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Service Bulletin Commercial Airplane Group 747 Service Bulletin Number: 747-53A2303 Date: June 02, 1988 Revision 2: October 01, 2009 ATA System: 5310 5311 SUBJECT: FUSELAGE - Nose Section - Station 400 to 520 Stringer Lap Splice Inspection, Repair and Modification BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1989 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise. June 02, 1988 Revision 2: October 01, 2009 747-53A2303 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 79 BOEING SERVICE BULLETIN 747-53A2303 BLANK PAGE BLANK PAGE June 02, 1988 Revision 2: October 01, 2009 747-53A2303 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 79 BOEING SERVICE BULLETIN 747-53A2303 Table of Contents Revision Transmittal Sheet . 5 Summary . 7 1. PLANNING INFORMATION . 11 A. Effectivity . 11 1. Airplanes . 11 2. Spares Affected . 22 B. Concurrent Requirements . 22 C. Reason . 22 D. Description . 24 E. Compliance. 26 F. Approval . 31 G. Manpower . 32 H. Weight and Balance Changes . 34 I. Electrical Load Data . 34 J. References . 34 1. Existing Data: . 34 2. Data supplied with this Service Bulletin: . 36 3. Installation Drawings Used in the Preparation of this Service Bulletin: . 36 4. Process Data: . 36 K. Publications Affected . 36 L. Interchangeability and Intermixability of Parts . 36 2. MATERIAL INFORMATION . 37 A. Material - Price and Availability. 37 B. Industry Support Information . 37 C. Parts Necessary For Each Airplane . 38 1. Kits/Parts: . 38 2. Parts and Materials Supplied by the Operator: . 40 3. Parts Modified and Reidentified: . 40 4. Parts Removed and Not Replaced: . 40 D. Parts Necessary to Change Spares . 40 E. Special Tooling - Price and Availability. 40 F. Special Tooling Necessary to do this Service Bulletin . 40 3. ACCOMPLISHMENT INSTRUCTIONS . 41 A. GENERAL INFORMATION . 41 B. WORK INSTRUCTIONS . 42 FIGURE 1: THIS FIGURE IS DELETED . 48 FIGURE 2: INITIAL INSPECTIONS . 49 FIGURE 3: INTERNAL ACCESS AND RESTORATION. 54 FIGURE 4: THIS FIGURE IS DELETED . 56 FIGURE 5: TOP ROW PROTRUDING HEAD FASTENER MODIFICATION INSPECTION . 57 FIGURE 6: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND REPAIR DOUBLER INSTALLED BY SERVICE BULLETIN 747-53A2321 - INSPECTION . 64 FIGURE 7: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND SKIN REPLACEMENT MODIFICATION BY SERVICE BULLETIN 747-53A2321 - INSPECTION . 66 FIGURE 8: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND REPAIR DOUBLER INSTALLED Table of Contents June 02, 1988 Revision 2: October 01, 2009 747-53A2303 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 79 BOEING SERVICE BULLETIN 747-53A2303 BY SERVICE BULLETIN 747-53A2321 - ALTERNATIVE INSPECTION . 68 FIGURE 9: DOUBLER INSTALLED BY THIS SERVICE BULLETIN AND SKIN REPLACEMENT MODIFICATION BY SERVICE BULLETIN 747-53A2321 - ALTERNATIVE INSPECTION 70 APPENDIX A: DISCREPANT STRUCTURE REPORT . 72 APPENDIX B: ALTERNATIVE LAP SPLICE TRIM INSTRUCTIONS . 75 APPENDIX C: EXTENSION OF THE 141U2100 MODIFICATION DOUBLERS WHEN AN SRM REPAIR IS PRESENT. 79 Table of Contents June 02, 1988 Revision 2: October 01, 2009 747-53A2303 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 79 Commercial Airplanes 747 Service Bulletin Number: 747-53A2303 Revision Transmittal Sheet Original Issue: June 02, 1988 Revision 2: October 01, 2009 ATA System: 5310 5311 SUBJECT: FUSELAGE - Nose Section - Station 400 to 520 Stringer Lap Splice Inspection, Repair and Modification This Revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes on which the Flight Safety inspections are being accomplished. The repeat inspection interval has been reduced from 5,000 flight-cycles to 3,000 flight-cycles since the last Flight Safety inspection was accomplished, or within 1,000 flight-cycles after the date on Revision 2, whichever occurs later. More work is also necessary on airplanes modified as shown in the initial release and/or Revision 1 of this service bulletin. Airplanes that have accomplished a protruding head fastener modification or a modification as given in certain Structural Repair Manual (SRM) repairs will be required to accomplish the doubler modification as given in Paragraph 1.E., Compliance. In addition, airplanes that have had a structural modification accomplished as given in the SRM or other Boeing service bulletins will be required to accomplish post modification inspections as given in Paragraph 1.E., Compliance. REASON FOR REVISION This revision is sent to update inspection requirements and to update the post modification inspection requirements for airplanes that have accomplished a modification as shown in the initial release and/or Revision 1 of this service bulletin. This revision is also sent to remove the optional top row protruding head fastener modification, as well as modifications per certain SRM repairs. Changes to this service bulletin include: – Airworthiness Directive (AD) 90-21-17 supersedes AD 89-05-03. – Specific repair figures in SRM 53-30-03 are referenced as an acceptable modification. – Compliance information is added to Paragraph 1.E., Compliance. Existing compliance information to accomplish the Flight Safety Inspection Program, the Economics Based Inspection Program and the modification has been moved from the logic diagrams in Figure 1 to Tables 1 and 2 of Paragraph 1.E., Compliance. Compliance information for the repeat post modification inspections is included in Table 3 of Paragraph 1.E., Compliance. New compliance information for the inspection and modification of airplanes with certain SRM repairs or the optional top row protruding head fastener modification that was shown in the original release and Revision 1 of this service bulletin is added to Tables 4 and 5. – The 747 Non-Destructive Test manual, Boeing service bulletins, a Service Related Problem, a Boeing Document, an AD and SRM references are added to Paragraph 1.J., References. – Primer and Sealant are added to the Parts and Materials Supplied by the Operator. – Paragraph 3.B., Work Instructions have been extensively rewritten. Original Issue: June 02, 1988 Revision 2: October 01, 2009 747-53A2303 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 79 BOEING SERVICE BULLETIN 747-53A2303 – Figure 1 is deleted. The information previously in the logic diagrams has been moved to the tables in Paragraph 1.E., Compliance. – The NDT procedures referenced in Figure 2 have been changed. – Figure 4 is deleted to remove the top row protruding head fastener modification. – Figure 5 is added to inspect the top row protruding head fastener modification accomplished by previous releases of this service bulletin for cracks. – Figure 6 is added to provide inspections for airplanes with doublers installed by this service bulletin and doublers installed by service bulletin 747-53A2321 for cracks. – Figure 7 is added to provide inspections for airplanes with doublers installed by this service bulletin and the skin replacement modification by service bulletin 747-53A2321 for cracks. – Figure 8 is added to provide alternative inspections to the Figure 6 inspections for cracks. – Figure 9 is added to provide alternative inspections to the Figure 7 inspections for cracks. – Appendix B is added to provide alternative lap splice trim instructions. – Appendix C is added to show how the Drawing 141U2100 modification doublers should be changed when an SRM repair is present in the modification area. Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. 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 Original Issue: June 02, 1988 Revision 1: March 29, 1990 Revision 2: October 1, 2009 Original Issue: June 02, 1988 Revision 2: October 01, 2009 747-53A2303 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 79 Commercial Airplanes 747 Service Bulletin Number: 747-53A2303 Summary Original Issue: June 02, 1988 Revision 2: October 01, 2009 ATA System: 5310 5311 SUBJECT: FUSELAGE - Nose Section - Station 400 to 520 Stringer Lap Splice Inspection, Repair and Modification CONCURRENT REQUIREMENTS None. BACKGROUND Based on a structural review of the 747 airplane, incorporation of a modification per Revision 2 of this service bulletin is recommended on aging airplanes. Accomplishment of the intent of this service bulletin will ensure the structural integrity of the fuselage skin
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