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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2878 Original Issue: May 19, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Section 44 - Crown Skin Inner Surface - 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:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2016 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Unpublished Work.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: May 19, 2016 747-53A2878 1 of 109
7.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 2 of 109 BOEING SERVICE BULLETIN 747-53A2878
ALERTALERT
BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected12
B. Concurrent Requirements12
C. Reason12
D. Description12
E. Compliance14
F. Approval20
G. Manpower20
H. Weight and Balance Changes21
I. Electrical Load Data22
J. References22
1. Existing Data:22
2. Data Supplied with this Service Bulletin:22
3. Installation Drawings Used in the Preparation of this Service Bulletin:24
K. Publications Affected24
L. Interchangeability and Intermixability of Parts24
M. Software Accomplishment Summary24
2. MATERIAL INFORMATION25
A. Material - Price and Availability25
B. Industry Support Information32
C. Parts Necessary for Each Airplane32
1. Kits/Parts32
2. Parts and Materials Supplied by the Operator60
3. Parts Modified and Reidentified60
4. Parts Removed and Not Replaced60
D. Parts Necessary to Change Spares61
E. Special Tooling - Price and Availability61
F. Special Tooling Necessary to do this Service Bulletin61
3. ACCOMPLISHMENT INSTRUCTIONS63
A. GENERAL INFORMATION63
B. WORK INSTRUCTIONS65
FIGURE 1: LEFT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1283, 1350, 1480
INSPECTION [Group 1]73
FIGURE 2: RIGHT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1283, 1350,1480
INSPECTION [Group 1]75
FIGURE 3: LEFT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1241, 1350, 1480
INSPECTION [Group 2]77
FIGURE 4: RIGHT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1241, 1350, 1480
INSPECTION [Group 2]79
FIGURE 5: LEFT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1283, 1350, 1480
MODIFICATION AND REPAIR [Group 1]81
FIGURE 6: RIGHT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1283, 1350, 1480
MODIFICATION AND REPAIR [Group 1]86
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 3 of 109 BOEING SERVICE BULLETIN 747-53A2878
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FIGURE 7: LEFT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1241, 1350, 1480
MODIFICATION AND REPAIR [Group 2]90
FIGURE 8: RIGHT SIDE FUSELAGE CROWN SKIN INNER SURFACE AT STA 1241, 1350, 1480
MODIFICATION AND REPAIR [Group 2]95
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: INSPECTION, MODIFICATION AND REPAIR OF THE FUSELAGE CROWN SKIN STA 1265 TO STA 1500
[Group 1]99
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INSPECTION, MODIFICATION AND REPAIR OF THE FUSELAGE CROWN SKIN STA 1220 TO STA 1500
[Group 2]103
APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 3: POST MODIFICATION
OR POST REPAIR INSPECTION107
APPENDIX D: PART DEMAND INTENT109
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 4 of 109 BOEING SERVICE BULLETIN 747-53A2878
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2878Original Issue: May 19, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Section 44 - Crown Skin Inner Surface - 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 This service bulletin gives instructions to do inspections of the fuselage crown skin inner surface at Body Stations (STA) 1283, 1350, and 1480 for passenger airplanes, and STA 1241, 1350, and 1480 for freighters, and to install repairs if any crack or corrosion is found. If these inspections and repairs are not done, cracks or corrosion can develop rapidly on the crown skin inner surface. If the cracks or corrosion are not repaired, the cracks can rapidly join together and can cause a sudden decompression and loss of structural integrity.
Operators of 747-400 airplanes have told Boeing about wide spread corrosion damage that was found on the skin inner surface along the upper bulkhead at STA 1480, between stringers S-15L and S-16R. Corrosion was also found on the fuselage skin inner surface aft of the STA 1350 frame between stringers S-15 and S-16R and between stringers S-17 and S-18R and on the skin inner surface aft of the STA 1283 frame, between stringers S-5L and S-8L.
Accomplishment of the inspections in this service bulletin and installation of a repair or modification will help ensure the structural integrity of the fuselage crown skin at STA 1283, 1350, and 1480 for passenger airplanes and STA 1241, 1350, and 1480 for freighters.
Boeing Service Related Problem (SRP) 747-SRP-53-0447 is 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., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 5 of 109
ReferenceAffectedPlanning Data Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications 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 YesSpecial Tooling Required ACTION (PRR 85901-137RS) Do a detailed inspection for any missing or degraded finish, any sign of corrosion, such as lifted, peeling or blistering paint, and for any crack on the skin inner surface at the locations that follow:
Group 1:
1. STA 1265 to STA 1301 between stringers S-12L and S-12R.
2. STA 1335 to STA 1372 between stringers S-12L and S-19L.
3. STA 1335 to STA 1372 between stringers S-12R and S-19R.
4. STA 1460 to STA 1500 between stringers S-19L and S-19R.
Group 2:
1. STA 1220 to STA 1265 between stringers S-12L and S-12R.
2. STA 1335 to STA 1372 between stringers S-12L and S-19L.
3. STA 1335 to STA 1372 between stringers S-12R and S-19R.
4. STA 1460 to STA 1500 between stringers S-19L and S-19R.
If no missing or degraded finish, no sign of corrosion and no crack is found, repeat the inspections in accordance with this service bulletin.
If any missing or degraded finish, any sign of corrosion, or any crack is found, do a general visual inspection for similar conditions on the remaining interior surface of the affected skin panel and install a repair in accordance with this service bulletin.
NOTE: Entire panels for the S-12 to S-19 repairs (65B04197-23/-24 for passenger and -25/-26 for freighter) may be purchased. If the repairs are required for leading and trailing edges of these panels, removal and replacement would be preferable.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 6 of 109 BOEING SERVICE BULLETIN 747-53A2878
ALERTALERT
EFFECTIVITY 747-400, 747-400D, and 747-400F airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 90-25-05 R1 and AD 2004-07-22 R1 are related to this service bulletin. The effective date of AD 90-25-05 R1 and AD 2004-07-22 R1 is January 22, 2008.
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 available for airplanes in warranty as of August 27, 2003. Please refer to Paragraph
2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.
MANPOWER Group 1:
Elapsed HoursTotal Task HoursAirplanes
449.902635.00747-400 and 747-400D Group 2:
Elapsed HoursTotal Task HoursAirplanes
449.402634.00747-400F Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX D 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: May 19, 2016 747-53A2878 7 of 109 BOEING SERVICE BULLETIN 747-53A2878
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BOEING SERVICE BULLETIN 747-53A2878
ALERT ALERT
- INSPECT STA 1265 TO STA 1301 BETWEEN STRINGERS 12L AND 12R -INSPECT STA 1335 TO STA 1372 BETWEEN STRINGERS 12L AND 19L
- INSPECT STA 1335 TO STA 1372 BETWEEN STRINGERS 12R AND 19R -INSPECT STA 1460 TO STA 1500 BETWEEN STRINGERS 19L AND 19R -INSPECT STA 1220 TO STA 1265 BETWEEN STRINGERS 12L AND 12R -INSPECT STA 1335 TO STA 1372 BETWEEN STRINGERS 12L AND 19L -INSPECT STA 1335 TO STA 1372 BETWEEN STRINGERS 12R AND 19R
- INSPECT STA 1460 TO STA 1500 BETWEEN STRINGERS 19L AND 19R STA 1480 STA 1000 0 0 0000 PASSENGER AIRPLANE SHOWN, 2377089
FREIGHTER AIRPLANE SIMILAR Original Issue: May 19, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2878 Work - See page 1 for details. 8 of 109
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2878 Original Issue: May 19, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Section 44 - Crown Skin Inner Surface - 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to 747-400, 747-400D and 747-400F airplanes, line numbers 968-1273 in 2 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below. Refer to PRR 85901-137RS for data about this change.
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 747-400 and 747-400D airplanes-1 747-400F airplanes-2 Airplane Models:
747-400, 747-400D, 747-400F GroupVariable Number 2RL401 2RL411 - RL416 2RL651 - RL653 1RM001 - RM005 1RM011 - RM012 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 9 of 109
GroupVariable Number 1RM021 - RM024 1RM026 - RM028 1RM036 - RM039 1RM041 - RM043 1RM051 1RM071 1RM081 - RM084 1RM091 1RM096 - RM097 1RM116 - RM117 1RM126 - RM131 1RM136 - RM147 1RM156 - RM158 1RM166 - RM177 1RM191 - RM192 1RM231 - RM233 1RM241 - RM244 1RM261 - RM264 1RM316 - RM318 1RM331 - RM333 1RM341 1RM351 - RM352 1RM801 - RM802 1RM811 - RM813 2RM851 - RM853 2RM856 - RM857 2RM861 2RM871 - RM873 2RM881 - RM885 2RM891 - RM899 2RM901 - RM903 2RM911 2RR701 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 10 of 109 BOEING SERVICE BULLETIN 747-53A2878
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GroupVariable Number 2RR721 - RR724 2RR746 - RR748 2RR851 - RR856 2RR861 - RR862 2RR951 - RR952 1RT010 - RT014 1RT034 - RT035 1RT134 - RT137 1RT151 - RT152 1RT161 - RT168 1RT411 - RT412 1RT442 - RT447 1RT465 - RT469 1RT497 - RT499 1RT519 - RT530 1RT535 1RT581 - RT590 1RT620 - RT630 1RT635 - RT640 1RT657 1RT697 - RT699 1RT745 - RT750 1RT755 - RT757 1RT784 1RT801 - RT803 1RT811 - RT814 1RT831 - RT837 1RT879 - RT880 1RT932 1RT945 - RT949 1RT953 - RT955 1RT966 - RT967 1RU001 - RU006 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 11 of 109 BOEING SERVICE BULLETIN 747-53A2878
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GroupVariable Number 1RU016 - RU017 1RU031 - RU032 1RU051 - RU052 1RU059 - RU062 1RU081 - RU083 1RU101 - RU102 1RU121 - RU132 1RU808 - RU809 1RU836 - RU841
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason This service bulletin gives instructions to do inspections of the fuselage crown skin inner surface at Body Stations (STA) 1283, 1350, and 1480 for passenger airplanes, and STA 1241, 1350, and 1480 for freighters, and to install repairs if any crack or corrosion is found. If these inspections and repairs are not done, cracks or corrosion can develop rapidly on the crown skin inner surface. If the cracks or corrosion are not repaired, the cracks can rapidly join together and can cause a sudden decompression and loss of structural integrity.
Operators of 747-400 airplanes have told Boeing about wide spread corrosion damage that was found on the skin inner surface along the upper bulkhead at STA 1480, between stringers S-15L and S-16R.
Corrosion was also found on the fuselage skin inner surface aft of the STA 1350 frame between stringers S-15 and S-16R and between stringers S-17 and S-18R and on the skin inner surface aft of the STA 1283 frame, between stringers S-5L and S-8L.
Accomplishment of the inspections in this service bulletin and installation of a repair or modification will help ensure the structural integrity of the fuselage crown skin at STA 1283, 1350, and 1480 for passenger airplanes and STA 1241, 1350, and 1480 for freighters.
Boeing Service Related Problem (SRP) 747-SRP-53-0447 is related to this service bulletin.
D. Description Do a detailed inspection for any missing or degraded finish, any sign of corrosion, such as lifted, peeling or blistering paint, and for any crack on the skin inner surface at the locations that follow:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 19, 2016 747-53A2878 12 of 109 BOEING SERVICE BULLETIN 747-53A2878