# Boeing Alert Service Bulletin 747-53A2860: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2014-0921; AD 2015-13-06 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-53A2860](https://openairdocs.org/service-documents/boeing/747-53a2860.md) - Title as filed: U.S. DOT/FAA - Service Bulletin 747-53A2860 Revision 01 - Pages: 107 - PDF: https://openairdocs.org/files/sha256/36/ec/36ecf8df5bc91794981bf287699000ff6fa2becd3dbe00d81eebbf0b4630f6f4 - Page: https://openairdocs.org/service-documents/boeing/747-53a2860/file/36ecf8df5bc9 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 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 Unpublished Work.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1: March 18, 2014 1 of 107 3.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 9 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. Original Issue: December 04, 2012 747-53A2860Revision 1: March 18, 2014 3 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 4 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 ALERTALERT ### Page 5 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 ### Page 6 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 ALERTALERT ### Page 7 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 ALERTALERT ### Page 8 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 ALERTALERT BLANK PAGE ### Page 9 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 ### Page 10 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 Air- plane 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 ALERTALERT ### Page 11 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 ALERTALERT ### Page 12 (OCR) 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 ### Page 13 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 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 PRR 85901-119RS for data about this change. DESCRIPTIONCONFIGURATIONGROUP 747-400 and 747-400F airplanes line number 1097-1238.-1 747-400 and 747-400F airplanes line number 1239-1307, 1309-1312, 1314, 1324-1325, 1327, 1335-1337, 1343, 1353-1354 and 1357-1358. -2 747-400 and 747-400F airplanes line number 1308, 1313, 1315-1323, 1326, 1328-1334, 1338-1342, 1344-1352, 1355-1356, and 1359-1419. -3 Airplane Models: 747-400, 747-400F GroupVariable Number 3RF001 - RF006 2RL401 - RL403 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 13 of 107 ### Page 14 GroupVariable Number 2RL411 - RL420 3RL421 - RL436 3RL451 - RL456 3RL461 - RL462 3RL471 - RL481 3RL491 - RL492 3RL501 - RL502 3RL511 - RL516 3RL521 - RL522 3RL531 - RL534 3RL551 3RL561 - RL568 3RL571 - RL572 3RL576 - RL577 3RL579 3RL581 - RL586 2RL651 - RL655 3RL671 - RL675 3RL681 - RL684 2RL751 - RL752 1RM001 - RM003 2RM004 - RM007 2RM010 1RM011 - RM012 2RM013 1RM021 - RM024 1RM026 - RM027 2RM028 - RM030 1RM036 - RM038 2RM039 - RM045 1RM051 2RM052 - RM053 1RM071 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 14 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 15 GroupVariable Number 1RM081 - RM084 1RM091 1RM096 - RM097 1RM116 - RM117 1RM126 - RM131 2RM132 1RM136 - RM147 1RM156 - RM157 2RM158 1RM166 - RM176 2RM177 1RM191 - RM192 1RM231 - RM232 2RM233 1RM241 - RM244 2RM245 - RM246 1RM261 - RM264 1RM316 2RM317 - RM318 1RM331 - RM332 2RM333 2RM341 2RM351 - RM355 2RM366 - RM367 2RM401 - RM403 2RM426 2RM431 2RM441 - RM443 2RM445 1RM801 2RM802 - RM803 1RM811 - RM813 1RM851 - RM852 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 15 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 16 GroupVariable Number 2RM853 - RM858 3RM859 1RM861 2RM862 3RM863 1RM871 2RM872 - RM876 3RM877 - RM880 1RM881 - RM885 2RM886 - RM887 3RM888 - RM890 1RM891 - RM899 2RM901 - RM905 3RM906 1RM911 1RR723 - RR724 1RR856 1RR862 1RT013 - RT014 1RT034 - RT035 1RT136 - RT137 1RT443 - RT447 1RT625 - RT630 1RT637 - RT640 1RT756 - RT757 1RT801 - RT803 1RT812 - RT814 1RT836 - RT837 1RT948 - RT949 1RT955 1RU017 1RU101 - RU102 1RU126 - RU132 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 16 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 17 2. Spares Affected None. B. Concurrent Requirements None. C. Reason 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 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. 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 17 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 18 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. Alert Revision 1 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. D. Description 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. Revision 1 - 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. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 141, 142, 143, 144747-400, 747-400F E. 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. 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 18 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 19 Accomplish the required actions, based on the applicable conditions in Table 1, Table 2 and Table 3, in accordance with Paragraph 3. Accomplishment Instructions. Table 1: STA 1480 Longeron Extension Fitting Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight-cycles af- ter the effective date of AD 2013-14-05. Before 3,000 to- tal flight-cycles. Do surface HFEC inspec- tions of the left and right longeron extension fit- tings for cracks in accor- dance with Paragraph 3.B., Work Instructions, PART 1. All airplanes. -Before further flight.Do the Temporary Repair in accordance with Para- graph 3.B., Work Instruc- tions, PART 2. Any crack found. All cracks are within limits. OR -Before further flight.Do the Repair in accor- dance with Paragraph 3.B., Work Instructions, PART 4. -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with Para- graph 3.B., Work Instruc- tions, PART 6. Any crack found that is not within limits. 2,100 flight-cycles-Repeat the surface HFEC inspection of the forward flange of the left and right longeron extension fitting in accordance with Para- graph 3.B., Work Instruc- tions, PART 1. No crack found. OR -Before further flight.Do the Modification in ac- cordance with Paragraph 3.B., Work Instructions, PART 5. 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 19 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 20 Table 1: STA 1480 Longeron Extension Fitting Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition --At the times in Table 2 of Para- graph 1.E., Compliance. In accordance with Table 2 of Paragraph 1.E., Compliance: Do an inspection of the Temporary Repair. Airplanes on which the temporary repair has been done in accordance with Paragraph 3.B., Work In- structions, PART 2. AND Do a repair or Longeron Extension Fitting Replace- ment. -At the times in Table 3 of Para- graph 1.E., Compliance. Do inspections of the Longeron Extension Fit- ting. Airplanes with the Modifica- tion installed in accordance with Paragraph 3.B., Work Instructions, PART 5, or the Repair installed in ac- cordance with Paragraph 3.B., Work Instructions, PART 4, or the Longeron Extension Fitting Replace- ment done in accordance with Paragraph 3.B., Work Instructions, PART 6. Table 2: Repair of Longeron Extension Fittings with the Temporary Repair Previously Accomplished Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,000 flight-cycles after ac- complishment of the Temporary Repair. Do a surface HFEC in- spection of the Tempo- rary Repair of the longeron extension fit- tings for cracks in accor- dance with Paragraph 3.B., Work Instructions, PART 3. Temporary Repair previous- ly accomplished in accor- dance with Paragraph 3.B., Work Instructions, PART 2. -Before further flight.Do the Repair in accor- dance with Paragraph 3.B., Work Instructions, PART 4. Any crack found. All cracks are within limits. -Before further flight.Do the Longeron Exten- sion Fitting Replacement shown in Paragraph 3.B., Work Instructions, PART 6. Any crack found that is not within limits. 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 20 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 21 Table 2: Repair of Longeron Extension Fittings with the Temporary Repair Previously Accomplished Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Do the Repair in accor- dance with Paragraph 3.B., Work Instructions, PART 4. No crack found. -At the times in Table 3 of Para- graph 1.E., Compliance. Do inspections of the Longeron Extension Fit- ting. Airplanes with the Repair installed in accordance with Paragraph 3.B., Work In- structions, PART 4, or the Longeron Extension Fitting Replacement done in accor- dance with Paragraph 3.B., Work Instructions, PART 6. Table 3: Post-Modification, Post-Repair or Post-Replacement Surface HFEC Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight-cycles af- ter the Revision 1 date of this service bulletin. Within 6,000 flight-cycles af- ter accomplish- ment of the Modification, Repair, or Longeron Exten- sion Fitting Re- placement. Do surface HFEC inspec- tions of any modified, re- paired or replaced longeron extension fitting for cracks in accordance with Paragraph 3.B., Work Instructions, PART 7. Airplanes with the Modifica- tion installed in accordance with Paragraph 3.B., Work Instructions, PART 5, or the Repair installed in ac- cordance with Paragraph 3.B., Work Instructions, PART 4, or the Longeron Extension Fitting Replace- ment done in accordance with Paragraph 3.B., Work Instructions, PART 6. -Before further flight.Do the Temporary Repair in accordance with Para- graph 3.B., Work Instruc- tions, PART 2. Any crack found. All cracks are within limits. OR -Before further flight.Do the Repair in accor- dance with Paragraph 3.B., Work Instructions, PART 4. -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with Para- graph 3.B., Work Instruc- tions, PART 6. Any crack found that is not within limits. 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 21 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 22 Table 3: Post-Modification, Post-Repair or Post-Replacement Surface HFEC Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 2,100 flight-cycles-Repeat the surface HFEC inspection of the forward flange of the left and right longeron extension fitting in accordance with Para- graph 3.B., Work Instruc- tions, PART 7. No crack found. --At the times in Table 2 of Para- graph 1.E., Compliance. In accordance with Table 2 of Paragraph 1.E., Compliance: Do an inspection of the Temporary Repair. Airplanes on which the temporary repair has been done in accordance with Paragraph 3.B., Work In- structions, PART 2. AND Do a repair or Longeron Extension Fitting Replace- ment. 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. In addition, the Manager of the FAA Seattle ACO approves the accomplishment of the inspections and corrective actions defined in this SB as an AMOC to the inspections and corrective actions defined in paragraphs (g), (h) and (i) of AD 2013-14-05. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (k) of the AD. All provisions of AD 2013-14-05 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. G. Manpower The table below shows an estimate of the task hours necessary to do this inspection, repair or modification for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:  Time to adjust to the workplace  Time to schedule the work 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 22 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 23  Time to inspect the work  Time to cure the materials  Time to make the parts  Time to find the tools. Table 1 - Longeron Extension Fitting Inspection Elapsed HoursTask HoursNumber of PersonsTask 1.887.504Open Access 1.001.001Inspect (Figure 1) 1.887.504Close Access 4.7516.00TOTAL FOR ONE SIDE OF THE AIRPLANE 9.5032.00TOTAL FOR EACH AIRPLANE NOTE: More time will be necessary for repairs if cracks are found. Table 2 - Longeron Extension Fitting Modification Elapsed HoursTask HoursNumber of PersonsTask 3.7515.004Open Access 2.0010.005Jack the Airplane (Figure 3) 2.004.002Inspect (Figure 6) 24.5098.004Longeron Extension Fitting Removal (Fig- ure 7) 2.505.002Longeron Extension Fitting Trim (Figure 11) 59.25237.004Longeron Extension Fitting Installation (Figure 8, 9 or 10) 2.0010.005Dejack the Airplane 3.7515.004Close Access 99.75394.00TOTAL FOR ONE SIDE OF THE AIRPLANE 199.50788.00TOTAL FOR EACH AIRPLANE NOTE: More time will be necessary for repairs if cracks are found. 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 23 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 24 Table 3 - Longeron Extension Fitting Replacement Elapsed HoursTask HoursNumber of PersonsTask 3.7515.004Open Access 2.0010.005Jack the Airplane (Figure 3) 24.5098.004Longeron Extension Fitting Removal (Fig- ure 7) 59.25237.004Longeron Extension Fitting Installation (Figure 8, 9 or 10) 2.0010.005Dejack the Airplane 3.7515.004Close Access 95.25385.00TOTAL FOR ONE SIDE OF THE AIRPLANE 190.50770.00TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes None. I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 85901-119RS b. Boeing Service Letter 747-SL-51-048 c. Boeing Service Related Problem (SRP) 747-SRP-53-0398 , 747-SRP-53-0444 d. Service Bulletin Index D6-30300 e. Standard Overhaul Practices Manual (SOPM) 20-10-03, 20-20-02, 20-41-02, 20-50-19, 20-50-20 f. 747 Fleet Team Digest (FTD) 53-11007 g. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00 h. 747-400 Aircraft Maintenance Manual (AMM) 07-10-00, 12-15-04, 25-52-01, 25-52-04, 27-51-01 , 51-21-04, 51-24-13 i. 747-400 Structural Repair Manual (SRM) 51-20-06, 51-40-09 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 24 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 25 j. 747-400F Structural Repair Manual (SRM) 51-20-06, 51-40-09 k. 747-400SF Structural Repair Manual (SRM) 51-40-09 l. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2013-14-05 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Skin, Frame, Stringer Instl - S-23 to WL 154.38 STA 1350 to STA 1480 65B01162 Crease Beam and WL 152 Deck Instl65B15254 Longeron Extension Fitting Installation65B15255 The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. M. Software Accomplishment Summary Not affected. 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 25 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 26 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 26 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT BLANK PAGE ### Page 27 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the Revision 1 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 1 date of this Service Bul- letin (Calendar Days) QTYDateNameKit Number $91,654.005245February 25, 2014 Top Kit - Group 1 and Group 2 015U1931-1 3April 2, 2014 $92,543.003632February 25, 2014 Top Kit - Group 3015U1931-2 B. Industry Support Information Boeing warranty remedies are available for 747 airplanes in warranty as of September 14, 2011. For inspection task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional task hours and parts are required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to this service bulletin number and reference the airplane variable number(s) in your purchase order. C. Parts Necessary for Each Airplane 1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. 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 27 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 28 Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -2-1 --Top Kit - Longeron Extension Fitting Replacement - Group 1 and Group 2 .-015U1931-1 --Top Kit - Longeron Extension Fitting Replacement - Group 3 -.015U1931-2 --Left Side Longeron Extension Fitting Replacement Kit .1015U1931-3 --Right Side Longeron Exten- sion Fitting Re- placement Kit .1015U1931-4 --Left Side Longeron Extension Fitting Replacement Kit 1.015U1931-5 --Right Side Longeron Exten- sion Fitting Re- placement Kit 1.015U1931-6 Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3 (a)-Left Side Longeron Extension Fitting Replacement Kit ...-015U1931-3 (a)-Right Side Longeron Exten- sion Fitting Re- placement Kit ..-.015U1931-4 (a)-Left Side Longeron Extension Fitting Replacement Kit .-..015U1931-5 (a)-Right Side Longeron Exten- sion Fitting Re- placement Kit -...015U1931-6 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 28 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 29 Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3 (c)-FITTING - LONGERON EX- TENSION ...165B15034U23 (c)-FITTING - LONGERON EX- TENSION ..1.65B15034U24 (c)-FITTING - LONGERON EX- TENSION .1..65B15034U25 (c)-FITTING - LONGERON EX- TENSION 1...65B15034U26 (c)-SHIM-LAMINATED111165B15254-245 (c)-SPLICE FITTING.1.1675U0006-1 (c)-SPLICE FITTING1.1.675U0006-2 (c)-SPLICE FITTING1111675U0006-3 (c)-SPLICE FITTING1111675U0006-4 (c)-SPLICE FITTING.1.1675U0006-5 (c)-SPLICE FITTING1.1.675U0006-6 (b)-BOLT1111BACB30NW12K9X (b)-BOLT2222BACB30NX6K10X (b)-BOLT1111BACB30NX6K12X (b)-BOLT3333BACB30NX6K2X (b)-BOLT3333BACB30NX6K6X (b)-BOLT1111BACB30NX6K7X (b)-BOLT30303030BACB30NX8K10X (b)-BOLT12121212BACB30NX8K11X (b)-BOLT4444BACB30NX8K12X (b)-BOLT1111BACB30NX8K21X (b)-BOLT1111BACB30NX8K23X (b)-BOLT8888BACB30NX8K4X (b)-BOLT20202020BACB30NX8K5X (b)-BOLT16161616BACB30NX8K6X (b)-BOLT40404040BACB30NX8K7X 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 29 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 30 Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3 (b)-BOLT36363636BACB30NX8K8X (b)-BOLT55555555BACB30NX8K9X (b)-BOLT..44BACB30US8K26 (b)-BOLT..44BACB30US8K28 (b)-BOLT..44BACB30US8K33 (b)-BOLT4444BACB30US9K21 (b)-BOLT44..BACB30US9K26 (b)-BOLT2222BACB30US9K27 (b)-BOLT44..BACB30US9K28 (b)-BOLT2222BACB30US9K30 (b)-BOLT44..BACB30US9K33 (b)-BOLT4444BACB30US9K34 --COLLAR1111BACC30BH12 --COLLAR11111111BACC30BH6 --COLLAR220220220220BACC30BH8 --NUT..1212BACN10HR8CD --NUT24241212BACN10HR9CD --SHIM1111BACS40R018B025F --SHIM3333BACS40R018E055F --SHIM3333BACS40R021E055F --SHIM2222BACS40R024E096F --SHIM2222BACS40R027B049F --SHIM1111BACS40R034B053F --SHIM1111BACS40R034B060F --WASHER..1212BACW10BP8CD --WASHER..1212BACW10BP8DP --WASHER24241212BACW10BP9CD --WASHER24241212BACW10BP9DP --WASHER, SELF- ALIGN 1111BACW10CA3CCK --WASHER, SELF- ALIGN 1111BACW10CA3PVK 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 30 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 31 Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3 (a) There are more parts than are necessary. (b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. (c) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the 'dash' configuration when installed as given in the Accomplishment Instructions of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Boeing Service Letter 747-SL-00-018 for more information. 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. NOTE: Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. NotesNameQTYPart Number / Specifi- cation (a) (b)Bolt2BACB30NX6K6X (a) (b)Bolt1BACB30NX6K7X (a) (b)Bolt2BACB30NX6K10X (a) (b)Collar5BACC30M6 -Sealant1 quartBMS 5-95 -Primer1 pintBMS 10-11, Type I (a) Applicable to the Temporary Repair in accordance with FIGURE 2. (b) Refer to 747 Structural Repair Manual Chapter 51 for alternate fasteners. 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares None. 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 31 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 32 E. Special Tooling - Price and Availability The 747-400 SRM 51-40-09, 747-400F SRM 51-40-09 and 747-400SF SRM 51-40-09 give data about cold working tools and sleeves necessary to do the Longeron Extension Fitting Replacement given in this service bulletin. These tools are available from industry sources. Engineering, service, and a kit of cold working tools made for this change are available from Fatigue Technology, Inc. or West Coast Industries, Inc.  Refer To: FTI Kit Number: FTI-747-53-2860-1 Fatigue Technology, Inc. P.O. Box C-88388 Seattle, WA 98188 USA Phone Number (206) 246-2010 Fax (206) 244-9886  Refer To: WCI Kit Number: WCI-747-53A-2860 West Coast Industries, Inc. 14900 Whitman Avenue North Seattle, WA 98133-6532 USA Phone Number (206) 365-7513 Fax (206) 365-7483 F. Special Tooling Necessary to do this Service Bulletin Cold working tools are necessary to do the Longeron Extension Fitting Replacement given in this service bulletin. To get the cold working tools, refer to Paragraph 2.E., Special Tooling - 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 32 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 33 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in SRM Chapter 51 4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 6. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 7. Deleted. 8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 9. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 10. Refer to APPENDIX A for a Master Fastener Table. 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 33 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 34 11. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 12. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 13. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 14. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data. 15. Refer to 747-400 AMM 51-21-04 as an accepted procedure for application of chemical conversion coating to aluminum parts. 16. Refer to SOPM 20-41-02 as an accepted procedure for application of finishes. 17. Refer to SOPM 20-50-19 as an accepted procedure for application of sealant. 18. Do not remove both longeron extension fittings from the airplane at the same time. 19. Refer to APPENDIX B for a procedure to determine the required dimensions for installation of new 675U0006-( ) splice fittings as an alternative to reinstallation of the existing splice fittings and new shims. 20. Refer to APPENDIX C for a logic diagram. Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. B. WORK INSTRUCTIONS PART 1 - Longeron Extension Fitting Inspection 1. Remove wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side), for external access to the inspection area. 2. Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with FIGURE 1. 3. If all cracks are within the limits shown in FIGURE 2, do one of the following: a. Do the Temporary Repair in accordance with PART 2. b. Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. 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 34 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 35 4. If any crack is not within the limits shown in FIGURE 2, do the Longeron Extension Fitting Replacement in accordance with PART 6. 5. If no crack is found, do one of the following: a. Install wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side). Put the airplane back to a serviceable condition. Repeat the inspection in accordance with PART 1 at the time given in Paragraph 1.E., Compliance, Table 1. b. Do the Modification in accordance with PART 5. PART 2 - Temporary Repair 1. Do the Temporary Repair by removing longeron extension fitting cracks in accordance with FIGURE 2. 2. Install wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side). Put the airplane back to a serviceable condition. Do an inspection in accordance with PART 3 at the time given in Paragraph 1.E., Compliance, Table 2. PART 3 - Inspection of Longeron Extension Fittings with the Temporary Repair Previously Accomplished 1. Remove wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side), for external access to the inspection area. 2. Get internal access to the fasteners in the affected longeron extension fitting. In the aft lower lobe cargo compartment, remove sidewall and ceiling linings and insulation blankets as necessary to access the fuselage skin in the area from STA 1480 to STA 1540. Refer to 747-400 AMM 25-52-01 and 747-400 AMM 25-52-04 as accepted procedures. 3. Jack the airplane in accordance with FIGURE 3. 4. Remove the longeron extension fitting in accordance with FIGURE 7. 5. Do a surface HFEC inspection of the Temporary Repair of the longeron extension fitting for cracks in accordance with FIGURE 4. 6. If any crack is found: a. If all cracks are within the limits shown in FIGURE 2, remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. b. If any crack is not within the limits shown in FIGURE 2, do the Longeron Extension Fitting Replacement in accordance with PART 6. 7. If no crack is found, do an additional insurance trim in the area of the Temporary Repair in accordance with FIGURE 5 and do the Repair in accordance with PART 4. 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 35 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 36 PART 4 - Repair 1. If not done previously, get internal access to the fasteners in the affected longeron extension fitting. In the aft lower lobe cargo compartment, remove sidewall and ceiling linings and insulation blankets as necessary to access the fuselage skin in the area from STA 1480 to STA 1540. Refer to 747-400 AMM 25-52-01 and 747-400 AMM 25-52-04 as accepted procedures. 2. If not done previously, jack the airplane in accordance with FIGURE 3. 3. Do open-hole HFEC inspections for cracks in accordance with FIGURE 6. a. If any crack is found, contact Boeing for repair instructions and do the repair. b. If no crack is found, continue to do the longeron extension fitting repair. 4. Remove the longeron extension fitting in accordance with FIGURE 7. 5. This step has been deleted. 6. Group 1: Install the longeron extension fitting in accordance with FIGURE 8. After installation, finish the area to match adjacent structure. 7. Group 2: Install the longeron extension fitting in accordance with FIGURE 9. After installation, finish the area to match adjacent structure. 8. Group 3: Install the longeron extension fitting in accordance with FIGURE 10. After installation, finish the area to match adjacent structure. 9. Reapply corrosion inhibiting compound, BMS3-35, BMS3-23, Type II or BMS3-29 to the affected area. Refer to 747-400 AMM 51-24-13 as an accepted procedure. 10. Dejack the airplane. Refer to 747-400 AMM 07-10-00 as an accepted procedure. 11. Install any aft lower lobe cargo compartment sidewall and ceiling linings and insulation blankets that were removed for internal access to the fasteners in the affected longeron extension fitting. Refer to 747-400 AMM 25-52-01 and 747-400 AMM 25-52-04 as accepted procedures. 12. Install wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side). 13. Put the airplane back to a serviceable condition. Do inspections in accordance with PART 7 at the time given in Paragraph 1.E., Compliance, Table 3. PART 5 - Modification 1. Get internal access to the fasteners in the affected longeron extension fitting. In the aft lower lobe cargo compartment, remove sidewall and ceiling linings and insulation blankets as necessary to access the fuselage skin in the area from STA 1480 to STA 1540. Refer to 747-400 AMM 25-52-01 and 747-400 AMM 25-52-04 as accepted procedures. 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 36 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 37 2. If not done previously, jack the airplane in accordance with FIGURE 3. 3. Do open-hole HFEC inspections for cracks in accordance with FIGURE 6. a. If any crack is found, contact Boeing for repair instructions and do the repair. b. If no crack is found, continue to do the longeron extension fitting modification. 4. Remove the longeron extension fitting in accordance with FIGURE 7. 5. This step has been deleted. 6. Do an insurance trim on the longeron extension fitting in accordance with FIGURE 11. 7. Group 1: Install the longeron extension fitting in accordance with FIGURE 8. After installation, finish the area to match adjacent structure. 8. Group 2: Install the longeron extension fitting in accordance with FIGURE 9. After installation, finish the area to match adjacent structure. 9. Group 3: Install the longeron extension fitting in accordance with FIGURE 10. After installation, finish the area to match adjacent structure. 10. Reapply corrosion inhibiting compound, BMS3-35, BMS3-23, Type II or BMS3-29 to the affected area. Refer to 747-400 AMM 51-24-13 as an accepted procedure. 11. Dejack the airplane. Refer to 747-400 AMM 07-10-00 as an accepted procedure. 12. Install any aft lower lobe cargo compartment sidewall and ceiling linings and insulation blankets that were removed for internal access to the fasteners in the affected longeron extension fitting. Refer to 747-400 AMM 25-52-01 and 747-400 AMM 25-52-04 as accepted procedures. 13. Install wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side). 14. Put the airplane back to a serviceable condition. Do inspections in accordance with PART 7 at the time given in Paragraph 1.E., Compliance, Table 3. PART 6 - Longeron Extension Fitting Replacement 1. If not done previously, get internal access to the fasteners in the affected longeron extension fitting. In the aft lower lobe cargo compartment, remove sidewall and ceiling linings and insulation blankets as necessary to access the fuselage skin in the area from STA 1480 to STA 1540. Refer to 747-400 AMM 25-52-01 and 747-400 AMM 25-52-04 as accepted procedures. 2. If not done previously, jack the airplane in accordance with FIGURE 3. 3. Do open-hole HFEC inspections for cracks in accordance with FIGURE 6. a. If any crack is found, contact Boeing for repair instructions and do the repair. 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 37 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 38 b. If no crack is found, continue to do the longeron extension fitting replacement. 4. Remove the longeron extension fitting in accordance with FIGURE 7. 5. Group 1: Install a new longeron extension fitting in accordance with FIGURE 8. After installation, finish the area to match adjacent structure. 6. Group 2: Install a new longeron extension fitting in accordance with FIGURE 9. After installation, finish the area to match adjacent structure. 7. Group 3: Install a new longeron extension fitting in accordance with FIGURE 10. After installation, finish the area to match adjacent structure. 8. Reapply corrosion inhibiting compound, BMS3-35, BMS3-23, Type II or BMS3-29 to the affected area. Refer to 747-400 AMM 51-24-13 as an accepted procedure. 9. Dejack the airplane. Refer to 747-400 AMM 07-10-00 as an accepted procedure. 10. Install any aft lower lobe cargo compartment sidewall and ceiling linings and insulation blankets that were removed for internal access to the fasteners in the affected longeron extension fitting. Refer to 747-400 AMM 25-52-01 and 747-400 AMM 25-52-04 as accepted procedures. 11. Install wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side). 12. Put the airplane back to a serviceable condition. Do inspections in accordance with PART 7 at the time given in Paragraph 1.E., Compliance, Table 3. PART 7 - Post-Modification, Post-Repair or Post-Replacement Surface HFEC Inspection 1. On airplanes with the Modification, the Repair, or the Longeron Extension Fitting Replacement previously accomplished, remove wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side), for external access to the inspection area. 2. Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with FIGURE 1. 3. If all cracks are within the limits shown in FIGURE 2, do one of the following: a. Do the Temporary Repair in accordance with PART 2. b. Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. 4. If any crack is not within the limits shown in FIGURE 2, do the Longeron Extension Fitting Replacement in accordance with PART 6. 5. If no crack is found, Install wing-to-body fairing panels 293C, 293H and 293K (left side) and 294C, 294H and 294K (right side). Put the airplane back to a serviceable condition. Repeat inspections in accordance with PART 7 at the time given in Paragraph 1.E., Compliance, Table 3. 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 38 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 39 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1480 LONGERON EXTENSION FITTING LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE STA 1480 LONGERON EXTENSION FITTING INSPECTION AREA FWD GROUP 1 AND GROUP 2 AIRPLANE SHOWN, GROUP 3 AIRPLANES SIMILAR FIGURE 1: LONGERON EXTENSION FITTING INSPECTION (SHEET 1 OF 2) 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. 39 of 107 ### Page 40 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. More DataQtyIdentificationNameTaskStep Surface HFEC for cracks in accor- dance with 747 NDT Part 6, 51-00-00, Procedure 4 or 23. --Longeron Extension Fitting Inspect1 FIGURE 1: LONGERON EXTENSION FITTING INSPECTION (SHEET 2 OF 2) 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 40 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 41 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1480 LONGERON EXTENSION FITTING LEFT SIDE SHOWN STA RIGHT SIDE OPPOSITE 1480 LONGERON EXTENSION FITTING C A GROUP 1 AND GROUP 2 AIRPLANE SHOWN, FWD 2167520 GROUP 3 AIRPLANES SIMILAR FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY REPAIR) (SHEET 1 OF 6) 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. 41 of 107 ### Page 42 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT TANGENT POINT - 1.7 D MINIMUM TYPICAL CRACK LONGERON 0.50 MAXIMUM TRIM EXTENSION FITTING +D O R 0.50 MINIMUM 1.10 MINIMUM 15) 8 15) TRIM LINE MAXIMUM REPAIRABLE CRACK 0.045 0.035 A-A GROUP 1 AND GROUP 2 TANGENT POINT - 1.7 D MINIMUM LONGERON TYPICAL EXTENSION 0.50 MAXIMUM TRIM CRACK • FITTING • R 0.50 MINIMUM 10 MINIMUM TRIM LINE MAXIMUM REPAIRABLE CRACK B-B 2167524 GROUP 3 FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY REPAIR) (SHEET 2 OF 6) Original Issue: December 04, 2012 Revision 1 March 18, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. LOL 1O ZE ### Page 43 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1480 LONGERON EXTENSION • STRAIGHT TAPER FITTING 1.10 'TANGENT MINIMUM POINT (AFTER INSURANCE CUT) FWD C-C 0.045 C 2171697 FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY REPAIR) (SHEET 3 OF 6) 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. 43 of 107 ### Page 44 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT 1.70 D MINIMUM LONGERON EXTENSION CRACK TYPICAL FITTING R 0.25 MINIMUM 0.25 MAXIMUM (5) TEM LINE MAXIMUM 2 REPAIRABLE CRACI D-D GROUP 3 ONLY 0.045 0.035 TRIMMED AREA R 0.12 MINIMUM WING-TO-BODY LONGERON FAIRING SUPPORT EXTENSION STRUCTURE FITTING E-E CROSS-SECTION OF 2284336 TYPICAL TRIMMED AREA FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY REPAIR) (SHEET 4 OF 6) Original Issue: December 04, 2012 Revision 1 March 18, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING Work - See page 1 for details. 747-53A2860 44 of 107 ### Page 45 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. NOTE: The temporary repair should only be done if any crack is found per FIGURE 1 and is fully contained in the shaded area of the longeron extension fitting shown. 1. 2. No more than one temporary repair should be done on each affected longeron extension fitting. More DataQtyIdentificationNameTaskStep Remove the fasten- ers that attach the flange of the longeron extension fitting to the wing-to- body fairing struc- ture. 5-FastenerRemove1 (a)--Longeron Extension Fitting Cut2 Do a Surface HFEC of the trimmed edge of the longeron ex- tension fitting for cracks in accor- dance with 747 NDT Part 6, 51-00-00, Procedure 4 or 23 to ensure that all crack indications have been removed. (b) --Longeron Extension Fitting Inspect (c)--Longeron Extension Fitting Cut3 (d)--Longeron Extension Fitting Shot Peen Apply chemical con- version coating and two coats of BMS 10-11, Type I primer to all bare aluminum surfaces. --FinishApply FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY REPAIR) (SHEET 5 OF 6) 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 45 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 46 More DataQtyIdentificationNameTaskStep Between the longeron extension fitting flange and the wing-to-body fairing support structure. --GapMeasure4 (e)--ShimPrepare ---ShimInstall (New) To 0.2026 - 0.2036 diameter (close ream) 5-Fastener HolesDrill / Ream5 (f)2BACB30NX6K10XBoltInstall (New)6 (f)2BACC30M6CollarInstall (New) (f)1BACB30NX6K7XBoltInstall (New)7 (f)1BACC30M6CollarInstall (New) (f)2BACB30NX6K6XBoltInstall (New)8 (f)2BACC30M6CollarInstall (New) (a) Remove the crack. Trim the longeron extension fitting the minimum necessary to remove the crack, but do not cut beyond the dimensions shown. Maintain a minimum trim radius of 0.5 inch. Surface finish to be 63AA or better. On Group 3 airplanes, trim as shown in either View B-B or View D-D. Do not trim in both locations on the same fitting. (b) If crack indications are found, trim the longeron extension fitting again the minimum necessary to remove the crack, but do not cut beyond the dimensions shown. If the cut edge of the longeron extension fitting has reached the edge of the shaded area shown, the Temporary Repair cannot be accomplished. Do the Longeron Extension Fitting Replacement shown in Paragraph 3.B., Work Instructions, PART 6. (c) If no crack indications are found, do an additional 0.040 inch deep trim of the longeron extension fitting as an insurance cut. Maintain a minimum trim radius of 0.5 inch. Surface finish to be 63AA or better. (d) Shot or flap peen the trimmed edge of the longeron extension fitting. Refer to SOPM 20-10-03, 747-400 SRM 51-20-06 or 747-400F SRM 51-20-06 as an accepted procedure. (e) Shim gaps that are 0.033 inch or less with BACS40R( )B( )F laminated shims. Gaps that are greater than 0.033 inch can be shimmed with 7075-T6 or 2024-T3 solid shims that are machined as necessary to fit the measured gaps. It is acceptable to use BACS40R( )A( )F laminated shims with fabricated solid shims. It is also acceptable to use flat and tapered fillers as necessary. Shim and filler thickness should not exceed 0.063 inch. Maximum gap prior to fastener installation is 0.005 inch. After delamination of laminated shims, apply one coat of BMS 10-11, Type 1 primer to all surfaces of the shim. Apply chemical conversion coating and two coats of BMS 10-11, Type 1 primer to all surfaces of solid shims. (f) Install all fasteners wet with BMS 5-95 sealant. Refer to SOPM 20-50-19, Method 2, as an accepted procedure. FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY REPAIR) (SHEET 6 OF 6) 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 46 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 47 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT VIII OUTBOARD WING JACK (567 V INBOARD WING JACK FO (2) III TAIL JACK 11 BODY JACK 2) VI NOSE JACK NOSE LANDING GEAR I BODY JACK (2 31 BODY LANDING GEAR IV INBOARD WING JACK (5) 67 VII OUTBOARD WING JACK 5) 6)( 380 370 360 JACKING AIRPLANE WEIGHT (1000 POUNDS) 350 340 10 14 20 30 36 40 (% M.A.C.) 1258 1290.8 1323.6 1356.3 1389.1 (BODY STATION) CENTER OF GRAVITY LOCATION TEFIGURE 3: JACKING THE AIRPLANE FOR THE REPAIR, REPLACEMENT OR THE MODIFICATION (SHEET 1 OF 3) 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. 47 of 107 ### Page 48 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane. NOTE: Jacking is to be accomplished with flaps retracted. As an alternative, remove the inboard flaps. Refer to 747-400 AMM 27-51-01 as an accepted procedure. Flaps are not to be operated while the airplane is on jacks. 1. 2. Jacking is to be accomplished indoors. 3. Airplane center of gravity can be changed with ballast up to a maximum of 10,000 pounds added forward of Body Station 1480. If ballast is added, make sure that it is added equally about the airplane centerline. Also make sure that the floor load is less than the allowable load specified in 747 Weight and Balance Manual D6-13700. 4. Keep the load difference between equivalent left and right side wing jacks less than 10 percent at all times. 5. The splice straps that connect the inner chords of the upper and lower bulkhead must not be removed while the airplane is jacked. 6. Do not remove both longeron extension fittings from the airplane at the same time. CAUTION: KEEP THE LOAD ON WING JACKS IV AND V LESS THAN 30,000 POUNDS EACH AND THE LOAD ON WING JACKS VII AND VIII LESS THAN 25,000 POUNDS EACH. JACK LOADS LARGER THAN THESE LIMITS CAN CAUSE STRUCTURAL DAMAGE TO THE WING. More DataQtyIdentificationNameTaskStep Into the jacking enve- lope shown. --Airplane Weight and Center of Gravity Adjust1 Use Jacks I, II and III only. Refer to 747-400 AMM 07- 10-00 as an accept- ed procedure. --AirplaneLift2 Refer to 747-400 AMM 12-15-04 as an accepted proce- dure. --Body Gear Shock StrutDeflate3 (a)--Body Landing GearHold4 (b)--Wing Jack IV, V, VII, VIII Apply5 (c)--Wing Jack IV, V, VII, VIII Apply6 (d)--Wing Jack IV, V, VII, VIII Stop7 FIGURE 3: JACKING THE AIRPLANE FOR THE REPAIR, REPLACEMENT OR THE MODIFICATION (SHEET 2 OF 3) 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 48 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 49 More DataQtyIdentificationNameTaskStep (a) Make sure that the gear is held in a position between full extension and full compression of the shock strut so that no load is put on the BS 1480 bulkhead by the weight of the gear. A pedestal can be installed under the tires to support the gear or the jack height can be adjusted so that the gear is supported by the wheels on the ground. Alternatively, the body landing gear can be removed. (b) Load the jacks to 5,000 pounds. Refer to 747-400 AMM 07-10-00 as an accepted procedure. (c) Increase load gradually. Keep the load difference between equivalent left and right side wing jacks less than 10 percent at all times. Do not exceed the maximum load limit for these jacks. (d) Stop increasing the load in Wing Jack IV, V, VII, VIII when the Tail Jack III load is 36,100 - 39,900 pounds. FIGURE 3: JACKING THE AIRPLANE FOR THE REPAIR, REPLACEMENT OR THE MODIFICATION (SHEET 3 OF 3) 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 49 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 50 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1480 LONGERON EXTENSION FITTING LEFT SIDE SHOWN RIGHT SIDE OPPOSITE STA 1480 LONGERON EXTENSION FITTING INSPECTION AREA POSSIBLE TRIMMED AREAS TYPICAL LONGERON EXTENSION FITTED WITH TEMPORARY REPAIR ACCOMPLISHED GROUP 1 AND GROUP 2 AIRPLANE SHOWN, 2167591 GROUP 3 AIRPLANE SIMILAR FIGURE 4: INSPECTION OF LONGERON EXTENSION FITTINGS WITH THE TEMPORARY REPAIR PREVIOUSLY ACCOMPLISHED (SHEET 1 OF 2) Original Issue: December 04, 2012 Revision 1 March 18, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2860 Work - See page 1 for details. 50 of 107 ### Page 51 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. More DataQtyIdentificationNameTaskStep Do a Surface HFEC of the edge of the longeron extension fitting, including the area trimmed as part of the Temporary Repair, for cracks in accordance with 747 NDT Part 6, 51-00- 00, Procedure 4 or 23. (a) --Longeron Extension Fitting Inspect1 (a) If any crack is found, refer to Paragraph 3.B., Work Instructions, PART 3. FIGURE 4: INSPECTION OF LONGERON EXTENSION FITTINGS WITH THE TEMPORARY REPAIR PREVIOUSLY ACCOMPLISHED (SHEET 2 OF 2) 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 51 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 52 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1480 LONGERON EXTENSION FITTING LEFT SIDE SHOWN RIGHT SIDE OPPOSITE STA 1480 LONGERON EXTENSION FITTING C E TRIMMED FWD AREA 2167670 FIGURE 5: LONGERON EXTENSION FITTING TEMPORARY REPAIR TRIM PRIOR TO REPAIR ACCOMPLISHMENT (SHEET 1 OF 5) 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. 52 of 107 ### Page 53 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT - 1.7 D MINIMUM LONGERON EXTENSION FITTING +DO R 0.50 MINIMUM B TRIM LINE FOR MAXIMUM TEMPORARY REPAIR 0.045 A-A 0.035 GROUP 1 AND GROUP 2 - 1.7 D MINIMUM LONGERON EXTENSION ' FITTING -DO *R 0.50 MINIMUM B TRIM LINE FOR MAXIMUM TEMPORARY REPAIR B-B 2167673 GROUP 3 FIGURE 5: LONGERON EXTENSION FITTING TEMPORARY REPAIR TRIM PRIOR TO REPAIR ACCOMPLISHMENT (SHEET 2 OF 5) Original Issue: December 04, 2012 Revision 1 March 18, 2014 Export Controlled ECCN: 9E991 - BOEING 747-53A2860 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 107 ### Page 54 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1480 LONGERON EXTENSION STRAIGHT TAPER - FITTING 1.10 TANGENT C MINIMUM POINT (AFTER INSURANCE CUT) FWD C-C TRIM LINE FOR MAXIMUM TEMPORARY REPAIR 0.045 0.035 C 2172144 FIGURE 5: LONGERON EXTENSION FITTING TEMPORARY REPAIR TRIM PRIOR TO REPAIR ACCOMPLISHMENT (SHEET 3 OF 5) 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. 54 of 107 ### Page 55 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT 1.70 D MINIMUM LONGERON EXTENSION FITTING R 0.25 0.25 MAXIMUM AFTER INSURANCE CUT TRIM LINE MAXIMUM FOR TEMPORARY REPAIR D-D GROUP 3 ONLY 0.045 0.035 TRIM LINE FOR MAXIMUM TEMPORARY, REPAIR TRIMMED AREA R 0.12 MINIMUM WING-TO-BODY LONGERON FAIRING SUPPORT EXTENSION STRUCTURE FITTING E-E CROSS-SECTION OF 2284528 TYPICAL TRIMMED AREA FIGURE 5: LONGERON EXTENSION FITTING TEMPORARY REPAIR TRIM PRIOR TO REPAIR ACCOMPLISHMENT (SHEET 4 OF 5) Original Issue: December 04, 2012 Revision 1 March 18, 2014 Export Controlled ECCN: 9E991 - BOEING 747-53A2860 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 107 ### Page 56 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. NOTE: These tasks should only be done after the inspection in FIGURE 4 has been done, with no crack indications found. More DataQtyIdentificationNameTaskStep (a)--Longeron Extension Fitting Cut1 (b)--Longeron Extension Fitting Shot Peen Apply chemical con- version coating and two coats of BMS 10-11, Type I primer to all bare aluminum surfaces. --FinishApply (a) Do an additional 0.040 inch deep trim of the previous trim done as part of the Temporary Repair as an insurance cut. Maintain a minimum trim radius of 0.5 inch. Surface finish to be 63AA or better. (b) Shot or flap peen the trimmed edge of the longeron extension fitting. Refer to SOPM 20-10-03, 747-400 SRM 51-20-06 or 747-400F SRM 51-20-06 as an accepted procedure. FIGURE 5: LONGERON EXTENSION FITTING TEMPORARY REPAIR TRIM PRIOR TO REPAIR ACCOMPLISHMENT (SHEET 5 OF 5) 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 56 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 57 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1480 LONGERON EXTENSION FITTING LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE STA 1480 ) 6 LOCATIONS LONGERON EXTENSION FITTING ) 6 LOCATIONS 2167696 FIGURE 6: INSPECTION OF THE LONGERON EXTENSION FITTING FOR THE REPAIR OR MODIFICATION (SHEET 1 OF 2) 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. 57 of 107 ### Page 58 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane. More DataQtyIdentificationNameTaskStep -12-FastenerRemove1 Do an open-hole HFEC inspection for cracks at each of these fastener holes in accordance with 747 NDT Part 6, 51- 00-00, Procedure 1, 11 or 16. 12-Longeron Extension Fitting, Skin and under- lying structure Inspect FIGURE 6: INSPECTION OF THE LONGERON EXTENSION FITTING FOR THE REPAIR OR MODIFICATION (SHEET 2 OF 2) 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 58 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 59 FIGURE 7: LONGERON EXTENSION FITTING REMOVAL (SHEET 1 OF 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 59 of 107 BOEING SERVICE BULLETIN 747-53A2860 ALERTALERT ### Page 60 (OCR) BOEING SERVICE BULLETIN 747-53A2860 ALERT ALERT STA 1540 + + ++++++++++++++++++++ STA 1480 ++++++++++++ +++ LONGERON EXTENSION + + FITTING A - FWD 2167733 FIGURE 7: LONGERON EXTENSION FITTING REMOVAL (SHEET 2 OF 7) Original Issue: December 04, 2012 Revision 1 March 18, 2014 Export Controlled ECCN: 9E991 - BOEING 747-53A2860 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 107 The text continues at https://openairdocs.org/service-documents/boeing/747-53a2860/file/36ecf8df5bc9.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.