Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2844

Original Issue: September 15, 2011

Revision 1: July 30, 2012

ATA System: 5300

SUBJECT: FUSELAGE - Station 1920 Splice Clip Fasteners 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.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2011 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Unpublished Work.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.

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3.0
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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 18

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 20

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION . . . . . . . . . . 24

FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L . . . . . . . . . . . . . . . 30

FIGURE 3: AUX SILL OUTER CHORD TEE - INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 4: SPLICE ANGLE FASTENER - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 37

FIGURE 5: TYPICAL CRACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 747-53A2844

Original Issue: September 15, 2011

Revision 1: July 30, 2012

ATA System: 5300

SUBJECT: FUSELAGE - Station 1920 Splice Clip Fasteners Inspection

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on the airplane(s) changed in accordance with the original issue of this service

bulletin.

REASON FOR REVISION

This revision is sent to clarify the Work Instructions, Figures and Step Table to be consistent with the information

in the Compliance Paragraph.

Illustrations have been changed in the Summary Art and Figures to meet current standards and added view

callouts for clarity.

These sections were changed:

1. In Paragraph 1.D., Description, changed 3.d.

2. Added Paragraph 1.M., Software Accomplishment Summary.

3. In Paragraph 3.B., Work Instructions, changed 4.a.(4).

4. In Figure 2, changed as follows:

a. Changed sheet 2 to add bubble 5.

b. Changed Step Table to add step 5 and foot note (e).

5. In Figure 3, changed sheet 3, to remove bubble 3 to match Step Table.

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.

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REVISION HISTORY

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
Commercial 

Airplanes 747

Service Bulletin

ALERT

Summary Number: 747-53A2844

Original Issue: September 15, 2011

Revision 1: July 30, 2012

ATA System: 5300

SUBJECT: FUSELAGE - Station 1920 Splice Clip Fasteners Inspection

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

An airplane that was undergoing Boeing Converted Freighter conversion was missing fasteners on the Station

1920 Splice Clip as part of the new converted components. This discrepancy was found after 23 aircraft had

been delivered and the possibility of this discrepancy exists on already delivered airplanes. A one time inspection

of the station 1920 splice clip will determine if the fasteners are missing, and installation of fasteners is required.

Installation of the missing fasteners, if required will restore structural integrity and minimize the possibility of

crack growth. If not corrected, undetected missing fasteners at the station 1920 splice clip and possible crack

growth can potentially lead to a significant loss of load carrying capacity of the structural detail resulting in the

inability to sustain limit load or potentially result in a decompression event.

ACTION

This service bulletin provides instructions to do as follows:

1. Do General Visual Inspection (GVI) of the station 1920 Splice Clip for correct fastener installation and

do the work that follows based on conditions found:

2. Condition 1 - Correct Fasteners Installed:

a. No further work require.

3. Condition 2 - Incorrect Fasteners Found OR Condition 3 - No Fasteners Found:

a. Do a Detailed Inspection (DI) of Frame 1920 Inboard Chord Splice Angle and the parts attached

to the angle for any crack.

b. Do a DI of the cutout hole in the Sill Web and the attached parts for any crack.

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c. Do a General Visual Inspection (GVI) of the Shear Tie and its fasteners for any crack.

d. Do a DI of the Shear Clip, Aux Sill Outer Chord Tee and the Splice Angle and their fasteners for

any crack.

e. Do Surface High Frequency Eddy Current (HFEC) inspection of the Radii of the Tee along 5" either

side of Frame at station 1920 for cracks.

f. Do Surface HFEC inspection around fastener heads common to the Tee for cracks.

4. Condition 4 - No Crack Found:

a. Install fasteners of the Splice Angle.

5. Condition 5 - Any Crack Found:

a. Remove any crack found.

b. Repair in accordance with Structural Repair Manual (SRM).

c. Do open hole HFEC inspections of all fasteners common to the repair(s) for cracks. If any crack

found, repair in accordance with Structural Repair Manual (SRM).

d. Install fasteners of the Splice Angle.

EFFECTIVITY

747-400 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).

COMPLIANCE

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 available for airplanes in warranty as of 11/19/2007. Please refer to Paragraph

2.B., Industry Support Information.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

747-400 5.0 5.0

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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ALERT ALERT
Refer to Paragraph 2.A., Material - Price and Availability

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2844

Original Issue: September 15, 2011

Revision 1: July 30, 2012

ATA System: 5300

SUBJECT: FUSELAGE - Station 1920 Splice Clip Fasteners Inspection

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

Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplane(s) shown below.

GROUP CONFIGURATION DESCRIPTION

1 - 747-400 airplanes that are Boeing Converted Freightters (BCF)

Airplane Models:

747-400

Variable Number Group

RT456 1

RT501 1

RT506 - RT510 1

RT513 1

RT516 1

RT518 1

RT520 1

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Variable Number Group

RT528 1

RT572 - RT575 1

RT655 - RT657 1

RT751 1

RT781 - RT782 1

RT967 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

An airplane that was undergoing Boeing Converted Freighter conversion was missing fasteners on the

Station 1920 Splice Clip as part of the new converted components. This discrepancy was found after

23 aircraft had been delivered and the possibility of this discrepancy exists on already delivered airplanes.

A one time inspection of the station 1920 splice clip will determine if the fasteners are missing, and

installation of fasteners is required. Installation of the missing fasteners, if required will restore structural

integrity and minimize the possibility of crack growth. If not corrected, undetected missing fasteners at

the station 1920 splice clip and possible crack growth can potentially lead to a significant loss of load

carrying capacity of the structural detail resulting in the inability to sustain limit load or potentially result

in a decompression event.

Revision 1 is sent to clarify the Work Instructions, Figures and Step Table to be consistent with the

information in the Compliance Paragraph.

Illustrations have been changed in the Summary Art and Figures to meet current standards and added

view callouts for clarity.

D. Description

This service bulletin provides instructions to do as follows:

1. Do General Visual Inspection (GVI) of the station 1920 Splice Clip for correct fastener installation

and do the work that follows based on conditions found:

2. Condition 1 - Correct Fasteners Installed:

a. No further work require.

3. Condition 2 - Incorrect Fasteners Found OR Condition 3 - No Fasteners Found:

a. Do a Detailed Inspection (DI) of Frame 1920 Inboard Chord Splice Angle and the parts attached

to the angle for any crack.

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
b. Do a DI of the cutout hole in the Sill Web and the attached parts for any crack.

c. Do a General Visual Inspection (GVI) of the Shear Tie and its fasteners for any crack.

d. Do a DI of the Shear Clip, Aux Sill Outer Chord Tee and the Splice Angle and their fasteners

for any crack.

e. Do Surface High Frequency Eddy Current (HFEC) inspection of the Radii of the Tee along 5"

either side of Frame at station 1920 for cracks.

f. Do Surface HFEC inspection around fastener heads common to the Tee for cracks.

4. Condition 4 - No Crack Found:

a. Install fasteners of the Splice Angle.

5. Condition 5 - Any Crack Found:

a. Remove any crack found.

b. Repair in accordance with Structural Repair Manual (SRM).

c. Do open hole HFEC inspections of all fasteners common to the repair(s) for cracks. If any

crack found, repair in accordance with Structural Repair Manual (SRM).

d. Install fasteners of the Splice Angle.

Revision 1 - No more work is necessary on the airplane(s) changed in accordance with the original

issue of this service bulletin.

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones

Model Zone

747-400 263

E. Compliance

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.

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
Table No. 1 - Station 1920 Splice Clip Fastener Inspection

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever occurs later)

Condition Action

Within 8,000 flight cycles -

after completion of freighter

modification.

Do a General Visual Inspection

(GVI) for correct fastener installation in accordance with Paragraph

3.B., Work Instructions, Step 2.

All Airplanes

Or

Within 250 flight cycles after the original issue date

of the service bulletin.

No further work required in accor- - -

dance with Paragraph 3.B., Work

Instructions, Step 3.

Condition 1

(Correct fasteners

installed)

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
Table No. 1 - Station 1920 Splice Clip Fastener Inspection

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever occurs later)

Condition Action

Do the 7 inspections for cracks as Before further flight. -

follows in accordance with Paragraph 3.B., Work Instructions,

Step 4.

Condition 2

(Incorrect Fasteners Installed)

Or

Condition 3 And

Do the work of condition 4 if no

crack found or do the work of

condition 5 if any crack found.

(No fasteners installed)

1) Do a Detailed Inspection of

Frame 1920 Inboard Chord Splice

Angle and the parts attached to

the angle.

And

2) Do a Detailed Inspection of the

cutout hole in the Sill Web and

the attached parts.

And

3) Do a General Visual Inspection

of the Shear Tie and its fasteners.

And

4) Do a Detailed Inspection of the

Shear Clip and the Splice Angle

and their fasteners.

And

5) Do a Detailed Inspection of the

Aux Sill Outer Chord Tee and attached parts.

And

6) Do Surface High Frequency

Eddy Current (HFEC) inspection

of the Radii of the Tee along 5"

either side of Frame at station

1920 using a transverse scan to

look for cracks.

And

7) Do Surface HFEC inspection

around fastener heads common

to the Tee for cracks.

Condition 4 Before further flight.

(No crack found)

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
Table No. 1 - Station 1920 Splice Clip Fastener Inspection

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever occurs later)

Condition Action

Install fasteners of the Splice Angle in accordance with Paragraph

3.B., Work Instructions, Step 5.

Do the work that follows in accor- Before further flight. -

dance with Paragraph 3.B., Work

Instructions, Step 6.

Condition 5

(Any crack found)

1) Remove any crack found.

And

2) Repair as applicable.

And

3) Do open hole HFEC inspections of all fasteners common to

the repair(s) for cracks.

If any crack found, repair as applicable.

And

4) Install fasteners of the Splice

Angle (65B17957-3).

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin 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 service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
• Time to make the parts

• Time to find the tools.

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.50 0.50

FIGURE 1 1 0.25 0.25

FIGURE 2 1 0.75 0.75

FIGURE 3 1 1.50 1.50

FIGURE 4 1 1.50 1.50

FIGURE 5 (a) 1 1.25 1.25

Close Access 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 5.00 5.00

(a) Estimate given in figure 5 is for a typical crack removal and is not included in

total shown. Times number of typical cracks to be removed by estimate given

to arrive at revised total.

H. Weight and Balance Changes

1. If no fastener changes are required:

None.

2. If maximum number of fastener are added:

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

747-400 + 0.7 +1304

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00

b. 747-400 Aircraft Maintenance Manual (AMM) 25-59-00

c. 747-400SF Structural Repair Manual (SRM) 51-40-02, 51-70-12, 51-70-13, 53-00-01

2. Data Supplied with this Service Bulletin:

None.

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

814B6801 Upper Panel Assembly - End Item, Freighter

This drawing were used to prepare this service bulletin. This drawing are not necessary to make

the specified changes, and are not supplied with this service bulletin. These drawings may not be

applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary

Not affected.

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are available for 747-400 airplanes in warranty as of 11/19/2007. For

inspection task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to

Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is

found during the inspection for airplanes in warranty as of that date and additional task hours and parts

are required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer

to this service bulletin number and reference the airplane variable numbers in your purchase order.

C. Parts Necessary for Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

Part Number / QTY Name Notes

Specification

BACB30NX8K9 7 HI-LOK (a)

BACB30NX10K9 2 HI-LOK (a)

BACC30BH8 7 COLLAR (a)

BACC30BH10 2 COLLAR (a)

(a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)

for supplier data.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

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ALERT ALERT
F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. 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 limits to tighten nuts and bolts are in SRM Chapter 51

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51. Alternate fasteners are listed in SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin 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.

6. A Detailed Inspection (DI) is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

7. A General Visual Inspection (GVI) is defined as: A visual examination of an interior

or exterior area, installation or assembly to detect obvious damage, failure or

irregularity. This level of inspection is made from within touching distance unless

otherwise specified. A mirror may be necessary to enhance visual access to all

exposed surfaces in the inspection area. This level of inspection is made under

normally available lighting conditions such as daylight, hangar lighting, flashlight or

drop-light and may require removal or opening of access panels or doors. Stands,

ladders or platforms may be required to gain proximity to the area being checked.

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ALERT ALERT
8. 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.

9. Boeing Service Letter 747-SL-51-048 Damage Reporting and Repair 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.

10. If it is necessary to remove more parts for access, you can remove 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.

11. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

The removed part can be discarded if a new or serviceable part is installed.

B. WORK INSTRUCTIONS

Splice Clip 65B17957-3 Fastener Installation - Inspection

1. Remove and keep the cargo liner and insulation blanket on the Main Deck door surround to gain

access to the Auxiliary Sill at stringer 4L at STA 1920, WL 350, LBL 30. Refer to 747-400 AMM

25-59-00 as an accepted procedure.

2. Do a General Visual Inspection (GVI) of the 65B17957-3 Splice Clip common to the 65B17669-47

Aux Sill Web and the 65B17669-606 Tie Clip for correct fastener installation in accordance with

FIGURE 1 and do the work that follows based on conditions found:

3. Condition 1 - Correct Fasteners Installed:

a. No further work required. Go to step 7.

4. Condition 2 - Incorrect Fasteners Installed OR Condition 3 - No Fasteners Found:

a. Do the following inspections for cracks in accordance with FIGURE 2.

(1) Do a Detailed Inspection (DI) of Frame 1920 Inboard Chord Splice Angle (69B15483-2)

and the parts attached to the angle.

(2) Do a DI of the cutout hole in the Sill Web (65B17669-47) and the attached parts.

(3) Do a General Visual Inspection (GVI) of the Shear Tie (69B18157-1) and its fasteners.

(4) Do a DI of the Shear Clip (65B17665-69) and the Splice Angle (65B17665-62) and their

fasteners and do a DI of the Aux Sill Outer Chord Tee (65B17829-1) and attached parts.

b. Do the following inspections accordance with FIGURE 3.

(1) Do Surface High Frequency Eddy Current (HFEC) inspection of the Radii of the Tee along

5" either side of Frame at station 1920 using a transverse scan to look for cracks.

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BOEING SERVICE BULLETIN 747-53A2844

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(2) Do Surface HFEC inspection around fastener heads common to the Tee along 5" each

side of Frame at station 1920 to look for cracks.

c. Based on condition found from the inspections (steps 4.a and 4.b) do the work of step 5 or

step 6.

5. Condition 4 - No Crack Found:

a. Install fasteners of the Splice Angle (65B17957-3) accordance with FIGURE 4. Refer to

747-400SF SRM 51-40-02 as an accepted procedure.

b. Go to step 7.

6. Condition 5 - Any Crack Found:

a. Remove any crack found in accordance with 747-400SF SRM 53-00-01 Figure 201, Repair

16 and 747-400SF SRM 51-70-12, 747-400SF SRM 51-70-13 and FIGURE 5.

For any crack found at a fastener hole, remove crack in accordance with 747-400SF SRM

51-10-02 Paragraph 11.B.3.b and Paragraph 11.B.4.

b. Repair as applicable in accordance with 747-400SF SRM 53-00-01 Figure 201, Repair 16,

and 747-400SF SRM 51-70-12, 747-400SF SRM 51-70-13.

c. Do open hole HFEC inspections of all fasteners common to the repair(s) for cracks. Refer to

747 NDT Part 6, 51-00-00, Figure 1 as an acceptable procedure. If any crack found, do as

follows:

(1) Remove any crack found in accordance with 747-400SF SRM 53-00-01 Figure 201,

Repair 16 and 747-400SF SRM 51-70-12, 747-400SF SRM 51-70-13 and FIGURE 5.

For any crack found at a fastener hole, remove crack in accordance with 747-400SF SRM

51-10-02 Paragraph 11.B.3.b and Paragraph 11.B.4.

(2) Repair as applicable in accordance with 747-400SF SRM 53-00-01 Figure 201, Repair

16, and 747-400SF SRM 51-70-12, 747-400SF SRM 51-70-13.

d. Install fasteners of the Splice Angle (65B17957-3) accordance with FIGURE 4. Refer to

747-400SF SRM 51-40-02 as an accepted procedure.

7. Install kept cargo liner and insulation blanket on the Main Deck door surround, removed to gain

access to the Auxiliary Sill at stringer 4L at STA 1920, WL 350, LBL 30. Refer to 747-400 AMM

25-59-00 as an accepted procedure.

8. Put the airplane back to a serviceable condition.

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ALERT ALERT
FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION

(SHEET 1 OF 6)

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ALERT ALERT
FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION

(SHEET 2 OF 6)

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ALERT ALERT
FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION

(SHEET 3 OF 6)

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ALERT ALERT
FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION

(SHEET 4 OF 6)

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ALERT ALERT
FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION

(SHEET 5 OF 6)

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect FASTENERS - - (a) (b) (c) (d)

(a) Do a General Visual Inspection to see if the fasteners shown have been installed and determined the

condition.

(b) Condition 1: Correct fasteners installed and the fasteners installed matches one of the three fastener

patterns shown (type of fastener and fastener pattern).

(c) Condition 2: Incorrect fasteners installed. The fasteners installed does not match any of the fastener

patten shown (type of fastener and fastener pattern).

(d) Condition 3: No fasteners installed.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

A HI-LOK BACB30NX8K9 - -

COLLAR BACC30BH8 - - (a)

B HI-LOK BACB30NX10K9 - -

COLLAR BACC30BH10 - - (a)

(a) BACC30X* or BACC30M* collar in lieu of BACC30BH* is acceptable.

FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION

(SHEET 6 OF 6)

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ALERT ALERT
FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L

(SHEET 2 OF 4)

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ALERT ALERT
FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 747-53A2844

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

Step Task Name Identification Qty More Data

1 Inspect SPLICE ANGLE 69B15483-2 - (a)

2 Inspect SILL WEB 69B17669-47 - (b)

3 Inspect SHEAR TIE 69B18157-1 - (c)

4 Inspect SPLICE ANGLE 65B17665-62 - Aft (d)

Inspect SHEAR CLIP 65B17665-69 - Fwd (d)

(e) And attached

parts.

TEE, AUX SILL OUTER 65B17829-1 -

CHORD

5 Inspect

(a) Do a Detailed Inspection of Frame 1920 Inboard Chord Splice Angle and the parts attached to the angle

for any crack.

(b) Do a Detailed Inspection of the cutout hole in the Sill Web and the attached parts for any crack.

(c) Do a General Visual Inspection of the Shear Tie and its fasteners for any crack.

(d) Do a Detailed Visual inspection of the Shear Clip and the Splice Angle and their fasteners for any crack.

(e) Do a Detailed Visual inspection of the Aux Sill Outer Chord Tee and attached parts for any crack.

FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 3: AUX SILL OUTER CHORD TEE - INSPECTION

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 3: AUX SILL OUTER CHORD TEE - INSPECTION

(SHEET 2 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for .

Step Task Name Identification Qty More Data

TEE, AUX SILL OUTER 65B17829-1 - (a)

CHORD

1 Inspect

TEE, AUX SILL OUTER 65B17829-1 - (b)

CHORD

2 Inspect

(a) Do a Surface High Frequency Eddy Current (HFEC) inspection of the Radii of the Aux Sill Outer Chord

Tee along 5" either side of Frame at station 1920 using a transverse scan to look for cracks in accordance

with 747 NDT Part 6, 51-00-00 Figure 4 or Figure 23.

(b) Do a Surface HFEC inspection for cracks of the internal surface of the Aux Sill Outer Chord Tee around

fastener heads along 5" each side of Frame at station 1920 to look for cracks in accordance with 747

NDT Part 6, 51-00-00 Figure 4 or Figure 23.

FIGURE 3: AUX SILL OUTER CHORD TEE - INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 4: SPLICE ANGLE FASTENER - INSTALLATION

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 4: SPLICE ANGLE FASTENER - INSTALLATION

(SHEET 2 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Install (New) HI-LOK BACB30NX10K9 2

Install (New) COLLAR BACC30BH10 2

2 Install (New) HI-LOK BACB30NX8K9 7

Install (New) COLLAR BACC30BH8 7

(a) Use of BACC30X* or BACC30M* collar in lieu of BACC30BH* is acceptable.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the

number of fasteners necessary for this figure.

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

A HI-LOK BACB30NX8K9 7 -

COLLAR BACC30BH8 7 -

B HI-LOK BACB30NX10K9 2 -

COLLAR BACC30BH10 2 -

FIGURE 4: SPLICE ANGLE FASTENER - INSTALLATION

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 5: TYPICAL CRACK REMOVAL

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each airplane.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Trim PART - - (a)

1. Maintain a minimum trim radius of 0.5 inch.

2. Break all sharp edges 0.015-0.030 inch.

3. Maintain a 125 microinch finish on all cut or

trimmed surfaces.

4. Finish all bare aluminum with chemical film

treatment and one coat of BMS 10-11, Type 1

Primer.

(a) Do the steps that follow:

1. Trim to remove the crack. Do a surface HFEC inspection along the edge of the trimmed surface

in accordance with 747 NDT Part 6, 51-00-00, Figure 4 or 23 to confirm that there is no crack.

2. Remove an additional 0.03 inch of material as an "insurance cut" to ensure crack removal.

Note: Do not trim beyond the tangent point of the radius of the horizontal flange. Ask Boeing for repair

data if crack removal requires trimming beyond the tangent point.

FIGURE 5: TYPICAL CRACK REMOVAL

(SHEET 2 OF 2)

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ALERT ALERT