Boeing ASB 747-53A2862: Revision 1, text

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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2862 Original Issue: April 03, 2014 Revision 1: July 24, 2015 ATA System: 5300 SUBJECT: FUSELAGE - Main Frame - STA 320 Crown Frame and Window Post #3 - Inspection and Repair 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:

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: April 03, 2014 747-53A2862Revision 1: July 24, 2015 1 of 366

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Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 2 of 366 BOEING SERVICE BULLETIN 747-53A2862

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Table of Contents

Revision Transmittal Sheet5

Summary9

1. PLANNING INFORMATION13

A. Effectivity13

1. Airplanes13

2. Spares Affected23

B. Concurrent Requirements24

C. Reason24

D. Description25

E. Compliance26

F. Approval37

G. Manpower37

H. Weight and Balance Changes39

I. Electrical Load Data40

J. References40

1. Existing Data:40

2. Data Supplied with this Service Bulletin:41

3. Installation Drawings Used in the Preparation of this Service Bulletin:41

K. Publications Affected41

L. Interchangeability and Intermixability of Parts42

M. Software Accomplishment Summary42

2. MATERIAL INFORMATION43

A. Material - Price and Availability43

B. Industry Support Information44

C. Parts Necessary for Each Airplane45

1. Kits/Parts45

2. Parts and Materials Supplied by the Operator53

3. Parts Modified and Reidentified53

4. Parts Removed and Not Replaced53

D. Parts Necessary to Change Spares53

E. Special Tooling - Price and Availability54

F. Special Tooling Necessary to do this Service Bulletin54

3. ACCOMPLISHMENT INSTRUCTIONS55

A. GENERAL INFORMATION55

B. WORK INSTRUCTIONS57

FIGURE 1: ACCESS WITH DRIPSHIELD MODIFICATION [Group 1-2]69

FIGURE 2: ACCESS WITH DRIPSHIELD MODIFICATION [Group 3-4]95

FIGURE 3: INSPECTION OF STA 320 CROWN FRAME, WINDOW POST#3 AND WINDOW UPPER SILL

.122

FIGURE 4: DISASSEMBLE STRUCTURE - LEFT SIDE [Group 1-2]138

FIGURE 5: DISASSEMBLE STRUCTURE - RIGHT SIDE [Group 1-2]146

FIGURE 6: REMOVE FRAME INNER CHORD [Group 1, Configuration 1; Group 2]154

FIGURE 7: REMOVE FRAME INNER CHORD [Group 1, Configuration 2]158

FIGURE 8: SILL CHORD TRIM162

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 3 of 366 BOEING SERVICE BULLETIN 747-53A2862

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FIGURE 10: REPLACE FRAME INNER CHORD + OUTBOARD WEB - RIGHT SIDE [Group 1-2] . . 187

FIGURE 11: REPLACE FRAME OUTBOARD WEB ONLY - LEFT SIDE [Group 1-2]206

FIGURE 12: REPLACE FRAME OUTBOARD WEB ONLY - RIGHT SIDE [Group 1-2]215

FIGURE 13: DISASSEMBLE STRUCTURE - LEFT SIDE [Group 3-4]224

FIGURE 14: DISASSEMBLE STRUCTURE - RIGHT SIDE [Group 3-4]233

FIGURE 15: REMOVE FRAME INNER CHORD [Group 3, Configuration 1; Group 4]242

FIGURE 16: REMOVE FRAME INNER CHORD [Group 3, Configuration 2]246

FIGURE 17: REPLACE FRAME INNER CHORD + OUTBOARD WEB - LEFT SIDE [Group 3-4] . . . 250 FIGURE 18: REPLACE FRAME INNER CHORD + OUTBOARD WEB - RIGHT SIDE [Group 3-4] . . 267

FIGURE 19: REPLACE FRAME OUTBOARD WEB ONLY - LEFT SIDE [Group 3-4]284

FIGURE 20: REPLACE FRAME OUTBOARD WEB ONLY - RIGHT SIDE [Group 3-4]293

FIGURE 21: ACCESS / RESTORE WITH DRIPSHIELD REMOVAL302

FIGURE 22: DRIPSHIELD RESTORE [Group 1-2]307

FIGURE 23: DRIPSHIELD RESTORE [Group 3-4]318

FIGURE 24: SILL PANEL REMOVE / REINSTALL329

FIGURE 25: INSPECTION OF STA 340 FRAME333

FIGURE 26: OVERSIZE FASTENERS FOR PART 5, PART 6 AND PART 7 REPAIRS336

FIGURE 27: FASTENER REWORK [Group 1-2]343

FIGURE 28: FASTENER REWORK [Group 3-4]349

FIGURE 29: DRIPSHIELD BRACKET MODIFICATION OR FABRICATION355

APPENDIX A: PATTERN FOR FIBERGLASS PLIES OF SPLICE STRAP [Group 1-2]358

APPENDIX B: PATTERN FOR FIBERGLASS PLIES OF SPLICE STRAP [Group 3-4]359

APPENDIX C: LOGIC DIAGRAM SUPPLEMENT TO PARAGRAPH 1.E., COMPLIANCE361

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 4 of 366 BOEING SERVICE BULLETIN 747-53A2862

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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2862Original Issue: April 03, 2014 Revision 1: July 24, 2015 ATA System: 5300 SUBJECT: FUSELAGE - Main Frame - STA 320 Crown Frame and Window Post #3 - Inspection and Repair This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Effects of this Revision on airplanes on which the Original Issue was previously accomplished:

ActionConditionGroup Do PART 11 of Paragraph 3.B., Work Instructions in accordance with Paragraph 1.E., Compliance.

If any of the following conditions apply:

– The STA 320 crown frame outboard web, inner chord, or both were replaced in accordance with PART 5, PART 6 or PART 7 respectively of Paragraph 3.B., Work Instructions of the Original Issue of this service bulletin.

– An oversize fastener repair was done in accordance with PART 1 of Paragraph 3.B., Work Instructions of the Original Issue of this service bulletin at specific fastener hole(s) identified in the Original Issue of this service bulletin as follows:

Group 1, 2 airplanes: Hole #11 or Hole #15.

Group 3, 4 airplanes: Hole #11.

All

(a) (b)

(a) The work given in PART 11 is to remove specific bolts installed in accordance with the Original Issue of this service bulletin and at each location to install a bolt with a countersunk washer under the head. The countersunk washer is needed to accommodate the fillet radius of the bolt. Instruction to install the countersunk washer was inadvertently omitted from the Original Issue of this service bulletin.

(b) The work given in PART 11 can be done with the next repeat inspection of the STA 320 crown frame.

See Paragraph 1.D., Description for more information.

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 5 of 366

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REASON FOR REVISION This revision is sent to give changed instruction and compliance times for the inspections given in this service bulletin. The inspections given in this service bulletin have been changed as a result of additional structural analysis performed by Boeing and because a frame crack has been found outside of the inspection area specified in the original issue of this service bulletin.

After the original issue of this service bulletin Boeing conducted a more refined structural analysis of the fuselage crown area around STA 320 and this analysis shows that the structural integrity of the fuselage will be maintained with more crack damage than was shown by previous analysis. This result allows for an increase in the level of crack damage that must be detected with the inspections given in this service bulletin. Accordingly, the open hole High Frequency Eddy Current (HFEC) inspection for cracks in the STA 320 frame and Window Post #3 specified in the original issue of this service bulletin has been eliminated and replaced by an inspection for more extensive crack damage. Inspections accomplished in accordance with this revision will be done with Detailed and Surface HFEC inspection procedures only. Also, the compliance times for the initial and repeat inspections have been extended with this revision.

Also, the area of the STA 320 crown frame to be inspected for cracks in accordance with this service bulletin has been extended inboard by approximately 6 inches because a frame crack was found outside of the inspection area specified in the original issue of this service bulletin. Also, a Surface HFEC inspection for cracks in the upper sill chord adjacent to the STA 320 crown frame has been added to this service bulletin because such cracks have been found previously and because it is necessary to consider and limit possible damage to this adjacent structure given the changes discussed above to relax the inspection of the STA 320 crown frame.

This revision also gives changes to the work instruction for the dripshield modification. The dripshield modification is included in this service bulletin to give an alternative method of access for the structural inspection. The configuration created by the dripshield modification has not been changed with this revision, but the instruction for the modification has been changed to incorporate findings from the initial accomplishment of the modification which was done as a part of the service bulletin validation program.

These sections were changed:

1. Paragraph 1.C., Reason: Updated service history data and added reasons for Revision 1.

2. Paragraph 1.D., Description: Revised description of inspection work and added a table to describe the effects of Revision 1 on airplanes changed in accordance with the Original Issue of this service bulletin.

3. Paragraph 1.E., Compliance: Revised Compliance Tables to reflect changes to inspection instruction and compliance times. Added Compliance Tables to cover "more work" associated with Revision 1 for airplanes changed in accordance with the Original Issue of this service bulletin.

4. Paragraph 1.G., Manpower: Added estimate for new Figure 25 inspection of left or right side of the STA 340 frame. Also revised estimates for the STA 320 frame inspection (Figure 3). Also revised the estimate for the dripshield modification for Group 3, 4 (Figures 2, 23) to reflect the fact that separate forward and aft splice straps are fabricated for Group 1, 2.

5. Paragraph 1.J.3.,Installation Drawings Used in the Preparation of this Service Bulletin: Added drawing reference for STA 340 frame installation.

6. Paragraph 2.C., Parts Necessary for Each Airplane: Identified superseding and supplemental fastener kits associated with changes made with Revision 1. Also added information related to the modification or change of a dripshield attachment Bracket Assembly.

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 6 of 366 BOEING SERVICE BULLETIN 747-53A2862

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7. Paragraph 3.B., General Information: Update notes to current standard.

8. Paragraph 3.B., Work Instructions: Changed instruction in PART 1 and PARTS 4-8 to reflect changes to the inspections and to give alternative oversize fastener installation data for repairs. Also revised PART 7 to increase the maximum width (material removed) for the frame inner chord cut from 0.060 to 0.120 inch. Also added PART 9: UPPER SILL REPAIR and PART 10: STA 340 FRAME INSPECTION.

9. Figure 1 and Figure 2: Revised instruction for the dripshield modification based on the initial accomplishment of the modification which was done as a part of the service bulletin validation program.

Also added flexibility to extend the removable segment of the dripshield inboard/up to improve access to the inboard end of the STA 320 frame inspection area.

10. Figure 3: Revised instruction for the inspection of the STA 320 frame and Window Post #3 and added instruction to inspect the window upper sill for cracks and missing fasteners. Removed instruction for the open hole HFEC inspection and also the associated instruction/data for the oversize fastener repair which will not apply for the longer cracks found with the revised inspections.

11. Figure 6 and Figure 15: Increased the maximum width (material removed) for the frame inner chord cut from 0.060 to 0.120 inch.

12. Figure 9 and Figure 10: Changed minimum edge margin at cut edge of the frame inner chord from 0.40 inch to 1.7D. Also revised instruction related to a dripshield attachment Bracket Assembly located near BL 0.

13. Figures 9-12, 17-20: Added countersunk washers (under head of bolt) to fastener codes C and G.

14. Figure 22 and Figure 23: Clarified instruction for applying sealant between the splice strap and dripshield and added instruction regarding the installation of fastener #6.

15. Revised Figure 25 to give instruction for inspection of the STA 340 Frame. The inspection instruction for Group 3, 4 airplanes previously given in Figure 25 is now given in Figure 3.

16. Added Figure 26 to give oversize fastener data that can be used with a PART 5 or PART 6 repair if an oversize fastener repair was made previously.

17. Added Figure 27 (Group 1, 2) and Figure 28 (Group 3, 4) to give "more work" instruction associated with Revision 1 of this service bulletin for airplanes changed in accordance with the Original Issue of this service bulletin.

18. Added Figure 29 to give instruction to modify/fabricate a dripshield attachment Bracket Assembly located near BL 0.

19. Added Appendix C to give a logic diagram representation of the information given in the Compliance paragraph.

As a part of a service bulletin validation program, the dripshield modification given in this service bulletin was completed on airplane RL430 by the original issue of this service bulletin. The dripshield modification completed on airplane RL430 is equivalent to a modification completed by Revision 1 of this service bulletin. Airplane RL430 has the configuration of a Group 2 airplane.

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.

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 7 of 366 BOEING SERVICE BULLETIN 747-53A2862

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Pages with no vertical lines have no changes.

REVISION HISTORY April 03, 2014Original Issue:

July 24, 2015Revision 1:

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 8 of 366 BOEING SERVICE BULLETIN 747-53A2862

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2862Original Issue: April 03, 2014 Revision 1: July 24, 2015 ATA System: 5300 SUBJECT: FUSELAGE - Main Frame - STA 320 Crown Frame and Window Post #3 - Inspection and Repair

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND The inspections given in this service bulletin are necessary to make sure that cracks that could exist in the STA 320 crown frame, Window Post #3 and the window upper sill will be found and repaired before damage from the cracks can have an effect on flight safety. Fatigue cracks that start at fastener holes in the frame inner chord can cause cracks to start in the frame web and together these cracks can extend with continued operation of the airplane to fully sever the frame. Also, cracks in the inner chord of Window Post #3 can extend and fully sever the post. Operation of the airplane with either condition could damage the body skin and cause in-flight decompression and a loss of structural integrity.

Fatigue cracks have been found in the STA 320 crown frame inspection area specified in this service bulletin by operators inspecting the frame inner chord in accordance with Boeing service bulletin 747-53A2784 (which addresses a production issue applicable to the Group 1 airplanes of this service bulletin). Service bulletin 747-53A2784 is applicable to only 747-400 model airplanes, so all the cracks reported by operators have been found on 747-400 airplanes. Models other than 747-400 are included in the effectivity of this service bulletin because the STA 320 crown frame in the included airplanes is of a similar configuration.

Frame inner chord cracks 0.03 - 0.22 inch in length have been found on 15 airplanes at flight cycles ranging from 11,498 to 31,315. Also, a 1.8 inch crack was found in the outboard web of the frame on one airplane with 14,749 flight cycles. Cracks have also been found in Window Post #3 which connects to the lower end of the inner chord of the STA 320 crown frame. Cracks 0.03 - 0.11 inch in length have been found in Window Post #3 on five airplanes at flight cycles ranging from 12,329 to 15,772. Also, fatigue cracks which had extended to fully sever the inner chord and outboard web of the frame were found on the 747-400 fatigue test airplane at 38,333 pressure cycles and significant cracks were found in both the frame inner chord and outboard web at 30,500 pressure cycles on the 747-100SR fatigue test airplane. The inspections specified in this service bulletin are given to make sure that the airplane is not operated with a severely damaged or severed frame or window post.

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 9 of 366

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After the original issue of this service bulletin, frame inner chord cracks were found at the two upper fastener holes common to the STA 320 frame reinforcement strap on an airplane with 16,854 flight cycles. These cracks were located outside of the inspection area specified in the original issue of this service bulletin. As a result of this finding, the Surface HFEC inspection for cracks in the frame inner chord was extended inboard to include the area of these cracks with Revision 1 to this service bulletin.

Also, after the original issue of this service bulletin Boeing conducted a more refined structural analysis of the fuselage crown area around STA 320 and this analysis showed that the structural integrity of the fuselage will be maintained with more crack damage than was shown by previous analysis. This result allowed for an increase in the level of crack damage that must be detected with the inspections given in this service bulletin. Accordingly, the open hole HFEC inspection for cracks in the STA 320 frame and Window Post #3 specified in the original issue of this service bulletin were eliminated with Revision 1 and replaced by inspections for more extensive crack damage done with Detailed and Surface HFEC inspection procedures only.

As a part of a service bulletin validation program, the dripshield modification given in this service bulletin was accomplished on airplane RL430 by the original issue of this service bulletin. The dripshield modification accomplished on airplane RL430 is equivalent to a modification completed by Revision 1 of this service bulletin.

Airplane RL430 has the configuration of a Group 2 airplane.

Boeing Service Related Problem (SRP) 747-SRP-53-0404 and 747-SRP-53-0462 are related to this service bulletin.

Boeing Fleet Team Digest (FTD) 747 FTD FTD-53-12005 is related to this service bulletin.

The table below 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., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 10 of 366 BOEING SERVICE BULLETIN 747-53A2862

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ACTION Detailed and Surface HFEC inspections for cracks in the inner chord and outboard webs of the STA 320 crown frame and in the left and right side Window Post #3 and upper sill structure are to be accomplished by a specified number of flight-cycles. Also, an inspection for missing fasteners is to be accomplished with the initial crack inspection of the frame and the upper sill. A repair is to be accomplished if there is any crack or missing fastener and repeat inspections for cracks in the frame, Window Post #3 and the upper sill are to be accomplished at specified intervals. The time to the next inspection of the STA 320 crown frame can be extended by replacing the inner chord of the frame and further extended by replacing both the inner chord and outboard webs of the frame.

A repair accomplished in accordance with this service bulletin can include replacement of the left or right side outboard web only, the left or right side frame inner chord segment only, or replacement of any combination of these components.

EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-08-01 is related to this service bulletin.

The effective date of AD 2005-08-01 is April 26, 2005.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-19-05 is related to this service bulletin.

The effective date of AD 2009-19-05 is October 27, 2009.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-22-02 is related to this service bulletin.

The effective date of AD 2012-22-02 is December 26, 2012.

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 repair procedures given in this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

Original Issue: April 03, 2014 747-53A2862Revision 1: July 24, 2015 11 of 366 BOEING SERVICE BULLETIN 747-53A2862

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BOEING SERVICE BULLETIN 747-53A2862

ALERT ALERT WINDOW

UPPER SILL UPPER SILL

INSPECTION AREA STA 320

OUTBOARD WEB FWD INBOARD + 61 WEB

RIGHT SIDE (RS)

FRAME INSPECTION AREA WINDOW INNER POST #3 CHORD

INSPECT THE OUTBOARD WEBS AND THE INNER CHORD OF THE STA 320 FRAME AND ALSO WINDOW POST #3 AND THE WINDOW UPPER SILL FOR CRACKS

AND MISSING FASTENERS USING DETAILED AND WEB OUTBOARD SURFACE HFEC INSPECTION PROCEDURES. DO REPAIRS FOR CRACKS OR MISSING FASTENERS

N ACCORDANCE WITH THIS SERVICE BULLETIN

LEFT SIDE (LS)

FRAME INSPECTION WINDOW POST #3 AREA 2188342 Original Issue: April 03, 2014 Revision 1: July 24, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2862 Work - See page 1 for detalls. 12 of 366

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