references to new Table 3 were added. Table 3 was added to describe the post-modification, post-replacement or post-repair inspections that are necessary.
4. In Paragraph 1.F., Approval, an Alternative Method of Compliance (AMOC) paragraph was added.
5. In Paragraph 1.J.1., Existing Data, the list of references has been updated.
6. In Paragraph 2.A., Material - Price and Availability data was added for new Top Kits 015U1931-1 and 015U1931-2.
7. In Paragraph 2.C.1., Kits/Parts, the contents of new Top Kits 015U1931-1 and 015U1931-2 and Subkits 015U1931-3, 015U1931-4, 015U1931-5 and 015U1931-6 have been listed.
8. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, the tables of operator furnished parts that were in the original issue of the service bulletin have been removed. These parts are now in new Top Kits 015U1931-1 and 015U1931-2.
9. In Paragraph 3.A., General Information, a note was deleted and new notes were added.
10. In Paragraph 3.B., Work Instructions, PARTS 4 and 5, changed step 3 and added reference to PART 7 and follow-on inspection requirements. In PART 6, added new step 3 and added reference to PART 7 and follow-on inspection requirements. PART 7 was added for the post-modification or post-repair inspections
11. FIGURE 2 has been changed to include a different temporary repair for Group 3 airplanes only, to clarify the trim dimensions, and to include instructions to install shims, if necessary, between the longeron extension fitting and the wing-to-body fairing support structure.
12. The title of FIGURE 3 has been changed and other changes were made to clarify the jacking requirements for longeron extension fitting removal and installation.
13. FIGURE 4 and FIGURE 5 have been changed to address the new temporary repair in FIGURE 2 for Group 3 airplanes only.
14. On Sheet 3 of FIGURE 7, added circle note 1 to the lower inboard splice fitting.
15. FIGURE 8, FIGURE 9 and FIGURE 10 have been changed to include the optional 675U0006-( ) splice fittings and instructions to install shims, if necessary, between the longeron extension fitting and the wing-to-body fairing support structure.
16. In APPENDIX A, added a title. Obsolete BACB30MY6K*X bolt callouts were changed to BACB30NX6K*X for fastener code C and G. Oversize washer callouts were added to fastener codes B, D and F. Also, under fastener code G, Washer BACW10CA6PVK was changed to BACW10CA3PVK, and washer BACW10CA6CCK was changed to BACW10CA3CCK.
17. APPENDIX B was added to show a procedure for determining the proper dimensions for the optional 675U0006-( ) splice fittings.
18. APPENDIX C was added to show a logic diagram for the inspections and alternatives in this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 6 of 107 BOEING SERVICE BULLETIN 747-53A2860
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Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY December 04, 2012Original Issue:
March 18, 2014Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 7 of 107 BOEING SERVICE BULLETIN 747-53A2860
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 8 of 107 BOEING SERVICE BULLETIN 747-53A2860
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2860Original Issue: December 04, 2012 Revision 1: March 18, 2014 ATA System: 5312 SUBJECT: FUSELAGE - Main Frame - Center Section - Longeron Extension Fitting Inspection, Repairs and Modification - Body Station 1480 to Body Station 1540
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, repair and modification of the longeron extension fittings at left and right Body Station (STA) 1480 for cracks. Cracks in the longeron extension fittings that are not found and repaired can become large and adversely affect the structural integrity of the airplane.
Longeron extension fittings are installed on the fuselage skin from STA 1480 to STA 1540 under the wing-to-body fairing, and attach the overwing longeron to the fuselage skin in Section 46. At the time of the original issue of this service bulletin, operators have told Boeing that thirteen cracked longeron extension fittings were found on eight airplanes. The cracks were found in the outboard flange of the fitting, which attaches to the wing-to-body fairing support frame web. Service history is given in the table that follows:
Service History Flight-HoursFlight-Cycles Crack Length Model Right Side Left Side 29,8123,2300.375-747-400 47,6908,1080.5000.125747-400F 48,0338,2131.7000.300747-400F 48,9218,3680.500.30747-400F 51,1248,8630.5000.125747-400F 52,2388,9880.070-747-400F 56,1249,850-0.188747-400 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 9 of 107
Service History Flight-HoursFlight-Cycles Crack Length Model Right Side Left Side 59,2329,6140.4000.240747-400F Analysis by Boeing indicates that these cracks are caused by fatigue combined with preload stress from improper fit-up during assembly. A manufacturing process change that began at line number 1199 may have resulted in preloading the longeron extension fittings. In addition, the longeron extension fittings installed in production beginning with line number 1097 have revised geometry at the fitting flange that attaches to the wing-to-body fairing structure, which may reduce the fatigue quality of the fitting.
Accomplishment of the longeron extension fitting inspections, repairs and modification in this service bulletin will make sure that cracks in the longeron extension fittings are found and repaired before they can become large and adversely affect the structural integrity of the airplane.
Since the original issue of this service bulletin, one operator has reported that a longeron extension fitting crack was found on an airplane outside the original service bulletin effectivity. An approximately 0.4 inch long crack was found in the right longeron extension fitting of an airplane with 10,045 flight-cycles and 70,959 flight-hours.
Boeing Fleet Team Digest (FTD) 747 FTD 53-11007 is related to this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-53-0398 and 747-SRP-53-0444 are 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 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 YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 10 of 107 BOEING SERVICE BULLETIN 747-53A2860
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ACTION (PRR 85901-119RS) Get access to the longeron extension fittings on the fuselage skin on the left and right sides of the airplane under the wing-to-body fairings at STA 1480. Do surface High Frequency Eddy Current (HFEC) inspections of the longeron extension fitting on the left and right sides of the airplane for cracks in accordance with this service bulletin.
If any crack is found that is within the limits given in this service bulletin, do the Temporary Repair in accordance with this service bulletin. At the time given in this service bulletin, also do the Repair in accordance with this service bulletin. If any crack is found that is not within the limits given in this service bulletin, replace the fitting in accordance with this service bulletin.
If no crack is found, put the airplane back to a serviceable condition. Do the surface HFEC inspection again at the time 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 2013-14-05 is related to this service bulletin.
The effective date of AD 2013-14-05 is August 26, 2013.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of September 14, 2011. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursTask
9.5032.00Longeron Extension Fitting Inspection
199.50788.00Longeron Extension Fitting Modification
190.50770.00Longeron Extension Fitting Replacement Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits.
Operator Supplied Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 11 of 107 BOEING SERVICE BULLETIN 747-53A2860
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BOEING SERVICE BULLETIN 747-53A2860
ALERT ALERT STA 1480
LONGERON
EXTENSION
FITTING
FUSELAGE SKIN STA 1480
LONGERON
EXTENSION
FITTING
DO A SURFACE HFEC INSPECTION
OF THE LONGERON EXTENSION FITTING FOR CRACKS. IF CRACKS TYPICAL
ARE FOUND, REPAIR IF WITHIN CRACK
LIMITS OR REPLACE THE FITTING IF NOT WITHIN LIMITS.
2167176 Original Issue: December 04, 2012 Revision 1: March 18, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2860 Work - See page 1 for details. 12 of 107