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Commercial Airplanes 747 Service Bulletin Number: 747-53A2860 Original Issue: December 04, 2012 Revision 3: November 11, 2019 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Unpublished Work.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 3: November 11, 2019 1 of 240
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 2 of 240 BOEING SERVICE BULLETIN 747-53A2860
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y9
1. PLANNING INFORMATION ........................................ 1 5 A . E f f e c t i v i t y ............................................... 1 5
1. Airplanes ............................................ 1 5 2 . S p a r e s A f f e c t e d ........................................ 1 9 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 2 1 E. Compliance .............................................. 2 2 F . A p p r o v a l ............................................... 3 0 G. Manpower .............................................. 3 1 H. Weight and Balance Changes .................................... 3 3 I. Electrical Load Data ......................................... 3 4 J . R e f e r e n c e s .............................................. 3 4
1. Existing Data: ......................................... 3 4
2. Data Supplied with this Service Bulletin: ........................... 3 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 5 K. Publications Affected ........................................ 3 5 L. Interchangeability and Intermixability of Parts ........................... 3 6 M. Software Accomplishment Summary ................................ 3 6
2. MATERIAL INFORMATION ........................................ 3 7 A. Material - Price and Availability ................................... 3 7 B. Industry Support Information .................................... 3 8 C. Parts Necessary for Each Airplane ................................. 3 8 1 . K i t s / P a r t s ............................................ 3 8
2. Parts and Materials Supplied by the Operator ........................ 4 6
3. Parts Modified and Reidentified ................................ 4 6
4. Parts Removed and Not Replaced .............................. 4 7 D. Parts Necessary to Change Spares ................................. 4 7 E. Special Tooling - Price and Availability ............................... 4 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 1 FIGURE 1: LONGERON EXTENSION FITTING INSPECTION [Group 1-3] ............... 6 4 FIGURE 2: LONGERON EXTENSION FITTING CRACK REMOVAL (TEMPORARY RE PAIR) [Group 1-3] .................................................. 6 6 FIGURE 3: JACKING THE AIRPLANE FOR THE REPAIR, REPLACEMENT OR TH E MODIFICATION [Group 1-3] ........................................... 7 2 FIGURE 4: INSPECTION OF LONGERON EXTENSION FITTINGS WITH THE TEM PORARY REPAIR P R E V I O U S L Y A C C O M P L I S H E D [ G r o u p 1 - 3 ] ........................ 7 5 FIGURE 5: LONGERON EXTENSION FITTING TEMPORARY REPAIR TRIM PRIOR TO REPAIR ACCOMPLISHMENT [Group 1-3] ............................... 7 7 FIGURE 6: INSPECTION OF THE LONGERON EXTENSION FITTING FOR THE R EPAIR OR MODIFICATION [Group 1-3] .................................. 8 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 3 of 240 BOEING SERVICE BULLETIN 747-53A2860
FIGURE 7: LONGERON EXTENSION FITTING REMOVAL [Group 1-3] ................ 8 4 FIGURE 8: LONGERON EXTENSION FITTING INSTALLATION [Group 1] ............... 9 1 FIGURE 9: LONGERON EXTENSION FITTING INSTALLATION [Group 2] .............. 1 0 4 FIGURE 10: LONGERON EXTENSION FITTING INSTALLATION [Group 3] . . . ........... 1 1 7 FIGURE 11: LONGERON EXTENSION FITTING INSURANCE TRIM PRIOR TO THE MODIFICATION [Group 1 - 3 ] ............................................... 1 3 0 FIGURE 12: PREPARATION FOR INSTALLATION OF PREVENTIVE MODIFICATI ON, LEFT SIDE [Group 1 - 3 ] ............................................... 1 3 2 FIGURE 13: PREVENTIVE MODIFICATION, LONGERON EXTENSION FITTING T RIM, LEFT SIDE [Group 1 - 3 ] ............................................... 1 4 3 FIGURE 14: PREVENTIVE MODIFICATION, STATION 1480 BULKHEAD TRIM, LEFT SIDE [Group 1-3] ................................................. 1 4 7 FIGURE 15: PREVENTIVE MODIFICATION INSTALLATION, LEFT SIDE [Grou p 1 - 3 ] ........ 1 5 2 FIGURE 16: PREPARATION FOR INSTALLATION OF PREVENTIVE MODIFICATION, RIGHT SIDE [Group 1 - 3 ] ............................................... 1 6 6 FIGURE 17: PREVENTIVE MODIFICATION, LONGERON EXTENSION FITTING TRIM, RIGHT SIDE [Group 1 - 3 ] ............................................... 1 7 7 FIGURE 18: PREVENTIVE MODIFICATION, STATION 1480 BULKHEAD TRIM, RIGHT SIDE [Group 1-3] ................................................. 1 8 1 FIGURE 19: PREVENTIVE MODIFICATION INSTALLATION, RIGHT SIDE [Gro u p 1 - 3 ] ........ 1 8 6 FIGURE 20: LONGERON EXTENSION FITTING INSPECTION [Group 4] ............... 2 0 0 FIGURE 21: LONGERON EXTENSION FITTING INSPECTION [Group 5] ............... 2 0 2 FIGURE 22: LONGERON EXTENSION FITTING CRACK REMOVAL - TRIM-OUT R EPAIR [Group 4] . 204 FIGURE 23: LONGERON EXTENSION FITTING CRACK REMOVAL - TRIM-OUT R EPAIR [Group 5] . 210 APPENDIX A: MASTER FASTENER CODE TABLE [Group 1-3] ...................... 2 1 6 APPENDIX B: 675U0006-( ) SPLICE FITTING MODIFICATION [Group 1-3] ............... 2 2 0 APPENDIX C: LOGIC DIAGRAM FOR TABLE 1: STA 1480 LONGERON EXTENSION FITTING HFEC INSPECTION [Group 1-3] .................................. 2 2 3 APPENDIX D: LOGIC DIAGRAM FOR TABLE 2: HFEC INSPECTION REQUIREMENTS AFTER COMPLETION OF PART 2: TEMPORARY REPAIR [Group 1-3] ...................... 2 2 7 APPENDIX E: LOGIC DIAGRAM FOR TABLE 3: HFEC INSPECTION REQUIREMENTS AFTER COMPLETION OF PART 4: REPAIR, PART 5: MODIFICATION OR PART 6: REPLACEMENT [Group 1-3] ................................................. 2 3 1 APPENDIX F: LOGIC DIAGRAM FOR TABLE 4: HFEC INSPECTION REQUIREMENTS AFTER COMPLETION OF PART 8: PREVENTIVE MODIFICATION ON A LONGERON EXTENSION FITTING WITH ANY CRACK FOUND THAT WAS WITHIN LIMITS [Group 1-3] .............. 2 3 5 APPENDIX G: PART DEMAND INTENT................................... 2 3 6 APPENDIX H: LOGIC DIAGRAM FOR TABLE 5: STA 1480 LONGERON EXTENSION FITTING HFEC INSPECTION [Group 4-5] .................................. 2 3 7 APPENDIX I: LOGIC DIAGRAM FOR TABLE 6: STA 1480 LONGERON EXTENSION FITTING HFEC INSPECTION [Group 4-5] .................................. 2 3 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 4 of 240 BOEING SERVICE BULLETIN 747-53A2860
Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2860Original Issue: December 04, 2012 Revision 3: November 11, 2019 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 Federal Aviation Administration (FAA) Airworthiness Directive AD 2015-13-06 and AD 2013-14-05 is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue, Revision 1 or Revision 2 was previously done:
None.
Airplane Line Numbers 88-1096 were added:
Airplanes 747-100, 747-100B, 747-100BSUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP and 747-SR, airplane line numbers 88-998 were added to new Group 4 of this service bulletin.
Airplanes 747-400, 747-400D and 747-400F, airplane line numbers 999-1096 were added to new Group 5 of this service bulletin.
REASON FOR REVISION This revision is sent to add airplanes to the service bulletin effectivity and add new inspections and repair instructions for the new added Group 4 and Group 5 airplanes. These airplanes were added after an operator found a crack in the longeron extension fitting flange while accomplishing Service Bulletin (SB) 747-532390 Revision 1 open hole High Frequency Eddy Current (HFEC) inspection. This SB gives inspection and repair instructions for crack detection of the longeron extension fitting flange not covered in SB 747-53A2390 for airplane Line Numbers 88-1096.
These sections were changed:
1. Summary; Background, Action, Effectivity, Compliance, Industr y Support Information, Manpower, Material Information and Illustration updated to include work for new Group 4 and Group 5 airplanes, and new Service Related Problem (SRP) references.
2. Paragraph 1.A., Effectivity; added new airplanes and updated Group Configuration Table to include new Group 4 and 5.
3. Paragraph 1.C., Reason; added the reason for this revision an d updated service history.
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Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 5 of 240
4. Paragraph 1.D., Description; added the effects of this revisi on statement and added new affected maintenance zones tables for new Group 4 and Group 5.
5. Paragraph 1.E., Compliance; added group applicability to tabl es 1 through 4, added references to APPENDIX H-I, and added new compliance Table 5 and 6 for new Group 4 and Group 5.
6. Paragraph 1.F., Approval; added group applicability headings.
7. Paragraph 1.G., Manpower; added Figure 20 and Figure 21 to Ta ble 1 and added new tables for new Group 4 and Group 5.
8. Paragraph 1.H., Weight and Balance Changes; Tables 1-5 update d and added new Table 6 for new Group 4 and Group 5.
9. Paragraph 1.J., References; added new references.
10. Paragraph 2.A., Material Information; updated group applicab ility, Reorder Lead Time (ROLT), Price Information, Industry Support Information, and added Table footnotes.
11. Paragraph 2.B., Industry Support Information; warranty state ment updated.
12. Paragraph 2.C.1., Parts Necessary for Each Airplane Kits/Par ts; updated group applicability for kits, Structural Repair Manual (SRM) references, and added table footnotes.
13. Paragraph 2.C.2., Parts and Materials Supplied by the Operat or; updated to include parts necessary to complete work for new groups and added table footnotes.
14. Paragraph 2.E., Special Tooling, Price and Availability; add ed group applicability headings.
15. Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin; added group applicability headings.
16. Paragraph 3.A., General Information; added new AMM reference and new Logic Diagram references.
17. Paragraph 3.B., Work instructions; PART 1 added new Group 4 and Group 5 Work Instructions, and updated excess information.
18. Paragraph 3.B., Work instructions, PART 4; longeron removal instructions added.
19. Paragraph 3.B., Work instructions; PART 8; updated preventat ive modification note.
20. Paragraph 3.B., Work instructions; added new group applicabi lity headings to Part 1 through Part 9.
21. Paragraph 3.B., Work instructions; Added Part 10 and 11 appl icability.
22. Figure 2; footnote added.
23. Figure 1-7 and Figure 11-19; added group applicability headi ngs.
24. Added new Figures 20 thru Figure 23 for new Group 4 and Grou p 5.
25. APPENDIX A; footnotes and parts added to table.
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Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 6 of 240 BOEING SERVICE BULLETIN 747-53A2860
26. APPENDIX C; added PART 3 and updated PART 9 description to t able.
27. APPENDIX D; updated PART 9 description to table.
28. APPENDIX E; added PART 3 and updated PART 9 description to t able.
29. APPENDIX F; updated PART 9 description to table.
30. APPENDIX A-F; added group applicability headings.
31. Added APPENDIX H-I new logic diagrams for new airplane Group s.
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:
July 12, 2016Revision 2:
November 11, 2019Revision 3:
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Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 7 of 240 BOEING SERVICE BULLETIN 747-53A2860
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 8 of 240 BOEING SERVICE BULLETIN 747-53A2860
BLANK PAGE
Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2860Original Issue: December 04, 2012 Revision 3: November 11, 2019 ATA System: 5312 SUBJECT: FUSELAGE - Main Frame - Center Section - Longeron Extension Fitting Inspection, Repairs and Modification - Body Station 1480 to Body Station 1540
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 SideLeft 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 99,70718,243-0.300747-400 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 9 of 240
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.
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.
Since revision 2 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 0.3 inch long crack was found in the left longeron extension fitting of an airplane with 18,243 flight-cycles and 99,707 flight-hours.
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 become large and adversely affect the structural integrity of the airplane.
Boeing Fleet Team Digest (FTD) 747 FTD 53-11007 is related to this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-53-0398, 747-SRP-53-0444, 747-SRP-53-0466 and 747-SRP-53-0572 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 ChangesYesWeight 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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION (PRR 85900-292R, 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.
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Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 10 of 240 BOEING SERVICE BULLETIN 747-53A2860
Group 1-3:
If any crack is found that is within the limits given in this service bulletin, do one of the repairs available in 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.
Group 1-3:
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.
Group 1-3:
A preventive modification may be done on longeron extension fittings without any crack or new longeron extension fittings. This is terminating action for inspections given in this service bulletin.
Group 4-5:
If any crack is found that is within the limits given in this service bulletin, do the repair available in this service bulletin.
Group 4-5:
If any crack is found that is not within the limits given in this service bulletin, contact The Boeing Company for repair instructions and do the repair.
Group 4-5:
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 747-100/-100B/100-BSUD/-200B/-200C/-200F/-300/-400/-400D/-400F/747SP and 747SR. Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE Group 1-3:
Federal Aviation Administration (FAA) Airworthiness Directive AD 2015-13-06 is related to this service bulletin.
The effective date of AD 2015-13-06 is September 1, 2015.
Group 1-3:
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.
Group 4-5:
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.
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Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 11 of 240 BOEING SERVICE BULLETIN 747-53A2860
MANPOWER Group 1-3:
Table 1: Manpower Elapsed HoursTotal Task HoursTask
9.5032.00Longeron Extension Fitting Inspection
199.50788.00Longeron Extension Fitting Modification
190.50770.00Longeron Extension Fitting Replacement
225.00908.00Longeron Extension Fitting Preventive Modification Group 4-5:
Table 2: Manpower Elapsed HoursTotal Task HoursTask 1632Longeron Extension Fitting Inspection
16.432.8STA 1480 Longeron Extension Fitting Crack Removal - Trim-out Repair Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Operator Supplied Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX G of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 04, 2012 747-53A2860Revision 3: November 11, 2019 12 of 240 BOEING SERVICE BULLETIN 747-53A2860