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Commercial Airplanes 747 Requirements Bulletin ALERT Number: 747-53A2895 RB Original Issue: September 12, 2019 ATA System: 5300 5321 SUBJECT: FUSELAGE - Skin - Section 41 and 42, Skin Lap Joint Inspection and Modification 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:
Copyright © 2019 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Unpublished Work.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: September 12, 2019 747-53A2895 RB 1 of 124
2.0
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2019 747-53A2895 RB 2 of 124 REQUIREMENTS BULLETIN 747-53A2895
ALERTALERT
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Table of Contents
1 . E F F E C T I V I T Y5
A. Airplanes5
B . S p a r e s A f f e c t e d6
2. CONCURRENT REQUIREMENTS6
3 . C O M P L I A N C E6
4. APPROVAL8
5. ACCOMPLISHMENT INSTRUCTIONS9
A. General Information9
B. Work Instructions ........................................... 1 1 FIGURE 1: SECTION 41 - STRINGER S-6 - LAP JOINT - MODIFICATION L EFT SIDE [Group 1-3] . 15 FIGURE 2: SECTION 41 - STRINGER S-6 - LAP JOINT - MODIFICATION R IGHT SIDE [Group 1] . . 20 FIGURE 3: SECTION 41 - STRINGER S- 23 - LAP JOINT - MODIFICATION LEFT SIDE [Group 1-2] . 24 FIGURE 4: SECTION 41 - STRINGER S-23 - LAP JOINT - MODIFICATION RIGHT SIDE [Group 1-3] . 30 FIGURE 5: SECTION 41 - STRINGER S-6 - LAP JOINT - MODIFICATION R IGHT SIDE [Group 2-3] . 36 FIGURE 6: SECTION 41 - STRINGER S-23 - LAP JOINT - MODIFICATION LEFT SIDE [Group 3] . . 40 FIGURE 7: SECTION 41 - STRINGER S-6 - LAP JOINT - POST-MODIFICAT ION INSPECTIONS LEFT SIDE [Group 1-3] ........................................ 4 6 FIGURE 8: SECTION 41 - STRINGER S-6 - LAP JOINT - POST-MODIFICAT ION INSPECTIONS RIGHT SIDE [Group 1-3] ........................................ 4 9 FIGURE 9: SECTION 41 - STRINGER S-23 - LAP JOINT - POST-MODIFICA TION INSPECTIONS LEFT SIDE [Group 1-3] ........................................ 5 2 FIGURE 10: SECTION 41 - STRINGER S-23 - LAP JOINT - POST-MODIFIC ATION INSPECTIONS RIGHT SIDE [Group 1-3] ........................................ 5 5 FIGURE 11: SECTION 41 - STRINGER S-6 - LAP JOINT - MODIFICATION LEFT SIDE [Group 4-6] . 58 FIGURE 12: SECTION 41 - STRINGER S-6 - LAP JOINT - MODIFICATION RIGHT SIDE [Group 4-6] . 63 FIGURE 13: SECTION 41 - STRINGER S-23 - LAP JOINT - MODIFICATION LEFT SIDE [Group 4-5] . 68 FIGURE 14: SECTION 41 - STRINGER S-23 - LAP JOINT - MODIFICATION RIGHT SIDE [Group 4-6] . 76 FIGURE 15: SECTION 42 - STRINGER S-44 - LAP JOINT - MODIFICATION LEFT SIDE [Group 4-6] . 84 FIGURE 16: SECTION 42 - STRINGER S-44 - LAP JOINT - MODIFICATION RIGHT SIDE [Group 4] . 89 FIGURE 17: SECTION 42 - STRINGER S-44 - LAP JOINT - MODIFICATION RIGHT SIDE [Group 5-6] . 94 FIGURE 18: SECTION 41 - STRINGER S-23 - LAP JOINT - MODIFICATION LEFT SIDE [Group 6] . . 99 FIGURE 19: SECTION 41 - STRINGER S-6 - LAP JOINT - POST-MODIFICA TION INSPECTIONS LEFT SIDE [Group 4-6] ....................................... 1 0 7 FIGURE 20: SECTION 41 - STRINGER S-6 - LAP JOINT - POST-MODIFICA TION INSPECTIONS RIGHT SIDE [Group 4-6] ....................................... 1 1 0 FIGURE 21: SECTION 41 - STRINGER S-23 - LAP JOINT - POST-MODIFIC ATION INSPECTIONS LEFT SIDE [Group 4-6] ....................................... 1 1 3 FIGURE 22: SECTION 41 - STRINGER S-23 - LAP JOINT - POST-MODIFIC ATION INSPECTIONS RIGHT SIDE [Group 4-6] ....................................... 1 1 6 FIGURE 23: SECTION 42 - STRINGER S-44 - LAP JOINT - POST-MODIFIC ATION INSPECTIONS LEFT SIDE [Group 4-6] ....................................... 1 1 9 FIGURE 24: SECTION 42 - STRINGER S-44 - LAP JOINT - POST-MODIFIC ATION INSPECTIONS RIGHT SIDE [Group 4-6] ....................................... 1 2 2 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2019 747-53A2895 RB 4 of 124 REQUIREMENTS BULLETIN 747-53A2895
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Commercial Airplanes 747 Requirements Bulletin ALERT Number: 747-53A2895 RB Original Issue: September 12, 2019 ATA System: 5300 5321 SUBJECT: FUSELAGE - Skin - Section 41 and 42, Skin Lap Joint Inspection and Modification
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING
PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1. EFFECTIVITY A. Airplanes This bulletin is applicable to 747-8, 747-8F Airplane(s), line number(s) 1420-1560 in 6 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.
The Variable Number table below includes all affected airplanes up to Line Number 1557. Affected airplanes after Line Number 1557 will show up as available as they are added to Maintenance Performance Toolbox
DESCRIPTIONCONFIGURATIONGROUP 747-8 Airplanes, line numbers 1434 - 1456.-1 747-8 Airplanes, line numbers 1459 - 1492.-2 747-8 Airplanes, line numbers 1494 and on.-3 747-8F Airplane, line number 1420.-4 747-8F Airplanes, line numbers 1421 - 1491.-5 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2019 747-53A2895 RB 5 of 124
DESCRIPTIONCONFIGURATIONGROUP 747-8F Airplanes, line numbers 1493 and on.-6 B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 747-53A2895 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 747-53A2895 RB mandatory.
Accomplish the required actions, based on the applicable conditions in Tables 1, 2, 3, and 4, in accordance with the Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Group 1-3:
Table 1: Structural Modification of the Left and Right Side Lap Joints at Stringers S-6 and S-23, Section 41 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 30,000 total flight cycles.
Do structural modification to left and right side lap joints at stringers S-6 and S-23.
All airplanes.
Group 1-3:
Table 2: Post-Modification Inspections of the Left and Right Side Lap Joints at Stringers S-6 and S-23, Section 41 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 15,000 flight cycles after accomplishing the modifications at stringers S-6 and S-23.
Do internal detailed and surface High Frequency Eddy Current (HFEC) inspections of the left and right side skin, along the edge fastener rows of the structurally modified lap joints at stringers S-6 and S- 23 for any crack.
Airplanes that have accomplished the modification of the lap joint at S-6 and S-23.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2019 747-53A2895 RB 6 of 124 REQUIREMENTS BULLETIN 747-53A2895
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Group 1-3:
Table 2: Post-Modification Inspections of the Left and Right Side Lap Joints at Stringers S-6 and S-23, Section 41 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.CONDITION 1 (ACTION 1):CONDITION 1:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK FOUND.
3,000 flight cycles.-CONDITION 1 (ACTION 2):
Repeat the internal detailed and surface HFEC inspections of the left and right side skin, along the edge fastener rows of the structurally modified lap joints at stringers S-6 and S-23 for any crack at unrepaired areas.
3,000 flight cycles.-Repeat the internal detailed and surface HFEC inspections of the left and right side skin, along the edge fastener rows of the structurally modified lap joints at stringers S-6 and S-23 for any crack at unrepaired areas.
CONDITION 2:
NO CRACK FOUND.
Group 4-6:
Table 3: Structural Modification of the Left and Right Side Lap Joints at Stringers S-6, S-23, Section 41 and, Stringer S-44, Section 42 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 30,000 total flight cycles.
Do structural modification to the left and right side lap joints at stringers S-6 and S- 23, and S-44.
All airplanes.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2019 747-53A2895 RB 7 of 124 REQUIREMENTS BULLETIN 747-53A2895
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Group 4-6:
Table 4: Post-Modification Inspections of the Left and Right Side Lap Joints at Stringers S-6, S-23, Section 41, and Stringer S-44, Section 42 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 15,000 flight cycles after accomplishing the modifications at stringers S-6, S-23 and S-44.
Do internal detailed and surface High Frequency Eddy Current (HFEC) inspections of the left and right side skin, along the edge fastener rows of the structurally modified lap joints stringers S-6, S-23, and S-44 for any crack.
Airplanes that have accomplished the modification of the lap joint at S- 6, S-23 and S-44.
-Before further flight.CONDITION 3 (ACTION 1):CONDITION 3:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK FOUND.
3,000 flight cycles.-CONDITION 3 (ACTION 2):
Repeat the internal detailed and surface HFEC inspections of the left and right side skin, along the edge fastener rows of the structurally modified lap joints at stringers S- 6, S-23, and S-44 for any crack at unrepaired areas.
3,000 flight cycles.-Repeat the internal detailed and surface HFEC inspections of the left and right side skin, along the edge fastener rows of the structurally modified lap joints at stringers S- 6, S-23, and S-44 for any crack at unrepaired areas.
CONDITION 4:
NO CRACK FOUND.
4. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document 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 document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
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Original Issue: September 12, 2019 747-53A2895 RB 8 of 124 REQUIREMENTS BULLETIN 747-53A2895
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5. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION NOTE: 1. This is an Enhanced Required for Compliance document. There w ill be a separate Service Bulletin (SB) and a separate Requirements Bulletin (RB). If an RB is mandated by an Airworthiness Directive (AD), then all applicable requirements specified in the RB must be done. For the related SB, some locations are marked RC Start and RC End to identify the requirements that are restated from the RB. For the related SB, the areas between RC Start and RC End, including sub-steps and any figures identified between RC Start and RC End, must be done to comply with the AD.
Therefore, an Alternative Method of Compliance (AMOC) is required for any deviations to steps between RC Start and RC End, including substeps and identified figures.
For the related SB, the steps not between RC Start and RC End may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC; this is provided that the steps between RC Start and RC End, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition.
Figures not required for compliance are omitted from the RB.
2. This is an Enhanced Required for Compliance document. The Boe ing processes used to create the Service Bulletin (SB) and the Requirements Bulletin (RB) ensure that the information between "RC Start" and "RC End" in the SB are identical to the information in the same sections (Compliance, Work Instructions...) of the RB which the SB refers to as the related document.
3. The compliance times for the actions in WORK INSTRUCTIONS are in Compliance.
4. 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.
5. 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 Values:
— Values for structural fasteners are given in 747 Structural Repair Manual, Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 747 Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 747 Aircraft Maintenance Manual (AMM).
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Original Issue: September 12, 2019 747-53A2895 RB 9 of 124 REQUIREMENTS BULLETIN 747-53A2895
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— Non-standard torque values for maintenance tasks are included in the applicable installation step.
6. 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.
7. Where the work instructions include installation of a kept pa rt, a new or serviceable part with the same part number can be installed as an alternative to the kept part.
8. If it is necessary to remove more parts for access, you can r emove 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.
9. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.
10. A Detailed Inspection is defined as: An intensive examinatio n of a specific item, installation or assembly to detect damage, failure or irregularity. This could include tactile assessment in which a component or assembly can be checked for tightness/security. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors and magnifying lenses may be necessary. Surface cleaning and elaborate access procedures may be required.
11. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
12. If the length of any fastener specified in this service bull etin 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. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin.
13. Manual titles are referred to by acronyms. Refer to Paragrap h 1.J., References, for definition of the acronyms.
14. Obey all of the warnings and cautions given in the specified manual sections.
15. 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.
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Original Issue: September 12, 2019 747-53A2895 RB 10 of 124 REQUIREMENTS BULLETIN 747-53A2895
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16. Although 747-8P SRM 51-40-08 and 747-8F SRM 51-40-08 give in structions for installation of countersink repair washers, it is not required to install repair washers in existing countersinks under the modification doublers that are installed in accordance with this service bulletin. As an alternative to repair washers, fill existing countersinks with BMS 5-95 sealant prior to doubler installation.
17. For airplanes that operate with Reduced Vertical Separation Minimum (RVSM), skin waviness measurements as given in 747-8P SRM 51-10-03 are not required after doublers are installed in accordance with this service bulletin.
18. For airplanes that operate with Reduced Vertical Separation Minimum (RVSM), skin waviness measurements as given in 747-8F SRM 51-10-03 are not required after doublers are installed in accordance with this service bulletin.
B. WORK INSTRUCTIONS Actions Required for Compliance:
1. Requirements.
Group 1-3:
Table 1: Structural Modification of the Left and Right Side Lap Joints at Stringers S-6 and S-23, Section 41 Refer to the listed procedures in SB 747-53A2895 Original Issue or later approved revisions as an accepted procedure Method of ComplianceActionCondition -FIGURE 1 and FIGURE 2 Group 1Do structural modification of the left and right lap joint at stringers S-6 and S-23.
All airplanes.
-FIGURE 3 and FIGURE 4 -FIGURE 1 and FIGURE 5 Group 2 -FIGURE 3 and FIGURE 4 -FIGURE 1 and FIGURE 5 Group 3 -FIGURE 6 and FIGURE 4 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2019 747-53A2895 RB 11 of 124 REQUIREMENTS BULLETIN 747-53A2895
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Group 1-3:
Table 2: Post-Modification Inspections of the Left and Right Side Lap Joints at Stringers S-6 and S-23, Section 41 Refer to the listed procedures in SB 747-53A2895 Original Issue or later approved revisions as an accepted procedure Method of ComplianceActionCondition -FIGURE 7 and FIGURE 8 Groups 1-3Do internal detailed and surface High Frequency Eddy Current (HFEC) inspections of the left and right side lap joint modifications at S-6 and S-23 for any crack.
Airplanes that have accomplished the modification of the lap joint at S-6 and S-23. -FIGURE 9 andFIGURE 10 --CONDITION 1 (ACTION 1):CONDITION 1:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK FOUND.
-FIGURE 7 and FIGURE 8 Groups 1-3CONDITION 1 (ACTION 2):
Repeat internal detailed and surface HFEC inspections of the left and right side lap joint modifications at stringers S-6 and S-23, Section 41, for any crack.
-FIGURE 9 and FIGURE 10 -FIGURE 7 and FIGURE 8 Groups 1-3Repeat internal detailed and surface HFEC inspections of the left and right side lap joint modifications at stringers S-6 and S-23 for any crack.
CONDITION 2:
NO CRACK FOUND.
-FIGURE 9 and FIGURE 10 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2019 747-53A2895 RB 12 of 124 REQUIREMENTS BULLETIN 747-53A2895