June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 218 

### Commercial **Airplane Group**  

# 747 Service Bulletin
**Number: 747-53A2484** Date: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 **SUBJECT:** FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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or otherwise.**BLANK PAGE** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

BLANK PAGE**Table of Contents** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**Table of Contents** Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 21 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 22 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 22 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 28 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 28 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 1: ACCESS AND RESTORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 FIGURE 2: STRINGER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 . . . . . . . . . . . . . . . . . 39 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460. . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 . . . . . . . . . . . . . . . . . 54 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480. . . . . . . . . . . . . . . . . . . . . . 59 FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500 . . . . . . . . . . . . . . . . . 69 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500. . . . . . . . . . . . . . . . . . . . . . 74 FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460 . . . . . . . . . . . . . . . . . 84 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460 . . . . . . . . . . . . . . . . . . . . . 89 FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480 . . . . . . . . . . . . . . . . 99**Table of Contents** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480 . . . . . . . . . . . . . . . . . . . . 104 FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500 . . . . . . . . . . . . . . . . 114 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500 . . . . . . . . . . . . . . . . . . . . 119 FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460 . . . . . . . . . . . . . . . 129 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460. . . . . . . . . . . . . . . . . . . . 134 FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480 . . . . . . . . . . . . . . . 144 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480. . . . . . . . . . . . . . . . . . . . 149 FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500 . . . . . . . . . . . . . . . 159 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500. . . . . . . . . . . . . . . . . . . . 164 FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460 . . . . . . . . . . . . . . . 174 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460 . . . . . . . . . . . . . . . . . . . 179 FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480 . . . . . . . . . . . . . . . 189 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480 . . . . . . . . . . . . . . . . . . . 194 FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500 . . . . . . . . . . . . . . . 204 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500 . . . . . . . . . . . . . . . . . . . 209Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 218 

### Commercial **Airplanes** 

# 747 Service Bulletin
**Number: 747-53A2484** 

### Revision Transmittal Sheet Original Issue: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 **SUBJECT:** FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes This Revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes changed as given in the initial release of this service bulletin. Airplane RS699 was added to Group 1 of the service bulletin effectivity. Airplanes RT631 and RT632, which have been converted to the Large Cargo Freighter (LCF) configuration, were moved from Group 3 to new Group 4. Federal Aviation Administration (FAA) Airworthiness Directive 2005-15-08 is related to this service bulletin. **REASON FOR REVISION** This revision is sent to: — In Effectivity, Paragraph 1.A., added airplane RS699 to Group 1. This airplane was omitted from the effectivity of the original release of this bulletin. — Moved airplanes RT631 and RT632, which have been converted to the Large Cargo Freighter (LCF) configuration, from Group 3 to new Group 4. — In WORK INSTRUCTIONS, Paragraph 3.B., revised access instructions due to different interior configurations. — In Compliance, Paragraph 1.E., added reference to AD 2005-15-08. Also, added compliance table and revised compliance information to agree with AD 2005-15-08. — In Material - Price and Availability, Paragraph 2.A., updated kit information to add new repair kits which contain repair angles made from improved materials. — In Industry Support Information, Paragraph 2.B., updated industry support statement. — In Figures 4, 6, 10, 12, 16, 22, and 26, corrected fastener quantities and fastener locations. — In Figures 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, and 26, revised views to show new updated repair parts. 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.Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**REVISION HISTORY** Original Issue: June 26, 2003 Revision 1: February 12, 2009June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 218 

### Commercial **Airplane Group**  

# 747 Service Bulletin
**Number: 747-53A2484** 

### Summary Date: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 **SUBJECT:** FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes
**CONCURRENT REQUIREMENTS** None. **BACKGROUND** Inspection of fuselage stringers adjacent to the window belt on the upper deck on 747 airplanes with Stretched Upper Decks (SUD) will make sure that stringer cracks do not grow to include the fuselage skin at the window areas of the upper deck. If stringer cracks at these locations are not found and repaired, the cracks can grow to include the fuselage skin along the window belt of the upper deck. Such skin cracks can result in extensive damage to the skin at the window belt, with related rapid decompression of the fuselage. Operators have told Boeing about cracks in the fuselage Stringers 8L, 8R, 10L and 10R at the Body Station 460, 480 and 500 frame locations. The airplanes in these reports had between 29,873 and 90,333 flight-hours, and between 9,691 and 25,513 flight cycles. Installation of the repair shown in this service bulletin (new frame clips and new, additional stringer splice and doublers) will restore the stringers’ strength. For locations where no stringer cracks are found, installation of the preventive modification shown in this service bulletin (new frame clips and a new load-spreading doubler) will prevent stringer cracks form occurring. Boeing Service Related Problem (SRP) 747-SRP-53-0174 is related to this service bulletin. Boeing Structural Item Interim Advisory (SIIA) 747-178 is related to this service bulletin. **ACTION** Get access to Stringers 8 and 10, on the left and right side of the airplane upper deck, between Body Stations (BS) 440 and 520. At Stringers 8L, 8R, 10L and 10R, do a detailed inspection of the stringers where the frame clips attach to the stringers, at BS 460, BS 480 and BS 500 frame locations. If cracks are found, install repairs as given in this service bulletin (if cracks exceed the repairable length as given in this service bulletin, use data from the 747 Structural Repair Manual with data given in this service bulletin to make the necessary repairs). Do the inspections again at the times given in Paragraph 1.E., "Compliance". To stop the special inspections given in this service bulletin, install the preventive modification shown in this service bulletin.June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 The airplane effectivity is divided into four groups, Group 1 airplanes are also in the effectivity of Service Bulletin 747-53A2265, and have 100 Degree countersink rivets installed in the fuselage skin. Group 2 airplanes are also in the effectivity of Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in the fuselage skin. Group 3 airplanes are not in the effectivity of Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in the fuselage skin. Group 4 airplanes have been modified to the 747- 400 Large cargo Freighter (LCF) configuration. **EFFECTIVITY** 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** See Service Bulletin Paragraph 1.E, Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures given in this service bulletin. **MANPOWER**

**MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability. **Task Total Task Hours Elapsed Hours** Preventive Modification (all 12 locations) 122 61 Repair (all 12 locations) 230 115June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CRACKS. ARE FOUND. CRACKS. ARE FOUND. S-10 S-8 460 STA 480 STA STA 500

RIGHT SIDE OPPOSITE

STR-10 LEFT SIDE SHOWN,

EDGE OF WINDOW CUTOUT

EDGE OF WINDOW CUTOUT CRACKS ARE FOUND. DO A REPAIR IF MODIFICATION IF NO CRACKS INSTALL PREVENTIVE EXAMINE THE STRINGER FOR

STR-8 CLIP

FRAME

FRAME CLIP

CRACKS ARE FOUND. DO A REPAIR IF MODIFICATION IF NO CRACKS INSTALL PREVENTIVE EXAMINE THE STRINGER FOR FWD

FWD

FWD B SEE

SEE C



### A

B

C SEE AN68182June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

BLANK PAGEOriginal Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 218 

### Commercial **Airplanes** 

# 747 Service Bulletin
**Number: 747-53A2484** Original Issue: June 26, 2003 Revision 1: February 12, 2009 ATA System: 5311 **SUBJECT:** FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, Modification And Repair - 747 SUD Airplanes
**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 airplanes shown below.

Airplane models: 747-100B SUD 747-200B 747-300 747-400 747-400D IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER **GROUP CONFIGURATION DESCRIPTION** 1 - 747-300 Airplanes within the effectivity of Service Bulletin 747-53A2265 and have 100 Degree countersink rivets installed in the fuselage skin. 2 - 747-200B, 100B SUD and 300 Airplanes within the effectivity of Service Bulletin 747-53A2265 and have special 120 Degree countersink rivets installed in the fuselage skin. 3 - 747-300, 747-400, and 747-400D airplanes through line number 875, not included in the effectivity of Service Bulletin 747-53A2265, with special 120 Degree countersink rivets installed in the fuselage skin, except 747-400 Large Cargo Freighter airplanes. 4 - 747-400 Large Cargo Freighter (LCF) airplanes through line number 875,Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
AEROLINEAS ARGENTINAS (ARG) 3 RT701–RT702 AEROSUR (REO) 1 RS235 AIR ATLANTA ICELANDIC (AID) 1 RS211 RS233 RS237 3 RS332–RS333 RT751 AIR CHINA (BEJ) 3 RT031–RT033 AIR CHINA CARGO (CGC) 3 RT101 RT103 AIR FRANCE (AFA) 2 RD721–RD722 3 RT071 RT121 RT591 RT711–RT712 AIR INDIA (AIN) 3 RS781–RS782 AIR NEW ZEALAND (ANZ) 3 RT671–RT672 RT703 AIR PACIFIC (APC) 3 RT502 RT504 AIR PULLMANTUR (PUL) 3 RS331 AIRBRIDGE CARGO (ABM) 3 RS762 ALL NIPPON AIRWAYS (ANA) 3 RT753 RT776–RT777 ATLAS AIR (TLS) 2 RS722 3 RT752 AVION AIRCRAFT TRADING H.F. (VNG) 3 RT633 BRITISH AIRWAYS (BAB) 3 RT471–RT489 CATHAY PACIFIC AIRWAYS (CAT) 3 RT451–RT458 RT508 RT511–RT512 RT781–RT782 CORSAIR (COR) 1 RS239–RS240Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
DRAGONAIR (DRG) 2 RS741 RS771 3 RT510 DUBAI AIR WING (DAW) 3 RT102 EVERGREEN INTERNATIONAL A/L (EVR) 4 RT631–RT632 EXPORT RESTRICTED AIRPLANES (YWV) 2 RS751–RS752 3 RT602 RT606 FINOVA (GRB) 2 RS761 GENERIC CUSTOMER/SUPPLIER (XXX) 2 RD382 GOVERNMENT OF JAPAN (JAG) 3 RT681–RT682 JAL INTERNATIONAL (JAL) 1 RS251–RS252 RS254 2 RS256 3 RS259 RS265–RS267 RT641–RT652 RU801 KALITTA AIR (KAC) 3 RT021–RT022 KLM - ROYAL DUTCH AIRLINES (KLM) 3 RT001–RT007 RT531–RT533 KOREAN AIR (KAL) 3 RT061 RT571–RT576 LUFTHANSA GERMAN AIRLINES (DLH) 3 RT041–RT047 RT431–RT438 MARTINAIR HOLLAND (MTH) 3 RT501 RT506–RT507 RT509 NORTHWEST AIRLINES (NWA) 3 RT401–RT410 OASIS HONG KONG AIRLINES (OHK) 3 RT503 ORIENT THAI AIRLINES (OTH) 1 RS253 RS292 RS712 2 RS001–RS002 RS257Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
PAKISTAN INT'L AIRLINES (PIA) 1 RS301 2 RS302–RS304 3 RS305–RS306 PHUKET AIRLINES (PHK) 1 RS238 RS241 RS711 2 RD381 RD605 QANTAS (QAN) 1 RS272–RS273 2 RS274–RS276 3 RT551–RT563 RT741–RT742 SATAIR (SAI) 2 RD606 SAUDI ARABIAN AIRLINES (SVA) 1 RS311–RS315 2 RS316–RS320 SAUDI ROYAL FLIGHT (SRF) 1 RS699 SOUTH AFRICAN AIRWAYS (SAA) 1 RS212 RS232 RS236 SOUTHERN AIR (SOF) 1 RS721 2 RD383 RD601–RD602 RD607 3 RS786 SURINAM AIRWAYS (SUR) 2 RS713 TAAG (ANGOLA AIRLINES) (ANG) 2 RS742 3 RS703 THAI AIRWAYS INTERNATIONAL (TII) 3 RT691–RT693 TRANSAERO AIRLINES (TRX) 1 RS271 2 RS255 RS258 3 RS263 RS268 UNICAL AVIATION (UNL) 2 RS341 3 RS342 UNITED AIR LINES (UAL) 3 RT601 RT603–RT605 RT607–RT610Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
WELLS FARGO (FSB) 3 RT505 IDENTIFICATION BY VARIABLE NUMBER **Variable Group** RD381–RD383 2 RD601–RD607 2 RD721–RD722 2 RS001–RS002 2 RS201 1 RS211–RS212 1 RS221–RS222 1 RS231–RS241 1 RS251–RS254 1 RS255–RS258 2 RS259 3 RS263 3 RS265–RS268 3 RS271–RS273 1 RS274–RS276 2 RS291–RS292 1 RS301 1 RS302–RS304 2 RS305–RS306 3 RS311–RS315 1 RS316–RS320 2 RS331–RS333 3 RS341 2 RS342 3 RS699 1 RS701–RS702 1 RS703 3 RS711–RS712 1 RS713 2 RS721 1 RS722 2 RS731–RS732 3 RS741–RS743 2 RS751–RS752 2 RS761 2Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

2. Spares Affected None. RS762 3 RS771 2 RS781–RS782 3 RS786 3 RT001–RT007 3 RT021–RT022 3 RT031–RT033 3 RT041–RT047 3 RT061 3 RT071 3 RT101–RT103 3 RT121 3 RT401–RT410 3 RT431–RT438 3 RT451–RT458 3 RT471–RT489 3 RT501–RT512 3 RT531–RT533 3 RT551–RT563 3 RT571–RT576 3 RT591 3 RT601–RT610 3 RT631–RT632 4 RT633 3 RT641–RT652 3 RT671–RT672 3 RT681–RT682 3 RT691–RT693 3 RT701–RT703 3 RT711–RT712 3 RT741–RT742 3 RT751–RT753 3 RT776–RT777 3 RT781–RT782 3 RU801 3 **Variable Group**Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
**B. Concurrent Requirements** None. **C. Reason** Inspection of fuselage stringers adjacent to the window belt on the upper deck on 747 airplanes with Stretched Upper Decks (SUD) will make sure that stringer cracks do not grow to include the fuselage skin at the window areas of the upper deck. If stringer cracks at these locations are not found and repaired, the cracks can grow to include the fuselage skin along the window belt of the upper deck. Such skin cracks can result in extensive damage to the skin at the window belt, with related rapid decompression of the fuselage. Operators have told Boeing about cracks in the fuselage Stringers 8L, 8R, 10L and 10R at the Body Station 460, 480 and 500 frame locations. The airplanes in these reports had between 29,873 and 90,333 flight-hours, and between 9,691 and 25,513 flight cycles. Installation of the repair shown in this service bulletin (new frame clips and new, additional stringer splice and doublers) will restore the stringers’ strength. For locations where no stringer cracks are found, installation of the preventive modification shown in this service bulletin (new frame clips and a new load-spreading doubler) will prevent stringer cracks form occurring. Boeing Service Related Problem (SRP) 747-SRP-53-0174 is related to this service bulletin. Boeing Structural Item Interim Advisory (SIIA) 747-178 is related to this service bulletin. This revision is sent to: — In Effectivity, Paragraph 1.A., added airplane RS699 to Group 1. This airplane was omitted from the effectivity of the original release of this bulletin. — Moved airplanes RT631 and RT632, which have been converted to the Large Cargo Freighter (LCF) configuration, from Group 3 to new Group 4. — In WORK INSTRUCTIONS, Paragraph 3.B., revised access instructions due to different interior configurations. — In Compliance, Paragraph 1.E., added reference to AD 2005-15-08. Also, added compliance table and revised compliance information to agree with AD 2005-15-08. — In Material - Price and Availability, Paragraph 2.A., updated kit information to add new repair kits which contain repair angles made from improved materials. — In Industry Support Information, Paragraph 2.B., updated industry support statement. — In Figures 4, 6, 10, 12, 16, 22, and 26, corrected fastener quantities and fastener locations. — In Figures 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, and 26, revised views to show new updated repair parts. **D. Description** Get access to Stringers 8 and 10, on the left and right side of the airplane upper deck, between Body Stations (BS) 440 and 520. At Stringers 8L, 8R, 10L and 10R, do a detailed inspection of the stringers where the frame clips attach to the stringers, at BS 460, BS 480 and BS 500 frame locations. If cracks are found, install repairs as given in this service bulletin (if cracks exceed the repairable length as given in this service bulletin, use data from the 747 Structural Repair Manual with data given in this service bulletin to make the necessary repairs). Do the inspections again at the times given in Paragraph 1.E., "Compliance". To stop the special inspections given in this service bulletin, install the preventive modification shown in this service bulletin.Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 The airplane effectivity is divided into four groups, Group 1 airplanes are also in the effectivity of Service Bulletin 747-53A2265, and have 100 Degree countersink rivets installed in the fuselage skin. Group 2 airplanes are also in the effectivity of Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in the fuselage skin. Group 3 airplanes are not in the effectivity of Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in the fuselage skin. Group 4 airplanes have been modified to the 747-400 Large cargo Freighter (LCF) configuration. No more work is necessary on airplanes changed as given in the initial release of this service bulletin. Accomplishment of the inspections in service bulletin 747-53A2265 concurrent with the inspections in this service bulletin on commonly affected airplanes is recommended due to common access. **E. Compliance** Boeing recommends that you do the inspections and related tasks as given below: Group 1-3: Table 1 - Stringer Inspection Airplanes with 19,000 Total Flight Cycles or less **Condition Action Compliance Time**  **(Whichever Occurs Last) Repeat Interval**  **(Not to Exceed)** All Do a detailed inspection as given in Paragraph 3.B., Work Instructions, PART 1 - INSPECTION Before 8,000 total flight cycles within 2,000 flight cycles after August 30, 2005, not to exceed 20,000 total flight cycles 3,000 flight cycles (a)

Cracks Found Repair as given in Paragraph 3.B., Work Instructions, PART 2 - REPAIR Before further flight - (a)

(a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500. Group 1-3: Table 2 - Stringer Inspection Airplanes with 19,001 Total Flight Cycles or more **Condition Action Compliance Time**  **(Whichever Occurs Last) Repeat Interval**  **(Not to Exceed)** All Do a detailed inspection as given in Paragraph 3.B., Work Instructions, PART 1 - INSPECTION - 1,000 flight cycles after August 30, 2005 3,000 Flight Cycles (a) Cracks Found Repair as given in Paragraph 3.B., Work Instructions, PART 2 - REPAIR Before Further Flight - (a)

(a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500.Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

Federal Aviation Administration (FAA) Airworthiness Directive 2005-15-08 is related to this service bulletin. **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. This service bulletin has been approved by the FAA. In addition, the manager of the FAA Seattle ACO approves the accomplishment of the applicable inspection, repair, and modification procedures of this service bulletin as an alternative method of compliance to the corresponding inspection, repair, and modification requirements of paragraphs (f), (g) and (h) of FAA AD 2005-15-08. This AMOC only applies to the areas inspected, repaired, or modified as given in this service bulletin. All provisions of AD 2005-15-08 that are not specifically referenced above remain fully applicable and must be complied with. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this inspection, repair and preventive modification 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 examine the work — Time to cure the materials — Time to make the parts Group 4: Table 3 - Stringer Inspection **Condition Action Compliance Time Repeat Interval**  **(Not to Exceed)** All Do a detailed inspection as given in Paragraph 3.B., Work Instructions, PART 1 - INSPECTION within 1,000 flight cycles after the date on Revision 1 of this service bulletin 1,500 flight cycles (a)

Cracks Found Repair as given in Paragraph 3.B., Work Instructions, PART 2 - REPAIR Before further flight (a) (a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500.Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

— Time to find the tools.

**NOTE:** The manpower estimates for open and close access have been determined assuming lavatory modules are installed, this is the most labor intensive configuration. All operators that have other monuments in these locations should require less time to open and close access. **H. Weight and Balance Changes** For all airplanes, use the tables below to find the weight and balance changes. Add the weight changes and the moment changes for all of the Preventive Modifications and/or Repairs that you make on the airplane to get the total Weight and Moment changes. **Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 37 18.5 Inspect (all locations) 2 3 1.5 Install Repair (one stringer/frame location) 2 12 6

Install Preventive Modification (one stringer/frame location) 2 3 1.5

Close Access 2 59 29.5 TOTAL FOR EACH AIRPLANE 114 57.0

**Preventive Modification**  **(Location) Change in Weight**  **(Pounds) Change in Moment**  **(Pound-Inches)** BS 460, S-8L +0.43 +197.8 BS 480, S-8L +0.43 +206.4 BS 500, S-8L +0.43 +215.0 BS 460, S-8R +0.43 +197.8 BS 480, S-8R +0.43 +206.4 BS 500, S-8R +0.43 +215.0 BS 460, S-10L +0.43 +197.8 BS 480, S-10L +0.43 +206.4 BS 500, S-10L +0.43 +215.0 BS 460, S-10R +0.43 +197.8 BS 480, S-10R +0.43 +206.4 BS 500, S-10R +0.43 +215.0Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Service Related Problem (SRP) 747-SRP-53-0174. b. 747 Maintenance Manual (AMM) Subject 25-21-02, 25-21-04, 25-22-03, 25-25-01, 25-28- 15, 25-40-03, 25-24-00, 25-19-03 and 25-19-04. c. 747 Structural Repair Manual (SRM) Subject 53-00-03 or 53-10-03. d. 747 Nondestructive Test (NDT) Manual Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16, and Part 6, Subject 51-00-00, Figure 4 or Figure 23. e. Boeing Standard Overhaul Practices Manual (BSOPM) 20-43-03. f. 747 Structural Item Interim Advisory (SIIA) 747-178. g. Boeing Service Bulletin 747-53A2265, "FUSELAGE - NOSE SECTION 41 - BODY FRAME STRUCTURE INSPECTIONS AND CRACK REPAIRS". h. Boeing Parts Standards Document D-590. i. Boeing Drawing 012W6100. j. FAA Airworthiness Directive 2005-15-08. 2. Data supplied with this Service Bulletin: None. **Repair (Location) Change in Weight**  **(Pounds) Change in Moment**  **(Pound-Inches)** BS 460, S-8L +1.13 +519.8 BS 480, S-8L +1.13 +524.4 BS 500, S-8L +1.13 +565.0 BS 460, S-8R +1.13 +519.8 BS 480, S-8R +1.13 +524.4 BS 500, S-8R +1.13 +565.0 BS 460, S-10L +1.13 +519.8 BS 480, S-10L +1.13 +524.4 BS 500, S-10L +1.13 +565.0 BS 460, S-10R +1.13 +519.8 BS 480, S-10R +1.13 +524.4 BS 500, S-10R +1.13 +565.0Original Issue: June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 3. Installation Drawings Used in the Preparation of this Service Bulletin:

These drawings were used to prepare this service bulletin. These drawings 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** None **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

**Drawing Number Title** 65B07653 SKIN PANEL INSTL - UPR, S-6 TO S-14 STA 340 TO 520 65B01716 FRAME INSTALLATION - BODY STATION 460 65B01717 FRAME INSTALLATION - BODY STATION 480 65B01718 FRAME INSTALLATION - BODY STATION 500 65B27201 BODY SECTION 41 INSTL. -200B SUD MODJune 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **Kit Number Name Date ROLT**  **(weeks) QTY Unit Price thru**  **31-Mar-2009** 691U1042-1 Top Kit, Repair Instl (a) (a) (a) (a) 691U1042-5 Top Kit, Preventive Instl Available 19 10 $7,290 691U1042-13 Top Kit, Repair Instl Jan 2009 33 30 $25,436 691U1042-15 Subkit, Repair Instl Jan 2009 33 - $12,718 691U1042-16 Subkit, Repair Instl Jan 2009 33 - $12,718 691U1042-17 Subkit, Part Kit - Repair Jan 2009 33 - $12,066 691U1042-18 Subkit, Part Kit - Repair Jan 2009 33 - $12,066 691U1042-19 Supplemental Kit Jan 2009 30 - $4,796 691U1042-21 Supplemental Kit Jan 2009 30 - $2,398 691U1042-22 Supplemental Kit Jan 2009 30 - $2,398 691U1042-2 Subkit, Fastener Kit Jan 2009 33 - $652 (a) 691U1042-1 Top Kit is no longer available.June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** One top kit for the preventive modification and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for the preventive modification on each airplane. One top kit for the repair and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for the repair on each airplane. **Existing Kit Name Supplemental Kit New Replacing Kit** 691U1042-1 (a) Top Kit, Repair Instl 691U1042-19 (f) 691U1042-13 (k) 691U1042-3 (b) Subkit, Repair Instl - LH 691U1042-21 (g) 691U1042-15 (l) 691U1042-4 (c) Subkit, Repair Instl - RH 691U1042-22 (h) 691U1042-16 (m) 691U1042-9 (d) Subkit, Part Kit - Repair - LH 691U1042-21 (g) 691U1042-17 (n) 691U1042-10 (e) Subkit, Part Kit - Repair -RH 691U1042-22 (h) 691U1042-18 (o) (a) Replaced by 691U1042-13. (b) Replaced by 691U1042-15. (c) Replaced by 691U1042-16. (d) Replaced by 691U1042-17. (e) Replaced by 691U1042-18. (f) Supplements 691U1042-1 and is only necessary if 691U1042-1 has shipped. Discard existing 691U1042-105 through -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers from existing -1 kit. (g) Supplements 691U1042-3 or -9 and is only necessary if 691U1042-3 or -9 has shipped. Discard existing 691U1042-105, -107, -109, -111, -113, and -115 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers from existing -3 or -9 kit. (h) Supplements 691U1042-4 or -10 and is only necessary if 691U1042-4 or -10 has shipped. Discard existing 691U1042-106, -108, -110, -112, -114, and -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers from existing -4 or -10 kit. (k) Equivalent to 691U1042-1 plus 691U1042-19 after 691U1042-105 through -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -1 kit. (l) Equivalent to 691U1042-3 plus 691U1042-21 after 691U1042-105, -107, -109, -111, -113, and -115 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -3 kit. (m) Equivalent to 691U1042-4 plus 691U1042-22 after 691U1042-106, -108, -110, -112, -114, and -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -4 kit. (n) Equivalent to 691U1042-9 plus 691U1042-21 after 691U1042-105, -107, -109, -111, -113, and -115 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -9 kit. (o) Equivalent to 691U1042-10 plus 691U1042-22 after 691U1042-106, -108, -110, -112, -114, and -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -10 kit.June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**Kit 691U1042**
**New Part Number QTY**  **Name Notes -12 -11 -8 -7 -5**  691U1042-5 . . . . - TOP KIT, PREVENTATIVE INSTL 691U1042-7 . . . - 1 SUBKIT, PREVENTATIVE INSTL 691U1042-8 . . - . 1 SUBKIT, PREVENTATIVE INSTL 691U1042-11 . - 1 1 . SUBKIT, PART KIT 691U1042-12 - . 1 1 . SUBKIT, FASTENER KIT 691U1042-118 . 6 . . . DOUBLER 691U1042-119 . 3 . . . FRAME CLIP 691U1042-120 . 3 . . . FRAME CLIP BACB30NX6K3 40 . . . . BOLT (a) BACB30NX6K3Y 18 . . . . BOLT (a) BACB30NX6K4Y 5 . . . . BOLT (a) BACB30NX6K5Y 3 . . . . BOLT (a) BACB30NX8K4Y 12 . . . . BOLT (a) BACB30VT6K3 12 . . . . BOLT (a) BACC30AC6 29 . . . . COLLAR BACC30AC8 12 . . . . COLLAR BACC30BH6 40 . . . . COLLAR BACC30BL6 12 . . . . COLLAR BACS40R010B040F . 2 . . . SHIM (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 012W6100 are used to determine the part numbers used as substitutes. **Kit 691U1042**
**New Part Number QTY**  **Name Notes -18 -17 -16 -15 -13 -2**  691U1042-2 . . 1 1 . - SUBKIT, FASTENER KIT 691U1042-13 . . . . - . TOP KIT, UPPER DECK WINDOW BELT REPAIR, STA 460 - STA 500 691U1042-15 . . . - 1 . SUBKIT, UPPER DECK WINDOW BELT REPAIR, LEFT SIDE 691U1042-16 . . - . 1 . SUBKIT, UPPER DECK WINDOW BELT REPAIR, RIGHT SIDEJune 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

691U1042-17 . - . 1 . . PART KIT - REPAIR, LEFT SIDE 691U1042-18 - . 1 . . . PART KIT - REPAIR, RIGHT SIDE 691U1042-100 12 12 . . . . REPAIR STRAP 691U1042-101 3 3 . . . . FRAME CLIP 691U1042-102 3 3 . . . . FRAME CLIP 691U1042-103 6 6 . . . . REPAIR ANGLE 691U1042-117 6 6 . . . . STRINGER SEGMENT 691U1042-133 . 1 . . . . REPAIR ANGLE 691U1042-134 1 . . . . . REPAIR ANGLE 691U1042-135 . 1 . . . . REPAIR ANGLE 691U1042-136 1 . . . . . REPAIR ANGLE 691U1042-137 . 1 . . . . REPAIR ANGLE 691U1042-138 1 . . . . . REPAIR ANGLE 691U1042-139 . 1 . . . . REPAIR ANGLE 691U1042-140 1 . . . . . REPAIR ANGLE 691U1042-143 . 1 . . . . REPAIR ANGLE 691U1042-144 1 . . . . . REPAIR ANGLE 691U1042-145 (691U1042-141 optional) . 1 . . . . REPAIR ANGLE 691U1042-146 (691U1042-142 optional) 1 . . . . . REPAIR ANGLE BACB30NX6K3 . . . . . 40 BOLT, PROT RUDING HD (a) BACB30NX6K3Y . . . . . 18 BOLT, PROT RUDING HD (a) BACB30NX6K4 . . . . . 66 BOLT, PROT RUDING HD (a) BACB30NX6K4Y . . . . . 6 BOLT, PROT RUDING HD (a) BACB30NX6K5 . . . . . 66 BOLT (a) BACB30NX6K5Y . . . . . 2 BOLT, PROT RUDING HD (a) BACB30NX8K4 . . . . . 12 HI-LOK (a) BACB30VT6K3 . . . . . 12 BOLT, PROT RUDING HEAD (a) BACB30VT6K5 . . . . . 12 BOLT (a) BACC30AC6 . . . . . 29 COLLAR BACC30BH6 . . . . . 172 COLLAR BACC30BH8 . . . . . 12 COLLAR BACC30BL6 . . . . . 24 COLLAR BACF3F007D019NN 1 1 . . . . FILLER- FLAT BACF3F008D029NN 1 1 . . . . FILLER, FLAT **Kit 691U1042**
**New Part Number QTY**  **Name Notes -18 -17 -16 -15 -13 -2** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

BACR15FV7KE9 . . . . . 51 RIVET (a) BACR15GF7D9 . . . . . 51 RIVET, 100 DEG (a) BACS40R010B048F 2 2 . . . . SHIM, LAMINATED (a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers used as substitutes. **Kit 691U1042**
**New Part Number QTY**  **Name Notes -22 -21 -19**  691U1042-19 . . - SUPPLEMENTAL KIT, UPPER DECK WINDOW BELT REPAIR, STA 460 - STA 500 691U1042-21 . - 1 SUPPLEMENTAL KIT, LEFT SIDE 691U1042-22 - . 1 SUPPLEMENTAL KIT, RIGHT SIDE 691U1042-133 . 1 . REPAIR ANGLE 691U1042-134 1 . . REPAIR ANGLE 691U1042-135 . 1 . REPAIR ANGLE 691U1042-136 1 . . REPAIR ANGLE 691U1042-137 . 1 . REPAIR ANGLE 691U1042-138 1 . . REPAIR ANGLE 691U1042-139 . 1 . REPAIR ANGLE 691U1042-140 1 . . REPAIR ANGLE 691U1042-143 . 1 . REPAIR ANGLE 691U1042-144 1 . . REPAIR ANGLE 691U1042-145 (691U1042-141 optional) . 1 . REPAIR ANGLE 691U1042-146 (691U1042-142 optional) 1 . . REPAIR ANGLE BACF3F007D019NN 1 1 . FILLER- FLAT BACF3F008D029NN 1 1 . FILLER, FLAT **Kit 691U1042**
**New Part Number QTY**  **Name Notes -18 -17 -16 -15 -13 -2** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 2. Parts and Materials Supplied by the Operator:

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. **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. **Part Number / Specification QTY Name Notes**  BMS 5-95 1 Pint Sealant (a) BMS 10-11, Type 1 1 Pint Primer (a) - - Chemical Conversion coating (b) BACB30NX6K6Y 6 Bolt (c) BACR15GF7D( ) - Rivet (d) BACR15FV7KE( ) - Rivet (e) (a) refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Reference: BSOPM 20-43-03 (c) Can be necessary at some frame clip locations when the repair or preventive modification is done (d) For Group 1 airplanes, additional rivets of grip lengths from 7 to 14 can be necessary if removal of rivets from fuselage skin is necessary to allow stringer repair. (e) For Group 2, 3 and 4 airplanes, additional rivets of grip lengths from 7 to 14 can be necessary if removal of rivets from fuselage skin is necessary to allow stringer repair.June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**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 distance, is plus or minus 0.03 inch. — Tolerance on rivet and bolt edge distance is plus or minus 0.05 inch unless otherwise specified. — Angular tolerance is plus or minus 2 degrees. — Hole dimensions for standard solid rivets are given in 747 Structural Repair Manual, Chapter 51. — Torque limits to tighten nuts and bolts are given in 747 Structural Repair Manual, Chapter 51. 4. For approved fastener and process material substitutions, refer to 747 Structural Repair Manual, Chapter 51, Alternate fasteners are given in 747 Structural Repair Manual Chapter 51 and Boeing Drawing 012W6100. 5. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 6. A Detailed Inspection 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. **B. WORK INSTRUCTIONS PART 1 - INSPECTION**  1. Get access to the inspection areas as given in Figure 1. 2. Do a detailed inspection as given in Figure 2. 3. Actions after you do the inspection:June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
a. If you do not find any cracks in any of the inspection areas, either: (1) Install the Preventive Modifications in the areas as given in "PART 3 - PREVENTIVE MODIFICATION" of these Accomplishment Instructions. -OR- (2) Close access to the inspection areas as given in Figure 1 and do the inspections of the un-cracked areas again at the times specified in the Compliance paragraphs of this service bulletin. b. If you find any cracks at any of the inspection areas, do the repair at cracked locations as given in "PART 2 - REPAIR" of these Accomplishment Instructions: And either: (1) Install the Preventive Modifications in the un-cracked areas as given in "PART 3 - PREVENTIVE MODIFICATION" of these Accomplishment Instructions. -OR- (2) Close access to the inspection areas as given in Figure 1 and do the inspections of the un-cracked areas again at the times specified in the Compliance paragraphs of this service bulletin.
**PART 2 - REPAIR** 1. Group 1: For repairs on Group 1 Airplanes, remove and discard Rivets BACR15FV7KE9 (with special "Briles" countersink head) from Fastener Kit 691U1042-2 before you begin a repair at any location. These rivets are not used on Group 1 airplanes. 2. Group 2-4: For repairs on Group 2, 3 and 4 Airplanes, remove and discard Rivets BACR15GF7D9 (with standard 100 degree countersink head) from Fastener Kit 691U1042-2 before you begin a repair at any location. These rivets are not used on Group 2, 3 and 4 airplanes. 3. Repair cracked stringers as given in the table below:. **Stringer Repair Table** Stringer Body Station Figure 8L 460 4 480 6 500 8 8R 460 10 480 12 500 14June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** If you cannot repair a stringer as given in this service bulletin, install a new section of stringer as given below: 1. For cracks at Body Station 460, cut the stringer at Body Stations 480 and 440. Use the Repair parts shown in this service bulletin at Body Station 480 and the stringer splice installation from Chapter 53 of the 747 SRM for Body Station 440 to install a new section of stringer between Body Stations 480 and 440. Install the Preventive Modification parts at Body Station 460. See Chapter 53 of the 747 Structural Repair Manual (SRM) to identify the correct stringer material for the new stringer section. 2. For cracks at Body Station 480, cut the stringer at Body Stations 460 and 500. Use the Repair parts shown in this service bulletin at Body Stations 460 and 500 to install a new section of stringer between Body Stations 460 and 500. Install the Preventive Modification parts at Body Station 480. See Chapter 53 of the 747 Structural Repair Manual (SRM) to identify the correct stringer material for the new stringer section. 3. For cracks at Body Station 500, cut the stringer at Body Stations 480, and remove the stringer end from the existing stringer splice at Body Station 520. Use the Repair parts shown in this service bulletin at Body Station 480 and the stringer splice installation from Chapter 53 of the 747 SRM for Body Station 520 to install a new section of stringer between Body Stations 460 and 500. Install the Preventive Modification parts at Body Station 480. See Chapter 53 of the 747 Structural Repair Manual (SRM) to identify the correct stringer material for the new stringer section. 4. For cracks at multiple body stations (460 thru 500), use a single stringer splice and refer to Notes 1 thru 3 above to determine the splice installation method for the ends of the new stringer section. At frame locations where there is no splice repair installed, install the Preventive Modification parts as given in this service bulletin. 4. Close access as given in Figure 1. 10L 460 16 480 18 500 20 10R 460 22 480 24 500 26 **Stringer Repair Table**June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**PART 3 - PREVENTIVE MODIFICATION** 1. Make modifications to stringers as given in the table below:

2. Close access as given in Figure 1. **Stringer Modification Table** Stringer Body Station Figure 8L 460 3 480 5 500 7 8R 460 9 480 11 500 13 10L 460 15 480 17 500 19 10R 460 21 480 23 500 25**FIGURE 1: ACCESS AND RESTORATION** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 1: ACCESS AND RESTORATION**

SIDEWALL STOAWAGE UNIT (TYPICAL) DOOR

DOOR
LAVATORY U15

PASSENGER COMPARTMENT TYPICAL UPPER DECK 440 STA 520 STA LAVATORY U14

2 11

6 7 4 9

10 8 5 3 12 1N83542

**(SHEET 1 OF 3) FIGURE 1: ACCESS AND RESTORATION**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. ACCESS **STEP TASK NAME AMM SUBJECT NOTES**

1 Remove/Keep Passenger Seats 25-25-01 Between Stations 470 and 520. Operators may have any of the equipment listed at this location. Lavatories 25-40-03 Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03
2 Remove/Keep Sidewall Stowage Units 25-28-15 Between Stations 440 and 520, as necessary 3 Remove/Keep Window Reveals 25-21-02 Between Stations 460 and 520 4 Remove/Keep Ceiling Panel 25-22-03 One panel, forward of Station 460, if installed 5 Remove/Keep Sidewall and Ceiling Insulation 25-21-04 Between Stations 440 and 520

6 Remove/Keep Lavatories, U-16, U-18, or U20 25-40-03 Operators may have any of the equipment listed at this location. Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03 Passenger Seats 25-25-01 RESTORATION **STEP TASK NAME AMM SUBJECT NOTES**

7 Install (Kept) Lavatories, U-16, U-18, or U20 25-40-03 Operators may have any of the equipment listed at this location. Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03 Passenger Seats 25-25-01 8 Install (Kept) Sidewall and Ceiling Insulation 25-21-04 - 9 Install (Kept) Ceiling Panel 25-22-03 - 10 Install (Kept) Window Reveals 25-21-02 - 11 Install (Kept) Sidewall Stowage Units 25-28-15 -

**(SHEET 2 OF 3) FIGURE 1: ACCESS AND RESTORATION**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

12 Install (Kept) Passenger Seats 25-25-01 Between Stations 470 and 520. Operators may have any of the equipment listed at this location. Lavatories 25-40-03 Closet 25-24-00 Flight Deck Crew Rest Lining 25-19-04 Flight Deck Crew Rest Partitions 25-19-03 RESTORATION **STEP TASK NAME AMM SUBJECT NOTES**

**(SHEET 3 OF 3) FIGURE 2: STRINGER INSPECTION**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 2: STRINGER INSPECTION**

LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE S-10 STA 460 STA 480 500 STA

S-8

FWD B SEE

SEE C



### A SEE AN68208

**(SHEET 1 OF 3) FIGURE 2: STRINGER INSPECTION**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

STR-10R OPPOSITE

TYPICAL CRACKS CLIP STR-10L

FRAME STR-8R OPPOSITE TYPICAL CRACKS

STR-8L

EDGE OF WINDOW CUTOUT CLIP

FRAME

FWD FWD

1



### C B 1N68215

**(SHEET 2 OF 3) FIGURE 2: STRINGER INSPECTION**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Stringer Detailed Inspection - Look at both sides of the stringer. Make a note about the locations and lengths of any cracks found

**(SHEET 3 OF 3) FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 3: STRINGER MODIFICAT ION - STRINGER 8L AT BS 460** 

S-10L S-8L STA 460 STA 480 500 STA

FWD B SEE AND C



### A SEE AN68231

**(SHEET 1 OF 5) FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 CLIP

STR-8L

DOUBLER CLIP

(3 LOCATIONS) (4 LOCATIONS)

(3 LOCATIONS) (WITH FILLER) (WITHOUT FILLER)

RADIUS FILLER

STR-8L UP FWD

UP FWD 

### B

C 5 2 1

6 B D 6 6 B C 6 7 8 3 7 8 4 3 A 6

6 3 A 4 AN68293

**(SHEET 2 OF 5) FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-119 1 -
5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 4.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460** 

S-10L S-8L STA 460 STA 480 500 STA

FWD 

### A B SEE SEE AN68325

**(SHEET 1 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CUT IN STRINGER CRACK TIP TO

0.44 MIN. EDGE MARGIN LOCATION OF CUT IN STRINGER

CRACK TIP CRACK STR-8L

STR-8L UP FWD

UP FWD D OR SEE C

E SEE 

### C 1

5 2



### B 3 3

4 3

2 2N68333

**(SHEET 2 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM



### OPTIONAL STRINGER CUT FOR SMALL CRACKS CUT IN STRINGER CRACK TIP TO 0.25 (MINIMUM) CRACK LOCATION OF CUT IN STRINGER

RADIUS IN STRINGER (MAXIMUM) CUT TO TANGENT LINE OF CRACK TIP UP FWD



### D 2 4

2

SEE EW13592

**(SHEET 3 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

STR-8L B
A B
A

UP
FWD



### E 9 19 21 12

7 19 20 15 10

6 19 20 19 20 8 19 20 19 20

13 17 16N68495

**(SHEET 4 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

STR-8L

RADIUS FILLER (WITHOUT FILLER) (WITH FILLER) (4 LOCATIONS)

STR8L REPAIR

SEGMENT STRINGER REPAIR ANGLE STRAPS

FILLER

UP FWD E 3

4 E 11 11 E 3 14 11

14 11 A 3

FWD
INBD A 3 A 3 4 A 4 A 4 A 4 A 4 B 5 C

C 3 C 3

5 C 4 B 4 A 4 A 4 A 4 A A 3



### A-A

B-B 3 F
G D D

11 D D D D D G D

G 18

F 3 4 F 4 F 5 F 5 F 5 F 5 F 5 F 5 F 5 F F 5 5 F 5 F G

G GN68588

**(SHEET 5 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 143 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-143 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners). — The minimum radius is 0.50 inch when you cut the stringer. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Filler BACF3F008D029NN 1 - 8 Put / Hold Repair Angle 691U1042-143 1 - 9 Put / Hold Frame Clip 691U1042-101 1 -
10 Cut Frame Clip 691U1042-101 1 cut the inboard end of the frame clip as necessary to get the correct length. 11 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 12 Install Frame Clip 691U1042-101 1 Use temporary fasteners 13 Put / Hold Repair Angle 691U1042-103 1 - 14 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 15 Install Repair Angle 691U1042-103 1 Use temporary fasteners 16 Cut Repair Strap 691U1042-100 2 - 17 Put / Hold Repair Strap 691U1042-100 2 - 18 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 19 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-101 1 Repair Angle 691U1042-143 1 Filler BACF3F008D029NN 1 Stringer Segment 691U1042-117 1

20 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Filler BACF3F008D029NN 1 Repair Angle 691U1042-143 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 21 Install Frame Clip 691U1042-101 1 refer to Fastener Code E 22 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 5: STRINGER MODIFICAT ION - STRINGER 8L AT BS 480** 

S-8L

S-10L STA STA STA 460 480 500

FWD 

### A AND C B SEE SEE AN68630

**(SHEET 1 OF 5) FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CLIP CLIP

STR-8L

30

(3 LOCATIONS) (WITH FILLER) (WITHOUT FILLER)

RADIUS FILLER DOUBLER

(3 LOCATIONS) (3 LOCATIONS) STR-8L UP FWD

UP FWD 7 8 4 2 1



### B

5



### C 3 A 6 4 A 6

5 A

6 B D 6 6 B C 6 7 8 3N68631

**(SHEET 2 OF 5) FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-119 1 -
5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length and shape 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 6.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480** 

S-10L S-8L 460 480 500 STA STA STA

FWD B SEE



### A SEE AN68655

**(SHEET 1 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM STR-8L

CRACK TIP STR-8L CUT IN STRINGER CRACK TIP TO

0.44 MIN. EDGE MARGIN LOCATION OF CUT IN STRINGER

CRACK FWD UP

UP FWD 1 D OR SEE C

3 3 3 2

5



### B

E SEE 2 4

2



### CN68662

**(SHEET 2 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 61 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM



### OPTIONAL STRINGER CUT FOR SMALL CRACKS CUT IN STRINGER CRACK TIP TO 0.25 (MINIMUM) CRACK LOCATION OF CUT IN STRINGER

RADIUS IN STRINGER (MAXIMUM) CUT TO TANGENT LINE OF CRACK TIP UP FWD



### D 2 4

2

SEE EW13613

**(SHEET 3 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 62 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

STR-8L B
A B
A

UP
FWD 18 19 7 9 8 11 20 18 19 18 16

19 18

6 18 19



### E 14 12 15N68683

**(SHEET 4 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 63 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

STR-8L

STR8L (WITH FILLER)

(3 LOCATIONS)

(WITHOUT FILLER)
RADIUS FILLER

REPAIR

SEGMENT STRINGER REPAIR ANGLE STRAPS 0.38 MIN.

UP FWD 

### A-A 5 E 10

4 E 10

E 3 13 10

13 10 A 3

FWD
INBD A 3 A 3 4 A 4 A 4 A 4 A 4 B 5 C

C 3 C 3

5 C 4 B 4 A 4 A 4 A 4 A A 3



### B-B 3 F
G G D

10 D D D D D G G

G 17

F 3 4 F 4 F 5 F 5 F 5 F 5 F 5 F 5 F 5 F F 5 5 F 5 F G

G G 10N69063

**(SHEET 5 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 64 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 65 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — Unless otherwise specified, the minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-145 (691U1042-141 optional) repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-145 (691U1042-141 optional) as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners). — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 66 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-145 (691U1042-141 opt) 1 - 8 Put / Hold Frame Clip 691U1042-101 1 -

9 Cut Frame Clip 691U1042-101 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-101 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 67 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-101 1 Repair Angle 691U1042-145 (691U1042-141 opt) 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-145 (691U1042-141 opt) 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 68 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 69 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 7: STRINGER MODIFICAT ION - STRINGER 8L AT BS 500** 

S-10L S-8L STA STA STA 460 480 500

FWD B SEE AND C



### A SEE AN69172

**(SHEET 1 OF 5) FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 70 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

(3 LOCATIONS)

(WITHOUT FILLER) CLIP (WITH FILLER)

RADIUS FILLER DOUBLER

(3 LOCATIONS) (3 LOCATIONS) STR-8L CLIP

STR-8L

UP FWD UP FWD

5



### C 7 8 4

3 A 6 3 A 6

4 A

6 B D 6 6 B C 6 7 8 3 

### B 1

2N69173

**(SHEET 2 OF 5) FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 71 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 72 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum, except in fastener holes. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-119 1 -
5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length and shape 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 8.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 73 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 74 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500** 

S-10L S-8L 460 480 500 STA STA STA

FWD B SEE



### A SEE AN69177

**(SHEET 1 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 75 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

0.44 MIN. EDGE MARGIN CRACK TIP TO CUT IN STRINGER STR-8L

TIP CRACK CRACK LOCATION OF CUT IN STRINGER

STR-8L FWD UP

UP FWD D OR SEE C 1

E SEE 3 3


### B 5 2

3



### C 2 2 4N69179

**(SHEET 2 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 76 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP CUT TO TANGENT LINE OF (MAXIMUM) RADIUS IN STRINGER IN STRINGER LOCATION OF CUT

CRACK 0.25 (MINIMUM) CRACK TIP TO CUT IN STRINGER



### OPTIONAL STRINGER CUT FOR SMALL CRACKS FWD UP

SEE E 2 4

2



### DW13688

**(SHEET 3 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 77 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

STR-8L A B B
A

UP FWD 18 19 7



### E 9

8 18 11 20 19 18 16 15

19 18 14 12

6 18 19N69180

**(SHEET 4 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 78 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

SEGMENT STRINGER REPAIR STRAPS REPAIR ANGLE

STR-8L STR-8L

(WITHOUT FILLER) (WITH FILLER)

(3 LOCATIONS)

RADIUS FILLER

UP FWD D 5 F 5 F D 17

F 3

G 3 F 4 F 4 F 5 F 5 F 5 F 5 F 5 F 5 F F 5 5 F D D G D D G
G

D G G

G 10



### B-B 13 10

E 3

4 E 10 10 E 3 5 C 5 C

C 3 C 3



### A-A 13 10 A 3

FWD INBD A 3 A 3 4 A 4 A 4 A 4 A 4 B 4 B 4 A 4 A 4 A 4 A A 3N69181

**(SHEET 5 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 79 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 80 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 139 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-139 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners) — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 81 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-139 1 - 8 Put / Hold Frame Clip 691U1042-101 1 -

9 Cut Frame Clip 691U1042-101 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-101 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 82 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-101 1 Repair Angle 691U1042-139 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-139 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 83 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 84 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 9: STRINGER MODIFICAT ION - STRINGER 8R AT BS 460** 

S-10R S-8R 480 STA 460 STA 500 STA

FWD B SEE AND C



### A SEE AN69185

**(SHEET 1 OF 5) FIGURE 9: STRINGER MODIFICA**  **TION - STRINGER 8R AT BS 460** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 85 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 CLIP

STR-8R

(WITHOUT FILLER) (WITH FILLER)

(3 LOCATIONS) (3 LOCATIONS) CLIP

STR-8R DOUBLER (4 LOCATIONS) RADIUS FILLER UP FWD

FWD UP 

### B

C 1

2

5 3 A 4 A

B 6 D 6 B 6 7 8 4

C 6 7 8 3 3 A 6 6N69195

**(SHEET 2 OF 5) FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 86 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 9: STRINGER MODIFICA**  **TION - STRINGER 8R AT BS 460** June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 87 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-120 1 -
5 Cut Frame Clip 691U1042-120 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-120 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-120 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 10.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 88 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 89 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460** 

S-10R S-8R 460 STA STA 480 500 STA

FWD



### A B SEE SEE AN69210

**(SHEET 1 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 90 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM STR-8R

CRACK

CRACK TIP LOCATION OF CUT IN STRINGER

STR-8R

0.44 MIN. EDGE MARGIN CRACK TIP TO CUT IN STRINGER FWD UP

FWD UP 3 D OR SEE C

2

2 4 1 2

5

3 3



### C E SEE 

### BN69211

**(SHEET 2 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 91 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CUT IN STRINGER CRACK TIP TO 0.25 (MINIMUM)

CUT TO TANGENT LINE OF RADIUS IN STRINGER (MAXIMUM) CRACK TIP CRACK LOCATION OF CUT IN STRINGER



### OPTIONAL STRINGER CUT FOR SMALL CRACKS 2 2 4

SEE E 

### D UP FWDW13869

**(SHEET 3 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 92 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

STR-8R A B B
A

FWD UP 12 21 19 9

20 8 19



### E 10

19 20 17 16

19 20 15 13

6 19 20
7 19 20N69217

**(SHEET 4 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 93 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

STR-8R

STR-8R

FILLER REPAIR ANGLE RADIUS FILLER (WITHOUT FILLER) (4 LOCATIONS)

(WITH FILLER)

SEGMENT STRINGER REPAIR STRAPS

FWD UP 11 11 14 14 11

A 3 A 3 4 A 4 A 4 A 4 A 4 B 5 C 5 C

C 3 C 3 4 B 4 A 4 A 4 A 4 A A 3 A 3

4 F 3 F 4 F D D D D D

G D D D 18

F 5 5 F 5 F 5 F 5 F 5 F 5 F 5 F 5 F 5 F F 3 G G
G G G E 3 4 E 11 E 3 11

INBD FWD



### A-A

B-BN69363

**(SHEET 5 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 94 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 95 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 144 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-144 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners) — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 96 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Filler BACF3F008D029NN 1 - 8 Put / Hold Repair Angle 691U1042-144 1 - 9 Put / Hold Frame Clip 691U1042-102 1 -
10 Cut Frame Clip 691U1042-102 1 cut the inboard end of the frame clip as necessary to get the correct length. 11 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 12 Install Frame Clip 691U1042-102 1 Use temporary fasteners 13 Put / Hold Repair Angle 691U1042-103 1 - 14 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 15 Install Repair Angle 691U1042-103 1 Use temporary fasteners 16 Cut Repair Strap 691U1042-100 2 - 17 Put / Hold Repair Strap 691U1042-100 2 - 18 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 97 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 19 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-102 1 Repair Angle 691U1042-144 1 Filler BACF3F008D029NN 1 Stringer Segment 691U1042-117 1

20 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Filler BACF3F008D029NN 1 Repair Angle 691U1042-144 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 21 Install Frame Clip 691U1042-102 1 refer to Fastener Code E 22 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 98 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 99 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 11: STRINGER MODIFICA TION - STRINGER 8R AT BS 480** 

S-10R S-8R 460 STA 480 STA STA 500

FWD B SEE AND C



### A SEE AN69460

**(SHEET 1 OF 5) FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 100 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

STR-8R
(3 LOCATIONS) CLIP

DOUBLER (WITH FILLER) (WITHOUT FILLER)

(3 LOCATIONS) (3 LOCATIONS) RADIUS FILLER STR-8R CLIP

FWD UP UP FWD

4

C 5

B 6 3 7 8



### C 5 A 6 4 A

B 6 D 6 7 8

6 A 3 6 

### B 2 1N69461

**(SHEET 2 OF 5) FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 101 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 102 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-120 1 -
5 Cut Frame Clip 691U1042-120 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-120 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-120 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 12.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 103 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 104 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480** 

S-10R S-R8 460 STA 480 STA 500 STA

FWD B SEE SEE A



### AN69462

**(SHEET 1 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 105 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM STR-8R STR-8R

CRACK TIP CRACK

0.44 MIN. EDGE MARGIN CRACK TIP TO CUT IN STRINGER IN STRINGER LOCATION OF CUT

FWD UP FWD UP OR SEE C D

3 1

2 2



### C E SEE 4 3 

### B 5

2

3N69464

**(SHEET 2 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 106 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CUT TO TANGENT LINE OF RADIUS IN STRINGER (MAXIMUM) 0.060 MIN. FROM CUT IN STRINGER CRACK TIP TO 0.25 (MINIMUM)



### OPTIONAL STRINGER CUT FOR SMALL CRACKS CRACK TIP IN STRINGER LOCATION OF CUT

CRACK

SEE E 

### D FWD UP 2 4

2W13870

**(SHEET 3 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 107 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

STR-8R B
A A B

FWD UP 8 20 18 11 15 19 18 16

19 7 18



### E 9

19 18 14 12

6 18 19N69468

**(SHEET 4 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 108 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

STR-8R

STR-8R (WITHOUT FILLER) (WITH FILLER)

REPAIR ANGLE SEGMENT STRINGER REPAIR STRAPS RADIUS FILLER (3 LOCATIONS) 0.38 MIN.

FWD UP 10 17 4 E
E 3 13 10 13 10

10 INBD FWD E 3 10

G G G G

D D D D D D G G G G 5 F 5 F F 5 5 F 5 F 5 F 5 F 5 F 5 F 3 F 4 F 5 F F 3 4 F A 3 A 3 4 A 4 A 4 A 4 A 4 B 5 C 5 C
C 3 C 3 4 B 4 A 4 A 4 A 4 A A 3 A 3



### A-A

B-B 10N69474

**(SHEET 5 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 109 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 110 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — Unless otherwise specified, the minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-146 (691U1042-142 optional) repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-146 (691U1042-142 optional) as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners) — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 111 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-146 (691U1042-142 opt) 1 - 8 Put / Hold Frame Clip 691U1042-102 1 -

9 Cut Frame Clip 691U1042-102 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-102 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 112 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-102 1 Repair Angle 691U1042-146 (691U1042-142 opt) 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-146 (691U1042-142 opt) 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 113 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 114 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 13: STRINGER MODIFICAT ION - STRINGER 8R AT BS 500** 

S-10R S-8R 460 STA 480 STA STA 500

FWD 

### A B SEE AND C SEE AN69533

**(SHEET 1 OF 5) FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 115 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CLIP 30

STR-8R STR-8R

(WITH FILLER) (WITHOUT FILLER)

(3 LOCATIONS) (3 LOCATIONS) DOUBLER (3 LOCATIONS) RADIUS FILLER CLIP

FWD UP FWD UP

8 7 4 5 4 A 6 3 A

B 6 B 6 D 6 3 7 8 C 6 2

3 A 6



### C 1



### BN69534

**(SHEET 2 OF 5) FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 116 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 117 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-120 1 -
5 Cut Frame Clip 691U1042-120 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-120 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-120 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 14.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 118 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 119 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500** 

S-10R S-8R 460 STA 480 STA 500 STA

FWD B SEE SEE A



### AN69536

**(SHEET 1 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 120 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CRACK TIP 0.060 MIN. FROM IN STRINGER LOCATION OF CUT

CRACK CRACK TIP TO CUT IN STRINGER
0.44 MIN. EDGE MARGIN STR-8R STR-8R

UP FWD UP FWD

2 3 3 1

4 SEE C OR D

5 2

3

2

E SEE


### C BN69538

**(SHEET 2 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 121 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CUT IN STRINGER CRACK TIP TO 0.25 (MINIMUM)

CUT TO TANGENT LINE OF RADIUS IN STRINGER (MAXIMUM)



### OPTIONAL STRINGER CUT FOR SMALL CRACKS CRACK TIP IN STRINGER LOCATION OF CUT

CRACK

SEE E 

### D FWD UP 2 4

2W13873

**(SHEET 3 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 122 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30

STR-8R A B
A B

FWD UP 7 18 19 15 19 18 16 9

19 18 14 12 8 20 18 11



### E 6 18 19N69539

**(SHEET 4 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 123 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

(3 LOCATIONS)

(WITHOUT FILLER) (WITH FILLER)

RADIUS FILLER STR-8R

REPAIR ANGLE REPAIR STRAPS SEGMENT STRINGER

STR-8R

UP FWD 17 13 10

13 10

10 E 3

10 4 E 10 E 3 FWD INBD A 3 A 3 4 A 4 A 4 A 4 A 4 B

5 C 5 C C 3 C 3 4 B 4 A 4 A 4 A 4 A A 3 A 3

G D D D D D D D G G F 3 4 F 5 F 5 F F 5 5 F 5 F 5 F 5 F 5 F 5 F 5 F 4 F 3 F

G G G G



### B-B A-AN69541

**(SHEET 5 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 124 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 125 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 140 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-140 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners) — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 126 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-140 1 - 8 Put / Hold Frame Clip 691U1042-102 1 -

9 Cut Frame Clip 691U1042-102 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-102 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 127 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-102 1 Repair Angle 691U1042-140 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-140 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 128 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 129 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 15: STRINGER MODIFICA TION - STRINGER 10L AT BS 460** 

S-10L S-8L STA 460 STA 480 500 STA

FWD B SEE AND C



### A SEE AN69546

**(SHEET 1 OF 5) FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 130 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CLIP

30 CLIP STR-10L

DOUBLER SHIM (3 LOCATIONS)

(WITH FILLER) (WITHOUT FILLER) STR-10L (4 LOCATIONS)

RADIUS FILLER (3 LOCATIONS) UP FWD

FWD UP 2

1



### B

7 8 3 7 8 3 5 6 B

C 6
4 7 8

6 6 A

5 A 6 3 A 6 B D 6



### CN69555

**(SHEET 2 OF 5) FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 131 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 132 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16

3 Put / Hold Doubler 691U1042-118 1 - Shim BACS40R010B040F 1 use if the gap between the doubler and the stringer is more than 0.005 inch. Remove laminations from shim until the gap is 0.005 inch or less. 4 Put / Hold Frame Clip 691U1042-120 1 -
5 Cut Frame Clip 691U1042-120 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes
7 Remove Frame Clip 691U1042-120 1 Prepare the parts for final installation Doubler 691U1042-118 1 Shim BACS40R010B040F 1
8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-120 1 Shim BACS40R010B040F 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 16.

**(SHEET 4 OF 5) FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 133 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 - 

### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 5 OF 5) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 134 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460** 

S-10L S-8L STA 460 STA 480 500 STA

FWD B SEE



### A SEE AN69564

**(SHEET 1 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 135 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CRACK TIP TO CUT IN STRINGER CRACK TIP EDGE MARGIN 0.44 MIN. CRACK

STR-10L STR-10L

LOCATION OF CUT IN STRINGER D OR SEE C

2 3

3

E SEE
2 5

UP FWD UP FWD



### C 4 3

1 2



### BN69603

**(SHEET 2 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 136 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CRACK

IN STRINGER LOCATION OF CUT 0.060 MIN. FROM CUT TO TANGENT LINE OF RADIUS IN STRINGER (MAXIMUM)

CRACK TIP TO CUT IN STRINGER 0.25 (MINIMUM) CRACK TIP



### OPTIONAL STRINGER CUT FOR SMALL CRACKS 2

4 2 SEE E



### D UP FWDW13877

**(SHEET 3 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 137 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 STR-10L

B B A A

20 16 19 17
9 19 12 21
10



### E 8

19 15 20 19 20 8 19 20 19 6 20

UP FWD 7 19 20

13N69606

**(SHEET 4 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 138 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

FILLER

REPAIR ANGLE SEGMENT STRINGER
REPAIR STRAPS STR-10L STR-10L RADIUS FILLER

(WITHOUT FILLER) (WITH FILLER)

(4 LOCATIONS)

UP FWD 5 F D D D D D D

5 F 5 F 5 F 5 F 4 F 3 F

18 5 F 5 F F 5 5 F F 3 4 F 5 F 11

G
G G D G G G



### B-B 14 11 FWD A 3 11 4 E 5 E

11

E 3

11 14

INBD A 3 4 A 4 A 4 A 4 A 4 B 5 C 5 C C 3 C 3

4 B 4 A 4 A 4 A 4 A A 3 A 3



### A-A

DN69613

**(SHEET 5 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 139 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 140 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 133 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-133 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners) — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 141 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Filler BACF3F007D019NN 1 -

8 Put / Hold Repair Angle 691U1042-133 1 - Shim BACS40R010B048F 1 use if the gap between the repair angle and the stringer is more than 0.005 inch. Remove laminations from shim until the gap is 0.005 inch or less. 9 Put / Hold Frame Clip 691U1042-102 1 -

10 Cut Frame Clip 691U1042-102 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 11 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 12 Install Frame Clip 691U1042-102 1 Use temporary fasteners 13 Put / Hold Repair Angle 691U1042-103 1 - 14 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 15 Install Repair Angle 691U1042-103 1 Use temporary fasteners **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 142 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. 16 Cut Repair Strap 691U1042-100 2 - 17 Put / Hold Repair Strap 691U1042-100 2 - 18 Drill Holes - refer to Fastener Code F for locations and hole sizes

19 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-102 1 Repair Angle 691U1042-133 1 Shim BACS40R010B048F 1 Filler BACF3F007D019NN 1 Stringer Segment 691U1042-117 1

20 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-133 1 Shim BACS40R010B048F 1 Filler BACF3F007D019NN 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 21 Install Frame Clip 691U1042-102 1 refer to Fastener Code E 22 Install Fasteners - if previously removed. Refer to Fastener Code G **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 143 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin.

**(SHEET 10 OF 10) FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 144 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 17: STRINGER MODIFICAT ION - STRINGER 10L AT BS 480** 

S-10L S-8L STA STA STA 460 480 500

FWD

AND C B SEE 

### A SEE AN69630

**(SHEET 1 OF 5) FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 145 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 CLIP

DOUBLER

(WITH FILLER) (WITHOUT FILLER) (3 LOCATIONS)

STR-10L (3 LOCATIONS)

RADIUS FILLER STR-10L

4 A 6
6 A 5 2

1

C 6 3 7 8
5



### C 6 5 A 6 A 7 8 4 D 6 6 B

FWD UP 6 B 

### B FWD UPN69635

**(SHEET 2 OF 5) FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 146 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 147 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-120 1 -
5 Cut Frame Clip 691U1042-120 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-120 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-120 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 18.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 148 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 149 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480** 

S-8L

S-10L 460 480 500 STA STA STA

FWD B SEE 

### A SEE AN69638

**(SHEET 1 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 150 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP CRACK TIP TO CUT IN STRINGER 0.44 MIN. EDGE MARGIN

IN STRINGER LOCATION OF CUT CRACK STR-10L STR-10L

D OR SEE C 5

2 3

UP FWD UP FWD

4 2



### C E SEE 3

1 2

3



### BN69643

**(SHEET 2 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 151 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

IN STRINGER LOCATION OF CUT 0.060 MIN. FROM CRACK 0.25 (MINIMUM) CRACK TIP CUT TO TANGENT LINE OF (MAXIMUM) RADIUS IN STRINGER

CRACK TIP TO CUT IN STRINGER



### OPTIONAL STRINGER CUT FOR SMALL CRACKS 4 2 2 SEE E

FWD UP



### DW13881

**(SHEET 3 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 152 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 STR-10L A
B A
B 18 19 7 6 18 19



### E 11 8 20 18 9

FWD UP 15 19 18 16 19 18 14 12N69656

**(SHEET 4 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 153 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

REPAIR ANGLE SEGMENT STRINGER STR-10L STR-10L RADIUS FILLER
(WITH FILLER) (WITHOUT FILLER)

REPAIR STRAPS UP FWD 

### A-A 10 5 E

4 E 10 10 5 E

10 13

5 F 5 F D 4 A 4 A 4 A
4 A 4 B

5 F 5 F 5 F 5 F F 5 5 F D D D D D 6 E

13 10

17 10

F 3 4 F G G G

5 F G

5 F 4 F 3 F
G G G

G FWD INBD



### B-B A 3 A 3 C 3 C 3
5 C 5 C 4 B 4 A 4 A 4 A 4 A A 3 A 3N69690

**(SHEET 5 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 154 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 155 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 135 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-135 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners) — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 156 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-135 1 - 8 Put / Hold Frame Clip 691U1042-102 1 -

9 Cut Frame Clip 691U1042-102 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-102 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 157 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-102 1 Repair Angle 691U1042-135 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-135 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 158 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 159 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 19: STRINGER MODIFICA TION - STRINGER 10L AT BS 500** 

S-8L

S-10L STA STA STA 460 480 500

FWD AND C B SEE 

### A SEE AN69745

**(SHEET 1 OF 5) FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 160 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CLIP

30 (WITH FILLER) (WITHOUT FILLER) (3 LOCATIONS)

STR-10L STR-10L

(3 LOCATIONS)

RADIUS FILLER DOUBLER CLIP

C 6

7 8 4 6 3 A
6 4 A

5

6 4 A 5 A D 6 6 B 2

FWD UP FWD UP

6 B

3 7 8 1



### C BN69746

**(SHEET 2 OF 5) FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 161 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 162 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-120 1 -
5 Cut Frame Clip 691U1042-120 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-120 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-120 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 20.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 163 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 164 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500** 

S-8L

S-10L 460 480 500 STA STA STA

FWD B SEE 

### A SEE AN69747

**(SHEET 1 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 165 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM 0.44 MIN. EDGE MARGIN

STR-10L

IN STRINGER LOCATION OF CUT CRACK TIP

CRACK CUT IN STRINGER CRACK TIP TO STR-10L

D OR SEE C

4 2

2 E SEE



### C UP
FWD 3

5

2 1 3

3

FWD UP 

### BN69749

**(SHEET 2 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 166 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

LOCATION OF CUT IN STRINGER 0.060 MIN. FROM CUT IN STRINGER CRACK TIP TO 0.25 (MINIMUM) CRACK RADIUS IN STRINGER (MAXIMUM) CUT TO TANGENT LINE OF CRACK TIP



### OPTIONAL STRINGER CUT FOR SMALL CRACKS 4 2 2 SEE E



### D UP FWDW13894

**(SHEET 3 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 167 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 STR-10L A A
B B 19 6 18

9 20 18 11 8 7 18 19

19 18 14 12

UP



### E FWD 15 19 18 16N69750

**(SHEET 4 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 168 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

(WITHOUT FILLER) (WITH FILLER) RADIUS FILLER

SEGMENT STRINGER REPAIR STRAPS REPAIR ANGLE STR-10L STR-10L

UP FWD 10 4 E

10 E 3

17 5 F 5 F 4 E

5 E

F 3 10

10 10 13

G
G G G D D D D

4 F 5 F 5 F F 5 5 F 5 F 5 F 5 F 5 F 4 F 3 F G G D D G G



### B-B 13 10

4 B C 3 C 3
5 C 5 C



### A-A FWD INBD A 3 A 3 4 A 4 A 4 A 4 A 4 B
4 A 4 A 4 A 4 A A 3 A 3N69751

**(SHEET 5 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 169 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 170 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 137 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-137 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners) — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 171 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-137 1 - 8 Put / Hold Frame Clip 691U1042-102 1 -

9 Cut Frame Clip 691U1042-102 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-102 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 172 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-102 1 Repair Angle 691U1042-137 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-137 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 173 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 174 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 21: STRINGER MODIFICAT ION - STRINGER 10R AT BS 460** 

S-10R S-8R STA 460 STA 480 500 STA

FWD B SEE AND C



### A SEE AN69754

**(SHEET 1 OF 5) FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 175 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

CLIP

(4 LOCATIONS)

(WITHOUT FILLER) (WITH FILLER) CLIP SHIM STR-10R (3 LOCATIONS) (3 LOCATIONS)

DOUBLER RADIUS FILLER

30 STR-10R

FWD UP FWD UP 2

1

3 A

5

6 6 A

5 A 8 4 7 7 8 3 7 8 3 C 6 B 6 D 6 B 6

6



### C BN69758

**(SHEET 2 OF 5) FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 176 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 177 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16

3 Put / Hold Doubler 691U1042-118 1 - Shim BACS40R010B040F 1 use if the gap between the doubler and the stringer is more than 0.005 inch. Remove laminations from shim until the gap is 0.005 inch or less. 4 Put / Hold Frame Clip 691U1042-119 1 -
5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes
7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installation Doubler 691U1042-118 1 Shim BACS40R010B040F 1
8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 Shim BACS40R010B040F 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 16.

**(SHEET 4 OF 5) FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 178 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 - 

### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 5 OF 5) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 179 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460** 

S-10R S-8R 460 STA 480 STA 500 STA

FWD SEE A

B SEE



### AN69772

**(SHEET 1 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 180 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CRACK

CRACK TIP
IN STRINGER LOCATION OF CUT 0.44 MIN. EDGE MARGIN

CRACK TIP TO CUT IN STRINGER STR-10R STR-10R

D SEE C OR 3

2 5 3

2 4 E SEE 2

UP FWD 

### C 3

1

FWD UP 

### BN69794

**(SHEET 2 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 181 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CRACK TIP TO CUT IN STRINGER 0.25 (MINIMUM) CRACK

IN STRINGER LOCATION OF CUT CRACK TIP (MAXIMUM) RADIUS IN STRINGER CUT TO TANGENT LINE OF



### OPTIONAL STRINGER CUT FOR SMALL CRACKS FWD UP 2

4 2 SEE E



### DW13904

**(SHEET 3 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 182 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 STR-10R A
B B A



### E 21 19 12 9
10 20

19 17 7 20 19

8 19 20 8 19 20

19 15 13 20

16

FWD UP 6 19 20N69807

**(SHEET 4 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 183 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

STR-10R (4 LOCATIONS)

REPAIR STRAPS REPAIR ANGLE RADIUS FILLER

(WITHOUT FILLER) (WITH FILLER)

STR-10R

FILLER

SEGMENT STRINGER

UP FWD 11

18



### B-B E 3 11

11 14

D D D G

3 F 3 F 4 F 5 F 5 F 5 F 5 F 5 F 5 F F 5 5 F 5 F 5 F 4 F 11 14

D G D D 

### A-A 5 E 11 4 E

A 3 A 3 4 A 4 A 4 A 4 A 4 B 5 C 5 C C 3 C 3

4 A 4 A 4 A 4 B 4 A A 3 A 3

FWD INBD

G
G

G
G D DN69830

**(SHEET 5 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 184 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 185 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 134 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-134 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners). — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 186 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Filler BACF3F007D019NN 1 -

8 Put / Hold Repair Angle 691U1042-134 1 - Shim BACS40R010B048F 1 use if the gap between the repair angle and the stringer is more than 0.005 inch. Remove laminations from shim until the gap is 0.005 inch or less. 9 Put / Hold Frame Clip 691U1042-101 1 -

10 Cut Frame Clip 691U1042-101 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 11 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 12 Install Frame Clip 691U1042-101 1 Use temporary fasteners 13 Put / Hold Repair Angle 691U1042-103 1 - 14 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 15 Install Repair Angle 691U1042-103 1 Use temporary fasteners **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 187 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. 16 Cut Repair Strap 691U1042-100 2 - 17 Put / Hold Repair Strap 691U1042-100 2 - 18 Drill Holes - refer to Fastener Code F for locations and hole sizes

19 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-101 1 Repair Angle 691U1042-134 1 Shim BACS40R010B048F 1 Filler BACF3F007D019NN 1 Stringer Segment 691U1042-117 1

20 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-134 1 Shim BACS40R010B048F 1 Filler BACF3F007D019NN 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 21 Install Frame Clip 691U1042-101 1 refer to Fastener Code E 22 Install Fasteners - if previously removed. Refer to Fastener Code G **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 188 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin.

**(SHEET 10 OF 10) FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 189 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 23: STRINGER MODIFICATI ON - STRINGER 10R AT BS 480** 

S-10R S-8R 460 STA 480 STA STA 500

FWD SEE A



### A AND C B SEEN69833

**(SHEET 1 OF 5) FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 190 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

DOUBLER

(WITHOUT FILLER) (WITH FILLER) CLIP

30 CLIP

STR-10R STR-10R

(3 LOCATIONS) (3 LOCATIONS)

RADIUS FILLER 6 C 3 7 8 4 A 6

5 A 6 A 5 A 6

8 4 7 2

1


### B

5 B 6 B 6 D 6

FWD UP 6 FWD UP



### CN69836

**(SHEET 2 OF 5) FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 191 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 192 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-119 1 -
5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 24.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 193 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 194 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480** 

S-10R S-8R 460 STA 480 STA 500 STA

FWD


### A SEE A

B SEEN69842

**(SHEET 1 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 195 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP

IN STRINGER LOCATION OF CUT CRACK STR-10R

CRACK TIP TO CUT IN STRINGER 0.44 MIN. EDGE MARGIN STR-10R FWD UP

FWD UP 3

SEE C OR D

2 4 1 5 3 3

2 2

E SEE 

### B

CN69858

**(SHEET 2 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 196 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CRACK TIP TO CUT IN STRINGER 0.25 (MINIMUM) CRACK

LOCATION OF CUT IN STRINGER CUT TO TANGENT LINE OF (MAXIMUM) RADIUS IN STRINGER CRACK TIP



### OPTIONAL STRINGER CUT FOR SMALL CRACKS UP FWD 2

4 2 SEE E



### DW13907

**(SHEET 3 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 197 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 STR-10R A
B B A 7 18 19

20 18 11 8 9 15 19 18 16 19 18 14 12 19 6 18

FWD UP



### EN69963

**(SHEET 4 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 198 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

RADIUS FILLER

STR-10R (WITH FILLER) (WITHOUT FILLER)

STR-10R

STRAPS REPAIR SEGMENT STRINGER REPAIR ANGLE UP FWD 10 4 E 10 5 E

5 F 5 F 4 A 4 A 4 A 4 B 6 E 10 5 E

13 10

10 13 INBD A 3 A 3 4 A 5 C C 3 C 3

5 C 4 B 4 A 4 A 4 A 4 A A 3 A 3

FWD

10

D D

3 F F 3 G G

G G D D D D G G

4 F 5 F 5 F 5 F 5 F 5 F F 5 5 F 5 F 4 F



### B-B 17 G G 

### A-AN69967

**(SHEET 5 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 199 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 200 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 136 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-136 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners). — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 201 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-136 1 - 8 Put / Hold Frame Clip 691U1042-101 1 -

9 Cut Frame Clip 691U1042-101 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-101 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 202 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-101 1 Repair Angle 691U1042-136 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-136 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 203 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10) FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 204 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 25: STRINGER MODIFICAT ION - STRINGER 10R AT BS 500** 

S-10R S-8R 460 STA 480 STA STA 500

FWD



### A AND C B SEE SEE AN69970

**(SHEET 1 OF 5) FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 205 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 (WITHOUT FILLER) STR-10R STR-10R

(WITH FILLER) (3 LOCATIONS)

CLIP DOUBLER (3 LOCATIONS)

RADIUS FILLER CLIP

C 6 3 A 6

4 A 6

5 B 6

8 4 7 3 7 8 B 6 D 6

FWD UP 4 A 5 A 6 1 2

FWD UP



### B

CN69971

**(SHEET 2 OF 5) FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 206 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

**(SHEET 3 OF 5) FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 207 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum radius on a cut part is 0.50 inch. — Remove all burrs and sharp edges from the parts. — All cut surfaces must be 125 microinches smooth. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 - 2 Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 51-00-00, Figure 1, Figure 11, or Figure 16 3 Put / Hold Doubler 691U1042-118 1 - 4 Put / Hold Frame Clip 691U1042-119 1 -
5 Cut Frame Clip 691U1042-119 1 cut the inboard end of the frame clip as necessary to get the correct length. 6 Drill Holes - - refer to Fastener Codes A, B, C and D for locations and hole sizes 7 Remove Frame Clip 691U1042-119 1 Prepare the parts for final installation Doubler 691U1042-118 1 8 Install Doubler 691U1042-118 1 refer to Fastener Codes A, B, C and D Frame Clip 691U1042-119 1 (a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 26.



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 4 OF 5) FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 208 of 218 

### BOEING SERVICE BULLETIN 747-53A2484
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. If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used to determine the part numbers used as substitutes. **CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - B Bolt BACB30NX6K3 0.187 - 0.190 Collar BACC30BH6 - C Bolt BACB30VT6K3 0.187 - 0.190 Collar BACC30BL6 - D Bolt BACB30NX8K4Y 0.278 - 0.281 Collar BACC30AC8 -

**(SHEET 5 OF 5) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 209 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500** 

S-10R S-8R 460 STA 480 STA 500 STA

FWD B SEE 

### A SEE AN69972

**(SHEET 1 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 210 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM 0.44 MIN. EDGE MARGIN

CUT IN STRINGER CRACK TIP TO CRACK

CRACK TIP

STR-10R

IN STRINGER LOCATION OF CUT STR-10R

UP FWD FWD UP

E SEE SEE C D OR 3

1 3 3

5

2

2 2



### C 4 

### BN69973

**(SHEET 2 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 211 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM CRACK TIP TO CUT IN STRINGER 0.25 (MINIMUM) CRACK

LOCATION OF CUT IN STRINGER CUT TO TANGENT LINE OF (MAXIMUM) RADIUS IN STRINGER CRACK TIP



### OPTIONAL STRINGER CUT FOR SMALL CRACKS UP FWD 2

4 2 SEE E



### DW13914

**(SHEET 3 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 212 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

30 STR-10R A
B B A

15 19 18 16 20 18 11 8 6 18 19 18 19 7

19 18 14 12

9

FWD UP



### EN69974

**(SHEET 4 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 213 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

RADIUS FILLER (WITH FILLER) (WITHOUT FILLER)

STR-10R

STR-10R

REPAIR ANGLE SEGMENT REPAIR STRAPS STRINGER UP FWD 4

E 10

E 3 10

10 13

10 13 10 5 E

4 E

4 B 4 A 4 A 4 A 4 A A 3 A 3 A 3 A 3 4 A 4 A 4 A 4 A 4 B C 3 C 3
5 C 5 C

INBD

10

D D D G G

G 17 D D G G D

3 F 4 F 5 F 5 F 5 F 5 F 5 F 5 F 5 F F 5 5 F 5 F 4 F F 3 G
G

G 

### A-A

B-B FWDN69975

**(SHEET 5 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 214 of 218 

### BOEING SERVICE BULLETIN 747-53A2484 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 the location shown in this figure. Parts from Kits 691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

**(SHEET 6 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 215 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

**NOTE:** Before you do the work given in the Step numbers, refer to the list below for general installation data: — The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042- 138 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener locations is 2.0. — The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the fastener diameter). — Use the pilot hole locations in Repair Angle 691U1042-138 as a guide when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent fasteners). — The minimum radius is 0.50 inch when you cut the stringer. — The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed. — Do not remove the full section of the stringer as shown in View C if you can remove all cracks by making the cut in the stringer that is shown in View D — Remove all burrs and sharp edges from the parts. — All surfaces must be 125 microinches smooth after you cut them. — Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except in fastener holes. — Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum. — Install all parts with Sealant BMS 5-95 on mating surfaces. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Remove / Discard Frame Clip - 1 -

2 Inspect Stringer - 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure you can cut the stringer at least 0.060 inch from the crack tip and also have the minimum 1.7 edge margin for adjacent fasteners. See View C and D for stringer cut details.

3 Remove / Discard Fasteners - - at Fastener Code G only if you must cut an entire section of stringer to remove cracks as shown in View C. Remove enough fasteners to allow you to put a thin CRES sheet between stringer and the skin structures.

**(SHEET 7 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 216 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

4 Cut Stringer - 1 Cut the stringer 0.030 inch beyond the crack tip. Cut the minimum amount of stringer segment out to remove cracks. To protect the skin, put a thin CRES sheet between the stringer and the skin if you cut an entire segment out. Inspect Stringer - 1 747 NDT Part 6, Subject 51-00-00, Figure 4 or Figure 23. Make sure there are no cracks found. Cut Stringer - 1 Cut an additional 0.030 inch of stringer to make sure all cracked material is removed. 5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area in the stringer 6 Put / Hold Stringer Segment 691U1042-117 1 - 7 Put / Hold Repair Angle 691U1042-138 1 - 8 Put / Hold Frame Clip 691U1042-101 1 -

9 Cut Frame Clip 691U1042-101 1 cut the inboard end of the frame clip as necessary to get the correct length and shape. 10 Drill Holes - - refer to Fastener Codes A, B, C, D and E for locations and hole sizes 11 Install Frame Clip 691U1042-101 1 Use temporary fasteners 12 Put / Hold Repair Angle 691U1042-103 1 - 13 Drill Holes - refer to Fastener Codes A, B and C for locations and hole sizes 14 Install Repair Angle 691U1042-103 1 Use temporary fasteners 15 Cut Repair Strap 691U1042-100 2 - 16 Put / Hold Repair Strap 691U1042-100 2 - 17 Drill Holes - refer to Fastener Code F for locations and hole sizes **STEP TASK NAME PART NUMBER QTY NOTES**

**(SHEET 8 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 217 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

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. If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the alternative part numbers. 18 Remove Repair Strap 691U1042-100 2 Prepare the parts for final installation Repair Angle 691U1042-103 1 Frame Clip 691U1042-101 1 Repair Angle 691U1042-138 1 Stringer Segment 691U1042-117 1

19 Install Stringer Segment 691U1042-117 1 refer to Fastener Codes A, B, C, D, E and F. Repair Angle 691U1042-138 1 Repair Angle 691U1042-103 1 Repair Strap 691U1042-100 2 20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E 21 Install Fasteners - if previously removed. Refer to Fastener Code G

**CODE NAME PART NUMBER HOLE DIA NOTES** A Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 - B Bolt BACB30NX8K4 0.247 - 0.250 Collar BACC30BH8 - **STEP TASK NAME PART NUMBER QTY NOTES**



### COUNTERSINK FASTENER C D

EXAMPLE OF FASTENER SYMBOL LENGTH/GRIP FASTENER

6F 7 LETTER CODE DIAMETER (OPTIONAL) HEAD LOCATION N = NEAR SIDE F = FAR SIDE (OPTIONAL)

(OPTIONAL)S36173

**(SHEET 9 OF 10) FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500**  June 26, 2003 Revision 1: February 12, 2009 747-53A2484 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 218 of 218 

### BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190 Collar BACC30BL6 -

D Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 Airplanes Only. DO NOT make the existing special countersink deeper in the skin. E Bolt BACB30NX6K( )Y 0.216 - 0.219 Collar BACC30AC6 - F Bolt BACB30NX6K( ) 0.187 - 0.190 Collar BACC30BH6 -

G Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. Do NOT make the existing countersink deeper in the skin. Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 Airplanes Only. Do NOT make the existing special countersink deeper in the skin. **CODE NAME PART NUMBER HOLE DIA NOTES**

**(SHEET 10 OF 10)**