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Commercial Airplanes 747 Service Bulletin Number: 747-56A2012 Original Issue: August 24, 2006 Revision 1: August 12, 2010 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment - Flight Compartment Windows - Inspection of Glass No. 2 and No. 3 Windows for Cracks in the Fail-Safe Interlayer Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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.
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8.0
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 2 0 B. Concurrent Requirements ...................................... 2 0 C. Reason ................................................ 2 0 D. Description .............................................. 2 2 E. Compliance .............................................. 2 3 F. Approval ............................................... 2 8 G. Manpower .............................................. 2 8 H. Weight and Balance Changes .................................... 2 9 I. Electrical Load Data ......................................... 2 9 J. References .............................................. 2 9
1. Existing Data: ......................................... 2 9
2. Data supplied with this Service Bulletin: ........................... 2 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 0 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 0
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary For Each Airplane ................................. 3 1
1. Kits/Parts: ........................................... 3 1
2. Parts and Materials Supplied by the Operator: ........................ 3 1
3. Parts Modified and Reidentified: ............................... 3 2
4. Parts Removed and Not Replaced: .............................. 3 2 D. Parts Necessary to Change Spares ................................. 3 2 E. Special Tooling - Price and Availability ............................... 3 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 4 FIGURE 1: NO. 2 AND NO. 3 WINDOW IDENTIFICATION ....................... 3 6 FIGURE 2: 65B27042-( ) AND 65B27043-( ) SINGLE STRUCTURAL GLASS PANE NO. 2 AND NO. 3 WINDOW DETAILED INSPECTION ............................. 4 0 FIGURE 3: 65B27046-( ) AND 65B27047-( ) SINGLE STRUCTURAL GLASS PANE NO. 2 AND NO. 3 WINDOW DETAILED INSPECTION ............................. 4 6
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Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-56A2012Original Issue: August 24, 2006 Revision 1: August 12, 2010 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment - Flight Compartment Windows - Inspection of Glass No. 2 and No. 3 Windows for Cracks in the Fail-Safe Interlayer This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2007-15-10 is related to this service bulletin.
No more work is necessary on airplanes changed as given in the original issue of this service bulletin. Continue to do repeat inspections as given in Revision 1 until the new dual structural glass pane windows are installed as given in Paragraph 1.E., Compliance.
No airplanes were added to the service bulletin effectivity; however, airplanes line number 1418 and on were removed.
REASON FOR REVISION This revision is sent to remove airplanes line number 1418 and on from the service bulletin effectivity and give terminating action for the requirements of continued inspection as given in this service bulletin. The inspections as given in this service bulletin are necessary on airplanes prior to line number 1418, which had single structural glass pane windows that can have cracks in the internal fail-safe interlayer. The inspections as given in this service bulletin are not necessary on airplanes line number 1418 and on, which have the new dual structural glass pane windows installed in production. The installation of the new dual structural glass pane windows as given in Revision 1 of this service bulletin is terminating action for the requirements of continued inspection as given in this service bulletin.
These sections were changed:
1. Summary (Background and Action); Paragraph 1.C., Reason; and Paragraph 1.D., Description, were changed to clarify the difference between the single structural and dual structural glass pane windows.
Correct names of different parts of the window assembly were added. Also added production incorporation information of the new dual structural glass pane window.
2. In Summary (Effectivity) and Paragraph 1.A., Effectivity, airplanes line number 1418 and on were removed.
3. In Summary (Compliance), added a reference to AD 2007-15-10.
4. In Paragraph 1.D., Description, a note in reference to sending inspection program and results was deleted.
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5. In Paragraph 1.E., Compliance, updated compliance tables to show conditions that affect the new dual structural glass pane windows, which is terminating action to the requirements of the continued inspection.
Also added a reference to AD 2007-15-10.
6. In Paragraph 1.F., Approval, an Alternative Method of Compliance statement to the requirements of AD 2007-15-10 was added.
7. In Paragraph 1.G., Manpower, the words "single structural glass pane" were added to the No. 2 and No. 3 window inspection task.
8. In Paragraph 1.J.1., Existing Data, references were updated.
9. In Paragraph 1.K., Publications Affected, affected publications and damage tolerance evaluation statement were added.
10. In Paragraph 1.L., Interchangeability and Intermixability of Parts, statement was updated.
11. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, part information was updated.
12. In Paragraph 3.A., General Information, 747 minor models were removed from the reference to Structural Repair Manual, Chapter 51. Also added a note.
13. In Paragraph 3.B., Work Instructions, updated PART 1 and PART 2 instructions that affect the new dual structural glass pane windows. Added PART 3 to give window replacement instructions.
14. In Figure 1, notes were updated and added new dual structural glass pane window part numbers in the step table.
15. In Figure 2 and Figure 3, updated the step tables to add and clarify inspection requirements of the windows.
Information Notice 747-56A2012 IN 01 and 02 were addressed.
16. In Summary Figure, Figure 2, and Figure 3, illustrations were updated to show text changes on part description.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY August 24, 2006Original Issue:
August 12, 2010Revision 1:
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Original Issue: August 24, 2006 747-56A2012Revision 1: August 12, 2010 6 of 52 BOEING SERVICE BULLETIN 747-56A2012
Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-56A2012Original Issue: August 24, 2006 Revision 1: August 12, 2010 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment - Flight Compartment Windows - Inspection of Glass No. 2 and No. 3 Windows for Cracks in the Fail-Safe Interlayer
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of the inspection given in this service bulletin will make sure that no cracks are present in the internal fail-safe interlayer of the No. 2 and No. 3 windows that use a single structural glass pane. Fail-safe interlayer cracks can cause the affected windows to not be capable of carrying cabin pressurization loads if the structural glass pane of the window becomes broken. This could result in loss of a window and rapid loss of cabin pressure. Loss of a window can also cause crew communication difficulties or incapacitation of the crew.
The left No. 2 and No. 3 windows are the pilot's side windows. The right No. 2 and No. 3 windows are the co-pilot's side windows.
Affected airplanes may have No. 2 and No. 3 windows that are made from either acrylic or glass. The detailed inspections in this service bulletin are required only for glass windows that use a single structural glass pane to carry pressure loads. Airplanes prior to line number 1418 had single structural glass pane window, which can have cracks in the internal fail-safe interlayer. Windows that use dual structural glass panes or acrylic panes do not require inspections. Airplanes line number 1418 and on have No. 2 and No. 3 windows that use dual structural glass panes, which are installed in production. For airplanes prior to line number 1418, installation of the new dual structural glass pane windows is terminating action for the requirements of continued inspection as given in this service bulletin.
There are two different, but interchangeable, designs for the No. 2 and No. 3 windows that use a single structural glass pane. The 65B27042-( ) and 65B27043-( ) windows consist of an outer glass pane and a structural inner glass pane, with a vinyl interlayer between them. The vinyl interlayer alone acts as the structural fail-safe load path if the structural inner glass pane becomes broken. The 65B27046-( ) and 65B27047-( ) windows consist of an outer glass pane and a structural inner glass pane, separated by an outboard urethane interlayer, a vinyl interlayer, and an inboard urethane interlayer. The vinyl and inboard urethane interlayers act as the structural fail-safe load path if the structural inner glass pane becomes broken.
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One operator told Boeing that a glass No. 3 window with 36,131 flight-hours and 5,607 flight-cycles departed an airplane in-flight. Loss of the window resulted in rapid loss of cabin pressure, and an emergency landing was performed. Investigation revealed that a crack was present in the fail-safe interlayer of the 65B27043-2 single structural glass pane No. 3 window, along the inner edge of the window's aluminum edge insert. When the structural inner glass pane cracked due to an electrical arcing event not associated with the interlayer cracking, the interlayer was not able to support the airplane's cabin pressurization load and the window departed the airplane. The remaining single structural glass pane No. 3 window and both single structural glass pane No. 2 windows of this airplane were inspected, and all were found to have cracks in the fail-safe interlayer.
Subsequent to this report, inspections accomplished by Boeing and some operators have found many additional instances of fail-safe interlayer cracks in 65B27042-( ) and 65B27043-( ) single structural glass pane No. 2 and No. 3 windows. In addition, several instances of inboard fail-safe interlayer cracks were found in 65B27046-( ) and 65B27047-( ) glass No. 2 and No. 3 windows.
Interlayer cracks are primarily caused by thermal stress due to the different thermal expansion properties of the vinyl, glass, and window edging material. Moisture ingression into the window can also contribute to interlayer cracks.
Accomplishment of the inspection in this service bulletin will ensure the structural integrity of the No. 2 and No.
3 windows that use a single structural glass pane.
Boeing Service Related Problem (SRP) 747-SRP-56-0016 is related to this service bulletin.
ACTION (PRR 85901-85S) Get internal access to the No. 2 and No. 3 windows on both the left and right sides of the airplane. Identify the windows (by part number) to determine if they are single structural glass pane, dual structural glass pane, or acrylic windows. No additional inspections are necessary on the following No. 2 and No. 3 windows, unless the windows are replaced with the single structural glass pane windows:
– 65B07639-( ) or 65B07640-( ) acrylic windows – 141U4821-( ), 141U4831-( ), 141U4822-( ), or 141U4832-( ) dual structural glass pane windows Do a detailed inspection for cracks or damage, particularly in the internal interlayers for the following No. 2 and No. 3 windows that use single structural glass panes: 65B27042-( ), 65B27043-( ), 65B27046-( ), and 65B27047-( ). If no cracks or damage are found, do the inspection again at the time as given in this service bulletin. If any cracks or damage as given in this service bulletin are found, replace the affected window before any more flights.
Do the inspection of all four windows again at the times as given in this service bulletin.
NOTE: Color photographs of typical No. 2 and No. 3 window damage can be found in Fleet Team Digest Articles 747 FTD 56-05001 and 747-400 FTD 56-05001. These articles can be accessed through the MyBoeingFleet website, or you may obtain copies from your local Boeing Field Service office.
As an alternative replace the single structural glass pane windows with dual structural glass pane windows.
Installation of the dual structural glass pane windows is terminating action for the requirements of continued inspections as given in Paragraph 1.E., Compliance. Installation of the dual structural glass pane windows is necessary at the time as given in Paragraph 1.E., Compliance.
EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, and 747SR airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity.
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COMPLIANCE See Service Bulletin Paragraph 1.E. for compliance information.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-15-10 is related to this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection or repair procedures given in this service bulletin.
MANPOWER Elapsed HoursTotal Task-HoursTask
2.504.50Window Identification and Inspection
MATERIAL INFORMATION Operator Supplied Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 747-56A2012
RIGHT WINDOW -LEFT WINDOW NO. 3 NO. 3
SEE SEE
OUTER GLASS PANE VINYL NO. 2 RIGHT WINDOW LEFT WINDOW NO. 2
FAIL-SAFE
INTERLAYER SEE SEE
STRUCTURAL INNER
GLASS PANE
ALUMINUM INSERT HUMP SEAL
- DO A DETAILED INSPECTION FOR
CRACKS IN THE FAIL-SAFE INTERLAYER. IF CRACKS ARE FOUND, REPLACE THE WINDOW.
PRESSURE SEAL FWD
EDGE MEMBER
TYPICAL SINGLE STRUCTURAL GLASS PANE NO. 2 AND NO. 3 WINDOWS U49986 Original Issue: August 24, 2006 Revision 1: August 12, 2010 747-56A2012
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 52
Commercial Airplanes 747 Service Bulletin Number: 747-56A2012 Original Issue: August 24, 2006 Revision 1: August 12, 2010 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment - Flight Compartment Windows - Inspection of Glass No. 2 and No. 3 Windows for Cracks in the Fail-Safe Interlayer
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 85901-85S for data about this change.
Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 747 airplanes line number 1 through 1417.-1 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 GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA266 1RA301 - RA318 1RA351 - RA360
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GroupVariable Number 1RA369 - RA373 1RA401 - RA418 1RA501 - RA502 1RA521 - RA528 1RA532 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 - RA635 1RA651 - RA652 1RA671 - RA677 1RA701 - RA702 1RA721 - RA731 1RA741 - RA745 1RA749 - RA750 1RA761 - RA762 1RA781 - RA784 1RA901 - RA916 1RB001 - RB016 1RB041 - RB044 1RB071 - RB075 1RB101 - RB102 1RB411 - RB413 1RB421 1RB601 - RB607 1RB681 - RB697 1RB711 1RB721 - RB723 1RB741 - RB748 1RD001 - RD004 1RD021 - RD022
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