# Boeing Alert Service Bulletin 747-53A2860: Revision 3 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2020-0208; AD 2020-15-14 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: SB-747-53A2860-03--BOEING - Pages: 240 - PDF: https://openairdocs.org/files/sha256/53/1e/531e1ce403d9a1a9932544d74f94ca91972428778fd775fda8c17466a795f744 - Page: https://openairdocs.org/service-documents/boeing/747-53a2860/file/531e1ce403d9 ## 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 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 Unpublished Work.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3: November 11, 2019 1 of 240 3.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 2 of 240 BOEING SERVICE BULLETIN 747-53A2860 BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 S u m m a r y ...................................................... 9 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 ### Page 4 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 ### Page 5 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. 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 5 of 240 ### Page 6 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. 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 6 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 7 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: 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 7 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 8 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 ### Page 9 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 ### Page 10 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 Air- plane 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. 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 10 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 11 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. 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 11 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 12 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 ### Page 13 (OCR) BOEING SERVICE BULLETIN 747-53A2860 STA 1480 LONGERON EXTENSION FITTING STA FUSELAGE SKIN 1480 LONGERON EXTENSION FITTING I GROUP 1-3: EXTENSION FITTING FOR CRACKS, IF CRACKS ARE FOUND, REPAIR IF WITHIN LIMITS OR REPLACE THE FITTING IF NOT WITHIN THE LIMITS TYPICAL GROUP 4-5: CRACK DO A SURFACE HFEC INSPECTION OF THE LONGERON EXTENSION FITTING FOR CRACKS. IF CRACKS ARE GROUP 1 SHOWN, GROUP 2-5 SIMILAR BOEING COMPANY IF NOT WITHIN LIMITS FOUND, REPAIR IF WITHIN LIMITS OR CONTACT THE 2167176 Original Issue: December 04, 2012 Revision 3: November 11, 2019 Export Controlled ECCN: 9E991 - BOEING 747-53A2860 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 240 ### Page 14 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 14 of 240 BOEING SERVICE BULLETIN 747-53A2860 BLANK PAGE ### Page 15 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 1. PLANNING INFORMATION A. Effectivity 1. Airplanes This bulletin is applicable to 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR Airplane(s), line number(s) 88-1419 in 5 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive. Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. 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. -3 747-100, 747-100B, 747-100BSUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP and 747-SR airplanes line numbers 88-998 -4 747-400, 747-400D and 747-400F airplanes line numbers 999-1096-5 Airplane Models: 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR 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 15 of 240 ### Page 16 GroupVariable Number 4RA027 - RA034 4RA113 - RA115 4RA163 - RA164 4RA216 - RA217 4RA245 - RA246 4RA255 - RA266 4RA304 - RA318 4RA360 4RA369 - RA373 4RA406 - RA418 4RA502 4RA524 - RA528 4RA532 - RA548 4RA559 - RA561 4RA582 4RA585 4RA633 - RA635 4RA651 - RA652 4RA671 - RA677 4RA701 - RA702 4RA721 - RA731 4RA741 - RA745 4RA749 - RA750 4RA761 - RA762 4RA781 - RA784 4RA910 - RA916 4RB001 - RB016 4RB044 4RB071 - RB075 4RB101 - RB102 4RB411 - RB413 4RB421 4RB601 - RB607 GroupVariable Number 4RB681 - RB697 4RB711 4RB721 - RB723 4RB741 - RB748 4RD001 - RD004 4RD021 - RD022 4RD041 - RD059 4RD071 - RD072 4RD081 - RD083 4RD091 - RD092 4RD101 - RD104 4RD121 - RD127 4RD131 - RD144 4RD166 - RD167 4RD171 - RD172 4RD181 - RD183 4RD201 - RD204 4RD221 - RD227 4RD231 - RD235 4RD241 - RD243 4RD251 - RD262 4RD271 - RD272 4RD291 - RD292 4RD301 - RD302 4RD311 4RD351 - RD358 4RD361 - RD366 4RD381 - RD383 4RD411 - RD414 4RD421 - RD426 4RD431 - RD435 4RD441 - RD442 4RD451 - RD456 GroupVariable Number 4RD461 4RD471 - RD475 4RD513 - RD519 4RD531 - RD533 4RD551 4RD561 4RD571 4RD581 - RD583 4RD591 - RD593 4RD601 - RD607 4RD621 - RD623 4RD641 - RD649 4RD651 - RD659 4RD661 4RD671 4RD681 - RD682 4RD691 - RD692 4RD701 - RD702 4RD721 - RD722 4RD741 - RD742 4RD751 - RD755 4RD761 4RD771 - RD775 4RD781 - RD783 4RD791 - RD792 4RE001 3RF001 - RF006 4RG001 - RG009 4RG091 4RG095 4RG101 - RG104 4RG121 - RG126 4RG141 - RG142 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 16 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 17 GroupVariable Number 4RG161 - RG164 4RG171 - RG174 4RG191 - RG193 4RG211 - RG213 4RG221 - RG222 4RH101 - RH102 4RH111 - RH112 4RH121 - RH122 4RJ131 - RJ133 4RJ151 - RJ152 4RJ301 - RJ303 4RJ321 - RJ322 4RJ331 - RJ333 2RL401 - RL403 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 GroupVariable Number 2RL751 - RL752 1RM001 - RM003 2RM004 - RM007 2RM010 1RM011 - RM012 2RM013 1RM021 - RM024 1RM026 - RM027 2RM028 - RM030 1RM036 - RM038 2RM039 - RM045 1RM051 2RM052 - RM053 1RM071 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 GroupVariable Number 1RM331 - RM332 2RM333 2RM341 2RM351 - RM355 2RM366 - RM367 2RM401 - RM403 2RM426 2RM431 2RM441 - RM443 2RM445 1RM801 2RM802 - RM803 1RM811 - RM813 1RM851 - RM852 2RM853 - RM858 3RM859 1RM861 2RM862 3RM863 1RM871 2RM872 - RM876 3RM877 - RM880 1RM881 - RM885 2RM886 - RM887 3RM888 - RM890 1RM891 - RM899 2RM901 - RM905 3RM906 1RM911 4RR001 - RR005 4RR021 - RR025 4RR031 4RR201 - RR206 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 17 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 18 GroupVariable Number 4RR221 - RR226 4RR261 - RR267 4RR301 - RR310 4RR331 - RR332 4RR336 4RR341 - RR345 4RR361 - RR362 4RR421 - RR422 4RR431 - RR432 4RR441 - RR442 4RR451 4RR501 - RR504 4RR521 - RR522 4RR526 4RR531 4RR551 - RR556 4RR561 4RR566 4RR701 5RR721 - RR722 1RR723 - RR724 5RR746 - RR748 5RR851 - RR855 1RR856 5RR861 1RR862 5RR951 - RR952 4RS001 - RS002 4RS201 4RS211 - RS212 4RS221 - RS222 4RS231 - RS241 4RS251 - RS259 GroupVariable Number 4RS263 4RS265 - RS268 4RS271 - RS276 4RS291 - RS292 4RS301 - RS306 4RS311 - RS320 4RS331 - RS333 4RS341 - RS342 4RS699 4RS701 - RS703 4RS711 - RS713 4RS721 - RS722 4RS731 - RS732 4RS741 - RS743 4RS751 - RS752 4RS761 - RS762 4RS771 4RS781 - RS782 4RS786 4RT001 - RT010 5RT011 - RT012 1RT013 - RT014 4RT021 - RT022 4RT031 - RT033 1RT034 - RT035 4RT041 - RT047 4RT061 4RT071 - RT075 4RT101 - RT103 4RT121 4RT131 - RT133 5RT134 - RT135 1RT136 - RT137 GroupVariable Number 5RT151 - RT152 4RT161 - RT162 5RT163 - RT168 4RT401 - RT412 4RT431 - RT441 5RT442 1RT443 - RT447 4RT451 - RT466 5RT467 - RT469 4RT471 - RT496 5RT497 - RT499 4RT501 - RT520 5RT521 - RT530 4RT531 - RT535 4RT551 - RT568 4RT571 - RT581 5RT582 - RT590 4RT591 4RT601 - RT622 5RT623 - RT624 1RT625 - RT630 4RT631 - RT635 5RT636 1RT637 - RT640 4RT641 - RT657 4RT671 - RT673 4RT681 - RT682 4RT691 - RT696 5RT697 - RT699 4RT701 - RT704 4RT711 - RT717 4RT741 - RT746 5RT747 - RT750 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 18 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 19 GroupVariable Number 4RT751 - RT755 1RT756 - RT757 4RT776 - RT777 4RT781 - RT784 1RT801 - RT803 5RT811 1RT812 - RT814 5RT831 - RT835 1RT836 - RT837 4RT861 - RT864 4RT876 - RT878 5RT879 - RT880 GroupVariable Number 4RT931 - RT932 5RT945 - RT947 1RT948 - RT949 4RT951 - RT954 1RT955 5RT966 - RT967 4RU001 5RU002 - RU006 5RU016 1RU017 4RU031 5RU032 GroupVariable Number 5RU051 - RU052 5RU059 - RU062 5RU081 - RU083 1RU101 - RU102 5RU121 - RU125 1RU126 - RU132 4RU801 - RU808 5RU809 4RU831 - RU839 5RU840 - RU841 -- -- 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 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 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 19 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 20 Service History Flight-HoursFlight-Cycles Crack Length Model Right SideLeft Side 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 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. Alert Revision 1 was 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. Revision 2 was sent to add a new preventive modification which is the terminating action for PART 1 inspection for longeron extension fittings that do not have any crack. The preventive modification increases the inspection interval on longeron extension fittings that have been repaired. Added references to new FAA AD 2015-13-06 which replaces FAA AD 2013-14-05 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 20 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 21 Revision 3 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. 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. 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 using 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. Effects of this Revision on airplanes on which Original Issue, Revision 1 or Revision 2 was previously done: None. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1-3: Affected Maintenance Zones ZoneModel 141, 142, 143, 144747-400, 747-400F 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 21 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 22 Group 4: Affected Maintenance Zones ZoneModel 141, 142, 143, 144747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR Group 5: Affected Maintenance Zones ZoneModel 141, 142, 143, 144747-400, 747-400D, 747-400F E. 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. A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX C, APPENDIX D, APPENDIX E, APPENDIX F, APPENDIX H and APPENDIX I. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. Group 1-3: Table 1: STA 1480 Longeron Extension Fitting HFEC 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 inspections of the left and right longeron extension fittings for cracks in accordance with PART 1. All airplanes. 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 22 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 23 Group 1-3: Table 1: STA 1480 Longeron Extension Fitting HFEC Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Do the Temporary Repair in ac- cordance with PART 2. Any crack found. All cracks are within limits. (a) OR -Before further flight.Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. (b) OR -Before further flight.Do the Preventive Modification in accordance with PART 8. (c) OR -Before further flight.Do the Longeron Extension Fit- ting Replacement in accordance with PART 6. AND Do the Preventive Modification in accordance with PART 8. (d) -Before further flight.Do the Longeron Extension Fit- ting Replacement in accordance with PART 6. Any crack found that is not within limits. (b) OR -Before further flight.Do the Longeron Extension Fit- ting Replacement in accordance with PART 6. AND Do the Preventive Modification in accordance with PART 8. (d) 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 23 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 24 Group 1-3: Table 1: STA 1480 Longeron Extension Fitting HFEC Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition 2,100 flight-cycles-Repeat the surface HFEC in- spection of the forward flange of the left and right longeron extension fitting in accordance with PART 1. No crack found. OR -Before further flight.Do the Modification in accor- dance with PART 5. (b) OR -Before further flight.Do the Preventive Modification in accordance with PART 8. (d) (a) Inspection requirements after completion of PART 2: Temporary Repair are in Table 2. (b) Inspection requirements after completion of PART 4: Repair, PART 5: Modification or PART 6: Replace- ment are in Table 3. (c) Inspection requirements after completion of PART 8: Preventive Modification on a Longeron Extension Fitting with any crack found that was within limits are in Table 4. (d) PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. Group 1-3: Table 2: HFEC Inspection Requirements After Completion of PART 2: Temporary Repair 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 PART 3. Temporary Repair previous- ly accomplished in accor- dance with PART 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 24 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 25 Group 1-3: Table 2: HFEC Inspection Requirements After Completion of PART 2: Temporary Repair Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. Any crack found. All cracks are within limits. (a) OR -Before further flight.Do the Preventive Modifi- cation in accordance with PART 8. (b) OR -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance PART 6. AND Do the Preventive Modifi- cation in accordance with PART 8. (c) -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with PART 6. Any crack found that is not within limits. (a) OR -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with PART 6. AND Do the Preventive Modifi- cation in accordance with PART 8. (c) 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 25 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 26 Group 1-3: Table 2: HFEC Inspection Requirements After Completion of PART 2: Temporary Repair Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Do the Repair in accor- dance with PART 4. No crack found. (a) OR -Before further flight.Do the Preventive Modifi- cation in accordance with PART 8. (b) OR -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with PART 6. AND Do the Preventive Modifi- cation in accordance with PART 8. (c) (a) Inspection requirements after completion of PART 4: Repair or PART 6: Replacement are in Table 3. (b) Inspection requirements after completion of PART 8: Preventive Modification on a Longeron Extension Fitting with any crack found that was within limits are in Table 4. (c) PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. Group 1-3: Table 3: HFEC Inspection Requirements After Completion of PART 4: Repair, PART 5: Modification or PART 6: Replacement Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight-cycles af- ter the effective date of AD 2015-13-06. 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 PART 7. Airplanes with the Modifica- tion installed in accordance with PART 5, or the Repair installed in accordance with PART 4, or the Longeron Extension Fitting Replace- ment done in accordance with PART 6. 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 26 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 27 Group 1-3: Table 3: HFEC Inspection Requirements After Completion of PART 4: Repair, PART 5: Modification or PART 6: Replacement Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Do the Temporary Repair in accordance with PART 2. Any crack found. All cracks are within limits. (a) OR -Before further flight.Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. (b) OR -Before further flight.Do the Preventive Modifi- cation in accordance with PART 8. (c) OR -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with PART 6. AND Do the Preventive Modifi- cation in accordance with PART 8. (d) -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with PART 6. Any crack found that is not within limits. (b) OR -Before further flight.Do the Longeron Exten- sion Fitting Replacement in accordance with PART 6. AND Do the Preventive Modifi- cation in accordance with PART 8. (d) 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 27 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 28 Group 1-3: Table 3: HFEC Inspection Requirements After Completion of PART 4: Repair, PART 5: Modification or PART 6: Replacement 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 PART 7. No crack found. OR -Before further flight.Do the Preventive Modifi- cation in accordance with PART 8. (d) (a) Inspection requirements after completion of PART 2: Temporary Repair are in Table 2 (b) Inspection requirements after completion of PART 4: Repair or PART 6: Replacement are in Table 3. (c) Inspection requirements after completion of PART 8: Preventive Modification on a Longeron Extension Fitting with any crack found that was within limits are in Table 4. (d) PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. Group 1-3: 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 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 6,000 flight-cy- cles after accomplish- ment of the Preventive Modification. Do surface HFEC inspections of any modified, repaired longeron extension fitting for cracks in accordance with PART 9. Airplanes that have accom- plished the Preventive Modifica- tion in accordance with PART 8 on a longeron extension fitting that had any cracks found. All cracks were within limits. -Before further flight.Contact The Boeing Company for repair instructions and do the repair. Any crack found. 6,000 flight-cycles-Repeat the surface HFEC in- spection of the forward flange of the left and right longeron extension fitting in accordance with PART 9. No crack found. 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 28 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 29 Group 4-5: Table 5: STA 1480 Longeron Extension Fitting HFEC Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight-cycles af- ter the Revision 3 date of this service bulletin. Before 13,000 total flight-cy- cles. Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with PART 1. All airplanes. -Before further flight.Do the Repair in accordance with PART 10. (a) Any crack found. All cracks are within limits. -Before further flight.Contact The Boeing Company for repair instructions and do the repair. Any crack found that is not within limits. AND 2,100 flight-cycles-Repeat the surface HFEC in- spection of the forward flange of the left and right longeron extension fitting in accordance with PART 1. 2,100 flight-cycles-Repeat the surface HFEC in- spection of the forward flange of the left and right longeron extension fitting in accordance with PART 1. No crack found. (a) Inspection requirements after completion of PART 10: Longeron Extension Fitting Crack Removal - Trim- out Repair are in Table 6. Group 4-5: Table 6: Post STA 1480 Longeron Extension Fitting Trim-out Repair Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 2,100 flight-cycles after ac- complishment of the Part 10 Longeron Extension Fitting Crack Removal Trim-out Repair. Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with PART 11. All airplanes. 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 29 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 30 Group 4-5: Table 6: Post STA 1480 Longeron Extension Fitting Trim-out Repair Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.Do the Repair in accordance with PART 10. Any crack found. All cracks are within limits. AND 2,100 flight cycles-Repeat the surface HFEC in- spections of the forward flange of the left and right longeron extension fittings for cracks in accordance with PART 11. -Before further flight.Contact The Boeing Company for repair instructions and do the repair. Any crack found that is not within limits. AND 2,100 flight-cycles-Repeat the surface HFEC in- spection of the forward flange of the left and right longeron extension fitting in accordance with PART 11. 2,100 flight-cycles-Repeat the surface HFEC in- spection of the forward flange of the left and right longeron extension fitting in accordance with PART 11. No crack found. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. Group 1-3: In addition, the Manager of the FAA Seattle ACO approves the accomplishment of the inspections, repairs, and modifications as defined by this service bulletin revision as an AMOC to the accomplishment of the inspections, repairs, and modifications as defined by Boeing SB 747-53A2860 Revision 1 required by paragraph (g), (h), (i), and (j) of AD 2015-13-06. All provisions of AD 2015-13-06 that are not specifically referenced in the above statement remain fully applicable and must be complied with accordingly. 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 30 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 31 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 • 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 or FIGURE 20 or FIGURE 21) 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. Group 1-3: 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 Re- moval (Figure 7) 2.505.002Longeron Extension Fitting Trim (Figure 11) 59.25237.004Longeron Extension Fitting In- stallation (Figure 8, 9, or 10) 2.0010.005Lower the Airplane 3.7515.004Close Access 99.75394.00TOTAL FOR ONE SIDE OF THE AIRPLANE 199.50788.00TOTAL FOR EACH AIRPLANE 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 31 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 32 NOTE: More time will be necessary for repairs if cracks are found. Group 1-3: 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 Re- moval (Figure 7) 59.25237.004Longeron Extension Fitting In- stallation (Figure 8, 9, 10) 2.0010.005Lower the Airplane 3.7515.004Close Access 95.25385.00TOTAL FOR ONE SIDE OF THE AIRPLANE 190.50770.00TOTAL FOR EACH AIRPLANE Group 1-3: Table 4: Preventive Modification Elapsed HoursTask HoursNumber of PersonsTask 3.7515.004Open Access 2.0010.005Jack the Airplane (Figure 3) 41.75167.004Preventive Modification Left Side (Figure 12, 13, 14 and 15) 41.75167.004Preventive Modification Right Side (Figure 16, 17, 18 and 19) 59.25237.004Longeron Extension Fitting In- stallation (Figure 8, 9, or 10) (a) 2.0010.005Lower the Airplane 3.7515.004Close Access 112.50454.00TOTAL FOR ONE SIDE OF THE AIRPLANE 225.00908.00TOTAL FOR EACH AIRPLANE (a) If the longeron extension fitting was installed in accordance with the Original Issue, Re- vision 1 or Revision 2 of this service bulletin, longeron extension fitting removal is not required. 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 32 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 33 Group 4: Table 5: STA 1480 Longeron Extension Fitting Crack Removal - Trim-out Repair Elapsed TimeTask HoursNumber of PersonsTask 8.216.42FIGURE 22 8.216.4TOTAL FOR ONE SIDE OF THE AIRPLANE 16.432.8TOTAL FOR EACH AIRPLANE Group 5: Table 6: STA 1480 Longeron Extension Fitting Crack Removal - Trim-out Repair Elapsed TimeTask HoursNumber of PersonsTask 8.216.42FIGURE 23 8.216.4TOTAL FOR ONE SIDE OF THE AIRPLANE 16.432.8TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes NOTE: Values below are per side. If more than one Repair/Modification/Replacement is being done, be sure to sum the total of each PART accomplished. Group 1-3: Table 1: PART 2: Temporary Repair Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane NoneNoneGroup 1-3 Group 1-3: Table 2: PART 4: Repair Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +2716.6+1.8Group 1-3: Group 1-3: Table 3: PART 5: Modification Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +2716.6+1.8Group 1-3: 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 33 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 34 Group 1-3: Table 4: PART 6: Longeron Extension Fitting Replacement Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +2716.6+1.8Group 1-3: Group 1-3: Table 5: PART 8: Preventative Modification Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +6107.2+4.1Group 1-3: Group 4-5: Table 6: PART 10: STA 1480 Longeron Extension Fitting Crack Removal - Trim-out Repair Change in Moment (Pounds-Inches) Change in Weight (Pounds) Airplane NoneNoneGroup 4-5: I. Electrical Load Data Not changed. J. References 1. Existing Data: a. Engineering Change Memo PRR 85901-119RS, PRR 85900-292R b. Boeing Service Letter 747-SL-00-018, 747-SL-51-048 c. Boeing Service Related Problem (SRP) 747-SRP-53-0398, 747-SRP -53-0444, 747-SRP-53-0466, 747-SRP-53-0572 d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2013-14-05, 2015-13-06 e. Service Bulletin Index D6-30300 f. Standard Overhaul Practices Manual (SOPM) 20-10-03, 20-20-02, 20-41-02, 20-43-03, 20-50-12, 20-50-19, 20-50-20 g. Standard Wiring Practices Manual (SWPM) 20-10-11 h. 747 Fleet Team Digest (FTD) 53-11007 i. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00 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 34 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 35 j. 747-100/200/300 Aircraft Maintenance Manual (AMM)12-09-03, 51 -21-04, 53-51-01 k. 747-100/200/300 Structural Repair Manual (SRM)51-10-07 l. 747-400 Aircraft Maintenance Manual (AMM) 06-09-03, 07-11-01, 12-15-04, 25-52-01, 25-52-04, 27-51-01, 32-13-16, 32-13-24, 33-51-03, 51-21-04, 51-24-13, 53-51-01 m. 747-400 Structural Repair Manual (SRM) 51-20-06, 51-20-13, 51-40-02, 51-40-09, 53-40-08 n. 747-400F Structural Repair Manual (SRM) 51-20-06, 51-20-13, 51-40-02, 51-40-09, 53-40-08 o. 747-400SF Structural Repair Manual (SRM) 51-20-06, 51-20-13, 51-40-02, 51-40-09, 53-40-08 p. 747-SP Structural Repair Manual (SRM) 51-10-07 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 BULKHEAD INSTL - AFT WHEEL WELL, LOWER STA 148065B15085 Crease Beam and WL 152 Deck Instl65B15254 Longeron Extension Fitting Installation65B15255 LONGERON EXTENSION FITTING KIT - PREVENTIVE MOD, STA 1480 - STA 1540 675U0009 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. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. 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 35 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 36 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 3: November 11, 2019 36 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 37 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 Group 1-3: 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 $99,950.003515February 25, 2014 Top Kit - Longeron Ex- tension Fitting Replace- ment Group 1 and Group 2 015U1931-1 3April 2, 2014 $99,950.003512February 25, 2014 Top Kit - Longeron Ex- tension Fitting Replace- ment Group 3 015U1931-2 $26,980.003289August 23, 2016 Top Kit - Longeron Ex- tension Fitting Kits - Preventive Mod, Sta 1480 - Sta 1540 015U2131-3 10September 21, 2016 10October 19, 2016 10November 16, 2016 $1,480.0029715August 23, 2016 Fastener Kit - Longeron Extension Fitting Kits - Preventive Mod, Sta 1480 - Sta 1540 675U0009-3 $850.0029715July 14, 2016Fastener Kit - Longeron Extension Fitting Kits - Preventive Mod, Sta 1480 - Sta 1540 675U0009-4 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 37 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 38 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. B. Industry Support Information Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures given in this service bulletin. 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: Kit(s) for the Action and Group shown below and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. Group 1-3: Group 3Group 2Group 1KitAction -11015U1931-1PART 6 Longeron Extension Fitting Replacement 1--015U1931-2 111015U2131-3PART 8 Longeron Extension Fitting Preventive Modification (a)(a)(a)675U0009-3 (b)(b)(b)675U0009-4 (a) Use 1 kit for each side without a Structural Repair Manual (SRM) web repair. Refer to 747-400 SRM 53-40-08 Repair 1 or 747-400F SRM 53-40-08 Repair 1 or 747-400SF SRM 53-40-08 repair 1. (b) Use 1 kit for each side with a SRM web repair. Refer to 747-400 SRM 53-40-08 Repair 1 or 747-400F SRM 53-40-08 Repair 1 or 747-400SF SRM 53-40-08 repair 1. Group 1-3: Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -2-1 --Top Kit - Longeron Extension Fitting Re- placement - Group 1 and Group 2 .-015U1931-1 --Top Kit - Longeron Extension Fitting Re- placement - Group 3 -.015U1931-2 --Left Side Longeron Extension Fitting Re- placement Kit -1015U1931-3 --Right Side Longeron Extension Fitting Replacement Kit -1015U1931-4 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 38 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 39 Group 1-3: Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -2-1 --Left Side Longeron Extension Fitting Re- placement Kit 1-015U1931-5 --Right Side Longeron Extension Fitting Replacement Kit 1-015U1931-6 Group 1-3: Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3 (a)-Left Side Longeron Exten- sion Fitting Replacement Kit ----015U1931-3 (a)-Right Side Longeron Exten- sion Fitting Replacement Kit ----015U1931-4 (a)-Left Side Longeron Exten- sion Fitting Replacement Kit ----015U1931-5 (a)-Right Side Longeron Exten- sion Fitting Replacement Kit ----015U1931-6 (c)-FITTING - LONGERON EXTENSION ---165B15034U23 (c)-FITTING - LONGERON EXTENSION --1-65B15034U24 (c)-FITTING - LONGERON EXTENSION -1--65B15034U25 (c)-FITTING - LONGERON EXTENSION 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 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 39 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 40 Group 1-3: Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3 (c)-SPLICE FITTING1-1-675U0006-6 (b)-BOLT1111BACB30NW12K9X (b)-BOLT2222BACB30NX6K10X (b)-BOLT1111BACB30NX6K12X (b)-BOLT3333BACB30NX6K2X (b)-BOLT3333BACB30NX6K6X (b)-BOLT1111BACB30NX6K7X (b)(d)-BOLT30303030BACB30NX8K10X (b)(d)-BOLT12121212BACB30NX8K11X (b)(d)-BOLT4444BACB30NX8K12X (b)(d)-BOLT1111BACB30NX8K21X (b)(d)-BOLT1111BACB30NX8K23X (b)(d)-BOLT8888BACB30NX8K4X (b)(d)-BOLT20202020BACB30NX8K5X (b)(d)-BOLT16161616BACB30NX8K6X (b)(d)-BOLT40404040BACB30NX8K7X (b)(d)-BOLT36363636BACB30NX8K8X (b)(d)-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 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 40 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 41 Group 1-3: Kit 015U1931 NotesExisting Part Number NameQTYNew Part Number -6-5-4-3 --COLLAR220220220220BACC30BH8 --NUT--1212BACN10HR8CD --NUT24241212BACN10HR9CD --SHIM1111BACS40R018B025F --SHIM3333BACS40R018E055F --SHIM3333BACS40R021E055F --SHIM2222BACS40R024E096F --SHIM2222BACS40R027B049F --SHIM1111BACS40R034B053F --SHIM1111BACS40R034B060F --WASHER--1212BACW10BP8CD --WASHER--1212BACW10BP8DP --WASHER24241212BACW10BP9CD --WASHER24241212BACW10BP9DP --WASHER, SELF-ALIGN1111BACW10CA3CCK --WASHER, SELF-ALIGN1111BACW10CA3PVK (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. (d) BACB30NX8K*X is an acceptable alternative to BACB30MY8K*X only for Code A, refer to Appendix A only. Note, BACB30MY8K*X was not provided in the Kit. 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 41 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 42 Group 1-3: Kit 015U2131 NotesExisting Part Number NameQTYNew Part Number -6-5-3 --LONGERON EXTENSION FITTING KIT - PREVENTIVE MOD, STA 1480 - STA 1540 LEFT SIDE --1015U2131-5 --LONGERON EXTENSION FITTING KIT - PREVENTIVE MOD, STA 1480 - STA 1540 RIGHT SIDE --1015U2131-6 --CHANNEL-1-675U0010-1 --WEB11-675U0010-10 --CHANNEL1--675U0010-2 --TEE-1-675U0010-3 --TEE1--675U0010-4 --DOUBLER11-675U0010-6 --LAMINATED SHIM11-675U0010-8 --DOUBLER11-675U0010-9 (b)-BOLT, 100 DEG HEX DR11-BACB30NW12K10X (b)-BOLT, PROTRUDING HD11-BACB30NX6K11X (b)-BOLT, PROTRUDING HD33-BACB30NX6K5Y (a)(b)(c)-BOLT, PROTRUDING HD5454-BACB30NX8K10X (a)(b)(c)-BOLT, PROTRUDING HD3737-BACB30NX8K11X (b)(c)-BOLT, PROTRUDING HD1818-BACB30NX8K12X (b)(c)-BOLT, PROTRUDING HD66-BACB30NX8K13X (a)(b)(c)-BOLT, PROTRUDING HD22-BACB30NX8K25X (a)(b)(c)-BOLT, HEX DRIVE22-BACB30NX8K27X (b)(c)-BOLT, PROTRUDING HD22-BACB30NX8K3X (b)(c)-BOLT, PROTRUDING HD11-BACB30NX8K4X (b)(c)-BOLT, PROTRUDING HD88-BACB30NX8K5X (b)(c)-BOLT, PROTRUDING HD22-BACB30NX8K6X (b)(c)-BOLT, PROTRUDING HD1313-BACB30NX8K7X (a)(b)(c)-BOLT, PROTRUDING HD3131-BACB30NX8K8X (a)(b)(c)-BOLT, PROTRUDING HD4747-BACB30NX8K9X 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 42 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 43 Group 1-3: Kit 015U2131 NotesExisting Part Number NameQTYNew Part Number -6-5-3 (a)(b)-BOLT, 12 PT HEAD44-BACB30US8K27X (a)(b)-BOLT, 12 PT HEAD22-BACB30US8K28X (a)(b)-BOLT, 12 PT HEAD22-BACB30US8K29X (a)(b)-BOLT, 12 PT HEAD22-BACB30US8K33X (a)(b)-BOLT, 12 PT HEAD22-BACB30US8K34X (a)(b)-BOLT44-BACB30US9K27X (a)(b)-BOLT, 12 PT HEAD22-BACB30US9K28X (a)(b)-BOLT22-BACB30US9K29X (a)(b)-BOLT22-BACB30US9K33X (a)(b)-BOLT, 12 PT HEAD22-BACB30US9K34X --COLLAR33-BACC30AC6 --COLLAR11-BACC30BH6 (a)-COLLAR227227-BACC30BH8 --COLLAR11-BACC30M12 --FILLER, RECTANGULAR55-BACF3H07RM008HN --FILLER, TAPERED11-BACF3T01D53-10B --NUT1212-BACN10HR8CD --NUT1212-BACN10HR9CD --SHIM, LAMINATED22-BACS40R018E055F --SHIM, LAMINATED33-BACS40R021E055F --SHIM, LAMINATED11-BACS40R024A057F --SHIM, LAMINATED11-BACS40R024E096F --WASHER, PLAIN1212-BACW10BP81CD --WASHER, PLAIN1212-BACW10BP81DP --WASHER, PLAIN1212-BACW10BP91CD --WASHER, PLAIN1212-BACW10BP91DP --GROMMET11-NAS557-8C (a) There are more parts than are necessary. 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 43 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 44 Group 1-3: Kit 015U2131 NotesExisting Part Number NameQTYNew Part Number -6-5-3 (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) BACB30NX8K*X is an acceptable alternative to BACB30MY8K*X only for Code A, refer to Appendix A only. Note, BACB30MY8K*X was not provided in the Kit. Group 1-3: Kit 675U0009 NotesExisting Part Number NameQTYNew Part Number -4-3 (a)-FASTENER KIT LONGERON EXTEN- SION FITTING - PREVENTIVE MOD --675U0009-3 (b)-FASTENER KIT LONGERON EXTEN- SION FITTING - PREVENTIVE MOD --675U0009-4 (c)(d)-BOLT, PROTRUDING7083BACB30NX6K2 (d)-BOLT, PROTRUDING1012BACB30NX6K2X (d)-BOLT, HEX DRIVE142BACB30NX6K2Y (d)-BOLT, PROTRUDING55BACB30NX6K3 (d)-BOLT, PROTRUDING57BACB30NX6K3X (d)-BOLT, PROTRUDING1119BACB30NX6K3Y (d)-BOLT, PROTRUDING79BACB30NX6K4 (d)-BOLT, PROTRUDING-9BACB30NX6K4X (d)-BOLT, PROTRUDING118BACB30NX6K4Y (d)-BOLT, PROTRUDING-8BACB30NX6K5X (d)-BOLT, PROTRUDING HD82BACB30NX6K5Y (d)-BOLT, PROTRUDING HD-2BACB30NX6K6X (d)-BOLT, PROTRUDING HD26BACB30NX6K6Y (d)-BOLT, PROTRUDING HD-2BACB30NX6K7X (d)-BOLT, PROTRUDING HD13BACB30NX6K7Y (d)-BOLT22BACB30NX6K9 (d)-BOLT, PROTRUDING HD2-BACB30NX8K2 (d)-HI-LOK10-BACB30NX8K3 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 44 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 45 Group 1-3: Kit 675U0009 NotesExisting Part Number NameQTYNew Part Number -4-3 (d)-HI-LOK8-BACB30NX8K4 (d)-HI-LOK2-BACB30NX8K5 (d)(e)-BOLT, PROTRUDING HD-1BACB30NX8K5X (d)-BOLT, PROTRUDING HD1-BACB30NX8K5Y (d)-BOLT5-BACB30NX8K6 (d)-BOLT, PROTRUDING HD2-BACB30NX8K7 (d)(e)-BOLT, PROTRUDING HD11BACB30NX8K7X (c)-COLLAR5244BACC30AC6 --COLLAR1-BACC30AC8 (c)-COLLAR102145BACC30BH6 --COLLAR332BACC30BH8 --WASHER, SELF-ALIGN-1BACW10CA61PV --WASHER, SELF-ALIGN-4BACW10CA62PV --WASHER, SELF-ALIGN-5BACW10CA7CC --WASHER, SELF-ALIGN2-BACW10CA8CC --WASHER, SELF-ALIGN2-BACW10CA8PV --WASHER, COUNTERSUNK-1BACW10EG61C --WASHER-4BACW10EG62C --WASHER, COUNTERSUNK2-BACW10EG8C (a) Use 1 kit for each side of the airplane that has not had a Station 1480 bulkhead frame web crack re- paired in accordance with 747-400 SRM 53-40-08 Repair 1 or 747-400F SRM 53-40-08 Repair 1 or 747-400SF SRM 53-40-08 repair 1. (b) Use 1 kit for each side of the airplane that has had a Station 1480 bulkhead frame web crack repaired in accordance with 747-400 SRM 53-40-08 Repair 1 or 747-400F SRM 53-40-08 Repair 1 or 747- 400SF SRM 53-40-08 repair 1. (c) There are more parts than are necessary. (d) 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. (e) BACB30NX8K*X is an acceptable alternative to BACB30MY8K*X only for Code A, refer to Appendix A only. Note, BACB30MY8K*X was not provided in the Kit. 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 45 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 46 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 / Specifica- tion (a)(b)Bolt2BACB30NX6K6X (a)(b)Bolt1BACB30NX6K7X (a)(b)Bolt2BACB30NX6K10X (a)(b)Collar5BACC30M6 (f)Corrosion Inhibiting compound2 ozBMS3-23, Type II -Corrosion Inhibiting compound2 ozBMS3-29 -Corrosion Inhibiting Compound2 ozBMS3-35 (c)Adhesive0.25 ozBMS 5-44 Class B OR BMS 5-45 Class B -Sealant1 quartBMS 5-95 (e)Primer1 pintBMS 10-11, Type I (d)(f)Chemical Conversion Coating2 ozChromate Conversion Coat, TYPE 2, CLASS A (a)(b)Bolt2BACB30NX6K12X (a) Applicable to the Temporary Repair in accordance with FIGURE 2 or Trim-out Repair FIGURE 22 or FIGURE 23 (b) Refer to 747 Structural Repair Manual Chapter 51 for alternate fasteners. (c) Refer to SOPM 20-50-12 for a list of acceptable Type 44 products. (d) Refer to SOPM 20-43-03 for a list of acceptable Type 2, Class A products. (e) Some primers contain Strontium Chromate and will not be available in the European Union after January 2019 without an authorization. EU operators are encouraged to ensure their suppliers are authorized to provide the material after the sunset date and that downstream users comply with the risk mitigation measures and operational conditions. (f) Some conversion coatings contain Chromium trioxide/Chromic acid and will not be available in the European Union after September 2017 without an authorization EU operators are encouraged to ensure their suppliers are authorized to provide the material after the sunset date. 3. Parts Modified and Reidentified None. 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 46 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 47 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability Group 1-3: 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 Group 1-3: 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 3: November 11, 2019 47 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 48 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 48 of 240 BOEING SERVICE BULLETIN 747-53A2860 BLANK PAGE ### Page 49 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 bulle tin 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 Rep air 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 3: November 11, 2019 49 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 50 11. The instructions in Paragraph 3.B., Work Instructions and th e 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 p art, 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 747-100/200/300 AMM 51-21-04 or 747-400 AMM 51-21-0 4 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 applicat ion of finishes. 17. Refer to SOPM 20-50-19 as an accepted procedure for applicat ion of sealant. 18. Do not remove both longeron extension fittings from the airp lane at the same time. 19. Refer to APPENDIX B for a procedure to determine the require d dimensions for installation of new 675U0006-( ) splice fittings as an alternative to reinstallation of the existing splice fittings and new shims. 20. Refer to the table that follows for logic diagrams. Logic di agrams 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. TABLELOGIC DIAGRAM Table 1:APPENDIX C STA 1480 Longeron Extension Fitting HFEC Inspection Table 2:APPENDIX D HFEC Inspection Requirements After Completion of PART 2: Temporary Repair Table 3:APPENDIX E HFEC Inspection Requirements After Completion of PART 4: Repair, PART 5: Modification or PART 6: Replacement Table 4:APPENDIX F HFEC Inspection Requirements After Completion of PART 8: Preventive Modification on a Longeron Extension Fitting With Any Crack Found That Was Within Limits 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 50 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 51 TABLELOGIC DIAGRAM Table 5:APPENDIX H STA 1480 Longeron Extension Fitting HFEC Inspection Table 6:APPENDIX I Post STA 1480 Longeron Extension Fitting Trim-out Repair Inspection B. WORK INSTRUCTIONS PART 1: Longeron Extension Fitting Inspection 1. Remove wing-to-body fairing panels for external access to the inspection area. Refer to 747-100/200/300 AMM 12-09-03 or 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-100/200/300 AMM 53-51-01 or 747-400 AMM 53-51-01 as an acceptable procedure. 2. Group 1-3: Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with FIGURE 1. a. If all cracks are within the limits shown in FIGURE 2, do ONE of the following: (1) Do the Temporary Repair in accordance with PART 2. NOTE: Inspection requirements after completion of PART 2: Temporary Repair are given in Paragraph 1.E., Compliance, Table 2. (2) Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. (3) Do the Preventive Modification in accordance with PART 8. NOTE: Inspection requirements after completion of PART 8: Preventive Modification with a Longeron Extension Fitting with any crack found that was within limits are given in Paragraph 1.E., Compliance, Table 4. (4) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. b. If any crack is not within the limits shown in FIGURE 2, do O NE of the following: (1) Do the Longeron Extension Fitting Replacement in accordance with PART 6. NOTE: Inspection requirements after completion of PART 6: Replacement are given in Paragraph 1.E., Compliance, Table 3. (2) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. 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 51 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 52 NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. c. If no crack is found, do ONE of the following: (1) Install wing-to-body fairing panels removed for access. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. (a) Put the airplane back to a serviceable condition. (b) Repeat the inspection in accordance with PART 1 at the time given in Paragraph 1.E., Compliance, Table 1. (2) Do the Modification in accordance with PART 5. NOTE: Inspection requirements after completion of PART 5: Modification are given in Paragraph 1.E., Compliance, Table 3. (3) Do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. 3. Group 4: Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with FIGURE 20. a. If all cracks are within the limits shown in FIGURE 22 do the Longeron Extension Fitting Crack Removal - Trim-out repair in accordance with PART 10. NOTE: Inspection requirements after completion of PART 10: Longeron Extension Fitting Crack Removal - Trim-out Repair are given in Paragraph 1.E., Compliance Table 6. b. If any crack is not within the limits shown in FIGURE 22, do the following: (1) Contact The Boeing Company for repair instructions and do the repair. (2) Repeat the inspection in accordance with PART 1: Longeron Extension Fitting Inspection at the time given in Paragraph 1.E., Compliance Table 5. c. If no crack is found, do the following: (1) Install wing-to-body fairing panels removed for access. Refer to 747-100/200/300 AMM 12-09-03 or 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-100/200/300 AMM 53-51-01 or 747-400 AMM 53-51-01 as an acceptable procedure. (a) Put the airplane back to a serviceable condition. (b) Repeat the inspection in accordance with PART 1: Longeron Extension Fitting Inspection at the time given in Paragraph 1.E., Compliance Table 5. 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 52 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 53 4. Group 5: Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with FIGURE 21. a. If all cracks are within the limits shown in FIGURE 23 do the Longeron Extension Fitting Crack Removal - Trim-out repair in accordance with PART 10. NOTE: Inspection requirements after completion of PART 10: Longeron Extension Fitting Crack Removal - Trim-out Repair are given in Paragraph 1.E., Compliance Table 6. b. If any crack is not within the limits shown in FIGURE 23, do the following: (1) Contact The Boeing Company for repair instructions and do the repair. (2) Repeat the inspection in accordance with PART 1: Longeron Extension Fitting Inspection at the time given in Paragraph 1.E., Compliance Table 5. c. If no crack is found, do the following: (1) Install wing-to-body fairing panels removed for access. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. (a) Put the airplane back to a serviceable condition. (b) Repeat the inspection in accordance with PART 1: Longeron Extension Fitting Inspection at the time given in Paragraph 1.E., Compliance Table 5. Group 1-3: 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 removed for access. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. 3. Put the airplane back to a serviceable condition. 4. Do an inspection in accordance with PART 3 at the time given in Paragraph 1.E., Compliance, Table 2. Group 1-3: PART 3: Inspection of Longeron Extension Fittings with the Temporary Repair Previously Accomplished 1. Remove wing-to-body fairing panels for external access to the inspection area. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. 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 53 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 54 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 FIGU RE 7. 5. Do a surface HFEC inspection of the Temporary Repair of the longeron extension fitting for cracks in accordance with FIGURE 4. a. If all cracks are within the limits shown in FIGURE 2, do ONE of the following: (1) Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. (2) Do the Preventive Modification in accordance with PART 8. NOTE: Inspection requirements after completion of PART 8: Preventive Modification with a Longeron Extension Fitting with any crack found that was within limits are given in Paragraph 1.E., Compliance, Table 4. (3) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. b. If any crack is not within the limits shown in FIGURE 2, do O NE of the following: (1) Do the Longeron Extension Fitting Replacement in accordance with PART 6. NOTE: Inspection requirements after completion of PART 6: Replacement are given in Paragraph 1.E., Compliance, Table 3. (2) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. c. If no crack is found, do ONE of the following: (1) Do the Repair in accordance with PART 4. NOTE: Inspection requirements after completion of PART 4: Repair are given in Paragraph 1.E., Compliance, in Table 3. (2) Do the Preventive Modification in accordance with PART 8. 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 54 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 55 NOTE: Inspection requirements after completion of PART 8: Preventive Modification with a Longeron Extension Fitting with any crack found that was within limits are given in Paragraph 1.E., Compliance, Table 4. (3) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. Group 1-3: 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 F IGURE 6. a. If any crack is found, contact The Boeing Company for repair instructions and do the repair. b. If no crack is found, continue to do the longeron extension f itting repair. 4. If not done previously, 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. Lower the airplane. Refer to 747-400 AMM 07-11-01 as an acce pted procedure. 11. Install any aft lower lobe cargo compartment sidewall and ce iling 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. 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 55 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 56 12. Install wing-to-body fairing panels removed for access. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. 13. Put the airplane back to a serviceable condition. 14. Do inspections in accordance with PART 7 at the time given in Paragraph 1.E., Compliance, Table 3. Group 1-3: 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. 2. If not done previously, jack the airplane in accordance with FIGURE 3. 3. Do open-hole HFEC inspections for cracks in accordance with F IGURE 6. a. If any crack is found, contact The Boeing Company for repair instructions and do the repair. b. If no crack is found, continue to do the longeron extension f itting modification. 4. Remove the longeron extension fitting in accordance with FIGU RE 7. 5. This step has been deleted. 6. Do an insurance trim on the longeron extension fitting in acc ordance 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, Typ e II or BMS3-29 to the affected area. Refer to 747-400 AMM 51-24-13 as an accepted procedure. 11. Lower the airplane. Refer to 747-400 AMM 07-11-01 as an acce pted procedure. 12. Install any aft lower lobe cargo compartment sidewall and ce iling 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 removed for access. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. 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 56 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 57 14. Put the airplane back to a serviceable condition. 15. Do inspections in accordance with PART 7 at the time given in Paragraph 1.E., Compliance, Table 3. Group 1-3: 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 F IGURE 6. a. If any crack is found, contact The Boeing Company for repair instructions and do the repair. b. If no crack is found, continue to do the longeron extension f itting replacement. 4. Remove the longeron extension fitting in accordance with FIGU RE 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. Lower the airplane. Refer to 747-400 AMM 07-11-01 as an accep ted procedure. 10. Install any aft lower lobe cargo compartment sidewall and ce iling 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 removed for access. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. 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. 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 57 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 58 Group 1-3: PART 7: Post- Modification, Post-Repair or Post-Replacement Surface HFEC Inspection 1. On airplanes with the Modification, the Repair, or the Longer on Extension Fitting Replacement previously accomplished, remove wing-to-body fairing panels for external access to the inspection area. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. 2. Do surface HFEC inspections of the left and right longeron extension fittings for cracks in accordance with FIGURE 1. a. If all cracks are within the limits shown in FIGURE 2, do ONE of the following: (1) Do the Temporary Repair in accordance with PART 2. NOTE: Inspection requirements after completion of PART 2: Temporary Repair are given in Paragraph 1.E., Compliance, Table 2. (2) Remove any longeron extension fitting cracks in accordance with FIGURE 2 and do the Repair in accordance with PART 4. NOTE: Inspection requirements after completion of PART 4: Repair, are given in Paragraph 1.E., Compliance, Table 3. (3) Do the Preventive Modification in accordance with PART 8. NOTE: Inspection requirements after completion of PART 8: Preventive Modification with a Longeron Extension Fitting with any crack found that was within limits are given in Paragraph 1.E., Compliance, Table 4. (4) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. b. If any crack is not within the limits shown in FIGURE 2, do O NE of the following: (1) Do the Longeron Extension Fitting Replacement in accordance with PART 6. NOTE: Inspection requirements after completion of PART 6: Replacement are given in Paragraph 1.E., Compliance, Table 3. (2) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. c. If no crack is found, do ONE of the following: 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 58 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 59 (1) Install wing-to-body fairing panels removed for access. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. (a) Put the airplane back to a serviceable condition. (b) Repeat inspections in accordance with PART 7 at the time given in Paragraph 1.E., Compliance, Table 3. (2) Do the Preventive Modification in accordance with PART 8. NOTE: Inspection requirements after completion of PART 8: Preventive Modification with a Longeron Extension Fitting with any crack found that was within limits are given in Paragraph 1.E., Compliance, Table 4. (3) Do the Longeron Extension Fitting Replacement in accordance with PART 6, and do the Preventive Modification in accordance with PART 8. NOTE: PART 8: Preventive Modification with a Longeron Extension Fitting with no crack found or a new Longeron Extension Fitting is the terminating action for inspections in this service bulletin. Group 1-3: PART 8: PREVENTIVE MODIFICATION 1. If not done previously, remove wing-to-body fairing panels fo r external access to the inspection area. Refer to 747-400 AMM 06-09-03 for panel numbers and location. Refer to 747-400 AMM 53-51-01 as an acceptable procedure. 2. 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. 3. If not done previously, jack the airplane in accordance with FIGURE 3. 4. Do preventive modification on the left side as follows: NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin longeron extension fitting removal is not required. a. Do the preparation for installation of Preventive Modificatio n in accordance with FIGURE 12 b. Trim longeron extension fitting in accordance with FIGURE 13 c. Trim the STATION 1480 bulkhead in accordance with FIGURE 14 d. Group 1: Install the longeron extension fitting in accordance with FIGURE 8. After installation, finish the area to match adjacent structure. 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 59 of 240 BOEING SERVICE BULLETIN 747-53A2860 ### Page 60 NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin this action is not required. e. Group 2: Install the longeron extension fitting in accordance with FIGURE 9. After installation, finish the area to match adjacent structure. NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin this action is not required. f. Group 3: Install the longeron extension fitting in accordance with FIGURE 10. After installation, finish the area to match adjacent structure. NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin this action is not required. g. Install Preventive Modification in accordance with FIGURE 15 5. Do preventive modification on the right side as follows: NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin longeron extension fitting removal is not required. a. Do the preparation for installation of Preventive Modificatio n in accordance with FIGURE 16 b. Trim longeron extension fitting in accordance with FIGURE 17 c. Trim the STATION 1480 bulkhead in accordance with FIGURE 18 d. Group 1: Install the longeron extension fitting in accordance with FIGURE 8. After installation, finish the area to match adjacent structure. NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin this action is not required. e. Group 2: Install the longeron extension fitting in accordance with FIGURE 9. After installation, finish the area to match adjacent structure. NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin this action is not required. f. Group 3: Install the longeron extension fitting in accordance with FIGURE 10. After installation, finish the area to match adjacent structure. NOTE: If the longeron extension fitting was installed in accordance with the Original Issue, Revision 1 or Revision 2 of this service bulletin this action is not required. g. Install Preventive Modification in accordance with FIGURE 19 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 60 of 240 BOEING SERVICE BULLETIN 747-53A2860 The text continues at https://openairdocs.org/service-documents/boeing/747-53a2860/file/531e1ce403d9.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.