### 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. 9E991 ECCN: 

## 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 Unpublished Work.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. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, DreamlinerTM, 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 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. BOEING is a trademark of Boeing Management Company.

Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 1 of 41 3.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 2 of 41 **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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 3 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 4 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**

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### 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 5 of 41**REVISION HISTORY** September 15, 2011 Original Issue: July 30, 2012 Revision 1:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 6 of 41 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 7 of 41c. 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 Elapsed Hours**  **Total Task Hours Airplanes**  5.0 5.0 747-400

**MATERIAL INFORMATION** Operator Supplied Parts/Materials.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 8 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**Refer to Paragraph 2.A., Material - Price and Availability

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 9 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 10 of 41 **BOEING SERVICE BULLETIN 747-53A2844 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.
**DESCRIPTION CONFIGURATION**  **GROUP** 747-400 airplanes that are Boeing Converted Freightters (BCF)

- 1

Airplane Models:
747-400 **Group Variable Number**  1 RT456 1 RT501 1 RT506 - RT510 1 RT513 1 RT516 1 RT518 1 RT520

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 11 of 41**Group Variable Number**  1 RT528 1 RT572 - RT575 1 RT655 - RT657 1 RT751 1 RT781 - RT782 1 RT967 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 12 of 41 **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 Zone**  **Model** 263 747-400 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 13 of 41 **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)**  **Action Condition** 

- 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

OrWithin 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 14 of 41 **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)**  **Action Condition** 

- Before further flight. Do the 7 inspections for cracks asfollows in accordance with Paragraph 3.B., Work Instructions, Step 4. Condition 2(Incorrect Fasteners Installed) Or And Condition 3 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 theAux 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. Before further flight. Condition 4 (No crack found)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 15 of 41 **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)**  **Action Condition**  Install fasteners of the Splice Angle in accordance with Paragraph 3.B., Work Instructions, Step 5.

- Before further flight. Do the work that follows in accor- dance with Paragraph 3.B., Work Instructions, Step 6. Condition 5 (Any crack found) 1) Remove any crack found. And 2) Repair as applicable. And3) 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 16 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**• Time to make the parts • Time to find the tools. **Elapsed Hours Task Hours**  **Number of Persons Task**  0.50 0.50 1 Open Access 0.25 0.25 1 FIGURE 1 0.75 0.75 1 FIGURE 2 1.50 1.50 1 FIGURE 3 1.50 1.50 1 FIGURE 4 1.25 1.25 1 FIGURE 5 (a) 0.50 0.50 1 Close Access 5.00 5.00 TOTAL FOR EACH AIRPLANE (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 (Pounds)**  **Airplane** +1304 + 0.7 747-400
**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 17 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**3. Installation Drawings Used in the Preparation of this Service Bulletin:

**Title Drawing Number**  Upper Panel Assembly - End Item, Freighter 814B6801 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 18 of 41 **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
**Notes Name**  **QTY Part Number /**  **Specification** (a) HI-LOK 7 BACB30NX8K9 (a) HI-LOK 2 BACB30NX10K9 (a) COLLAR 7 BACC30BH8 (a) COLLAR 2 BACC30BH10 (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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 19 of 41 **BOEING SERVICE BULLETIN 747-53A2844 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 20 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 21 of 41 **BOEING SERVICE BULLETIN 747-53A2844 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 22 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**(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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1: July 30, 2012 23 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION**  **(SHEET 1 OF 6)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 24 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION**  **(SHEET 2 OF 6)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 25 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION**  **(SHEET 3 OF 6)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 26 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION**  **(SHEET 4 OF 6)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 27 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION**  **(SHEET 5 OF 6)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 28 of 41 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b) (c) (d)

- - FASTENERS Inspect 1 (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.
**MORE DATA HOLE DIA**  **QTY IDENTIFICATION**  **NAME CODE** 

- - BACB30NX8K9 HI-LOK A (a)

- - BACC30BH8 COLLAR

- - BACB30NX10K9 HI-LOK B (a)

- - BACC30BH10 COLLAR (a) BACC30X* or BACC30M* collar in lieu of BACC30BH* is acceptable.

**FIGURE 1: SPLICE CLIP 65B17957-3 FASTENER INSTALLATION - INSPECTION (SHEET 6 OF 6)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 29 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L**  **(SHEET 1 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 30 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L**  **(SHEET 2 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 31 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 2: INSPECTIONS AT BODY STATION 1920 AND STRINGER 4L**  **(SHEET 3 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 32 of 41 **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.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

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

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

- 69B18157-1 SHEAR TIE Inspect 3 Aft (d)

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

- 65B17665-69 SHEAR CLIP Inspect (e) And attached parts. - 65B17829-1 TEE, AUX SILL OUTER CHORD Inspect 5 (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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 33 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 3: AUX SILL OUTER CHORD TEE - INSPECTION**  **(SHEET 1 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 34 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 3: AUX SILL OUTER CHORD TEE - INSPECTION**  **(SHEET 2 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 35 of 41 **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 .
**More Data Qty**  **Identification Name**  **Task Step**  (a)

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

- 65B17829-1 TEE, AUX SILL OUTER CHORD Inspect 2 (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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 36 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 4: SPLICE ANGLE FASTENER - INSTALLATION**  **(SHEET 1 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 37 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 4: SPLICE ANGLE FASTENER - INSTALLATION**  **(SHEET 2 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 38 of 41 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  2 BACB30NX10K9 HI-LOK Install (New) 1 2 BACC30BH10 COLLAR Install (New) 7 BACB30NX8K9 HI-LOK Install (New) 2 7 BACC30BH8 COLLAR Install (New) (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.
**MORE DATA HOLE DIA**  **QTY IDENTIFICATION**  **NAME CODE** 

- 7 BACB30NX8K9 HI-LOK A

- 7 BACC30BH8 COLLAR

- 2 BACB30NX10K9 HI-LOK B

- 2 BACC30BH10 COLLAR

**FIGURE 4: SPLICE ANGLE FASTENER - INSTALLATION (SHEET 3 OF 3)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 39 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT FIGURE 5: TYPICAL CRACK REMOVAL**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 40 of 41 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a)

- - PART Trim 1 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. Do the steps that follow: (a) 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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 15, 2011 747-53A2844 Revision 1 July 30, 2012 41 of 41 **BOEING SERVICE BULLETIN 747-53A2844 ALERT**  **ALERT**