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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-57A2357 Original Issue: September 12, 2016 ATA System: 5711 SUBJECT: WINGS - Wing Spars - Front Spar Station Inboard 628 to Front Spar Station Inboard 713 - Front Spar Web Inspection 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Unpublished Work.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: September 12, 2016 747-57A2357 1 of 49
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2016 747-57A2357 2 of 49 BOEING SERVICE BULLETIN 747-57A2357
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected13
B. Concurrent Requirements13
C. Reason13
D. Description13
E. Compliance14
F. Approval15
G. Manpower16
H. Weight and Balance Changes16
I. Electrical Load Data16
J. References16
1. Existing Data:16
2. Data Supplied with this Service Bulletin:17
3. Installation Drawings Used in the Preparation of this Service Bulletin:17
K. Publications Affected17
L. Interchangeability and Intermixability of Parts17
M. Software Accomplishment Summary17
2. MATERIAL INFORMATION19
A. Material - Price and Availability19
B. Industry Support Information19
C. Parts Necessary for Each Airplane19
1. Kits/Parts19
2. Parts and Materials Supplied by the Operator19
3. Parts Modified and Reidentified19
4. Parts Removed and Not Replaced19
D. Parts Necessary to Change Spares19
E. Special Tooling - Price and Availability19
F. Special Tooling Necessary to do this Service Bulletin19
3. ACCOMPLISHMENT INSTRUCTIONS21
A. GENERAL INFORMATION21
B. WORK INSTRUCTIONS22
FIGURE 1: LEFT WING FRONT SPAR WEB - FSSI 628 STIFFENER TO FSSI 713 FITTING - INSPECTION
.24
FIGURE 2: LEFT WING FRONT SPAR WEB - FSSI 628 STIFFENER TO FSSI 713 FITTING - SEALANT
APPLICATION32
FIGURE 3: RIGHT WING FRONT SPAR WEB - FSSI 628 STIFFENER TO FSSI 713 FITTING - INSPECTION
.36
FIGURE 4: RIGHT WING FRONT SPAR WEB - FSSI 628 STIFFENER TO FSSI 713 FITTING - SEALANT
APPLICATION44
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: FRONT SPAR WEB INSPECTION - LEFT & RIGHT SIDE - FSSI 628 STIFFENER TO FSSI 713 FITTING . . 48 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 12, 2016 747-57A2357 4 of 49 BOEING SERVICE BULLETIN 747-57A2357
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-57A2357Original Issue: September 12, 2016 ATA System: 5711 SUBJECT: WINGS - Wing Spars - Front Spar Station Inboard 628 to Front Spar Station Inboard 713 - Front Spar Web Inspection
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.
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of the inspections in this service bulletin will make sure any crack in the front spar web from Front Spar Station Inboard (FSSI) 628 to FSSI 713 is found and repaired. If this service bulletin is not accomplished, a crack in the front spar web in this location could grow undetected and allow a fuel leak which could lead to a fire.
One operator found a fuel leak which led to the discovery of a 13.4 inch long crack in the left wing front spar web inboard of pylon number 2 between FSSI 655.75 and FSSI 660. The airplane had 13,909 total flight-cycles and 107,151 total flight-hours.
Inspections of the front spar web between FSSI 628 and FSSI 713 will supersede 747 Supplemental Structural Inspection Document (SSID) inspections of Structural Significant Items (SSI) W-24A, W-24B, and W-24C.
The cracking addressed by this service bulletin is similar to the cracking addressed by Service Bulletins 747-57A2266 and 747-57A2311.
Boeing Fleet Team Digest (FTD) 747-400 FTD 57-15005 is related to this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-57-0285 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight 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/PartsNoKits/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 ACTION Get access to the forward side of the left and right wing spar web from stiffener at FSSI 628 to the fittings at FSSI 713.
Remove the fillet seals from the inboard and outboard edges of the stiffeners, fittings and from the inner edge of the upper and lower chords attached to the web from the outboard edge of the stiffener at FSSI 628 to the inboard edge of the fittings at FSSI 713. Also remove cap seals from rib post fastener heads at FSSI 656 and FSSI 684.
Do the following detailed, Ultrasonic (UT) and High Frequency Eddy Current (HFEC) inspections on each wing:
– Do a detailed inspection of the front spar web for any crack from the outboard edge of the stiffener at FSSI 628 to the inboard edge of the fittings at FSSI 713.
– Do a UT inspection for any crack in the front spar web under the stiffeners between FSSI 628 and FSSI 713 and under the outer edges of the upper link fittings and the outer edges of the midspar back up fittings.
– Do a UT inspection for any crack in the front spar web under the upper and lower chords from FSSI 628 to FSSI 713.
– Do a HFEC surface inspection for any crack in the front spar web at the edges of the upper and lower chords from FSSI 628 to FSSI 713.
– Do a HFEC inspection for any crack in the front spar web around the fastener heads common to the FSSI 656 rib post and FSSI 684 rib post.
If any crack is found, contact The Boeing Company for repair instructions and do the repair. Repeat the inspections in unrepaired areas.
If no crack is found, repeat the inspections.
EFFECTIVITY All 747-400/400D/400F Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-07-22 R1 is related to this service bulletin.
The effective date of AD 2004-07-22 R1 is January 22, 2008.
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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
41.880.8Group 1 Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 747-57A2357
ALERT ALERT
DO DETAILED, HIGH FREQUENCY
EDDY CURRENT AND ULTRASONIO
INSPECTIONS FOR ANY CRACK IN THE WEB OF THE FRONT SPAR.
IF ANY CRACK FOUND, CONTACT
BOEING FOR REPAIR INSTRUCTIONS AND DO THE REPAIR. REPEAT
INSPECTIONS IN UNREPAIRED AREAS.
SEAL RIB SSI OUTBOARD UPPER 713 LINK
FSSI FITTINGS 688
UPPER FSSI CHORD 711 RIB POST INBOARD FSSI 684 FITTINGS MIDSPAR BACK-UP
SEAL RIB WEB FSSI 656 RIB POST 628 FSSI RIB POST INDE CHORD LOWER RIGHT WING OPPOSITE LEFT WING SHOWN FRONT SPAR WEB 2500816 Original Issue: September 12, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-57A2357 Work - See page 1 for details. 8 of 49
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-57A2357 Original Issue: September 12, 2016 ATA System: 5711 SUBJECT: WINGS - Wing Spars - Front Spar Station Inboard 628 to Front Spar Station Inboard 713 - Front Spar Web Inspection
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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to all 747-400/400D/400F airplanes in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP All 747-400/400D/400F Airplanes.-1 Airplane Models:
747-400, 747-400D, 747-400F GroupVariable Number 1RF001 - RF006 1RL401 - RL403 1RL411 - RL436 1RL451 - RL456 1RL461 - RL462 1RL471 - RL481 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1RL491 - RL492 1RL501 - RL502 1RL511 - RL516 1RL521 - RL522 1RL531 - RL534 1RL551 1RL561 - RL568 1RL571 - RL572 1RL576 - RL577 1RL579 1RL581 - RL586 1RL651 - RL655 1RL671 - RL675 1RL681 - RL684 1RL751 - RL752 1RM001 - RM007 1RM010 - RM013 1RM021 - RM024 1RM026 - RM030 1RM036 - RM045 1RM051 - RM053 1RM071 1RM081 - RM084 1RM091 1RM096 - RM097 1RM116 - RM117 1RM126 - RM132 1RM136 - RM147 1RM156 - RM158 1RM166 - RM177 1RM191 - RM192 1RM231 - RM233 1RM241 - RM246 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1RM261 - RM264 1RM316 - RM318 1RM331 - RM333 1RM341 1RM351 - RM355 1RM366 - RM367 1RM401 - RM403 1RM426 1RM431 1RM441 - RM443 1RM445 1RM801 - RM803 1RM811 - RM813 1RM851 - RM859 1RM861 - RM863 1RM871 - RM899 1RM901 - RM906 1RM911 1RR701 1RR721 - RR724 1RR746 - RR748 1RR851 - RR856 1RR861 - RR862 1RR951 - RR952 1RT001 - RT014 1RT021 - RT022 1RT031 - RT035 1RT041 - RT047 1RT061 1RT071 - RT075 1RT101 - RT103 1RT121 1RT131 - RT137 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1RT151 - RT152 1RT161 - RT168 1RT401 - RT412 1RT431 - RT447 1RT451 - RT469 1RT471 - RT499 1RT501 - RT535 1RT551 - RT568 1RT571 - RT591 1RT601 - RT657 1RT671 - RT673 1RT681 - RT682 1RT691 - RT699 1RT701 - RT704 1RT711 - RT717 1RT741 - RT757 1RT776 - RT777 1RT781 - RT784 1RT801 - RT803 1RT811 - RT814 1RT831 - RT837 1RT861 - RT864 1RT876 - RT880 1RT931 - RT932 1RT945 - RT949 1RT951 - RT955 1RT966 - RT967 1RU001 - RU006 1RU016 - RU017 1RU031 - RU032 1RU051 - RU052 1RU059 - RU062 1RU081 - RU083 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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