Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2880

Original Issue: December 03, 2014

ATA System: 5311

SUBJECT: FUSELAGE - Nose Section - Nose Cargo Door Portal C-3 Frame Upper Closure Fitting

Inspection

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2014 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 15

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 18

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIGURE 2: OVERSIZE FASTENER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FIGURE 3: INSURANCE OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 1: C-3 FRAME UPPER

CLOSURE FITTING INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . 36

APPENDIX B: PART DEMAND INTENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

ALERT

Summary Number: 747-53A2880

Original Issue: December 03, 2014

ATA System: 5311

SUBJECT: FUSELAGE - Nose Section - Nose Cargo Door Portal C-3 Frame Upper Closure Fitting

Inspection

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

This service bulletin gives instruction to inspect the upper closure fitting and connected structure at the nose

cargo door portal C-3 frame for cracks. Cracks in the upper closure fitting that are not found and repaired can

grow with continued use of the airplane and cause a sudden decompression and loss of structural integrity.

Boeing issued service bulletin 747-53A2495 in 2003 to give inspections for cracks in the C-3 frame upper closure

fittings of 747-200F and 747-200C airplanes. Service bulletin 747-53A2495 was issued in response to crack

reports which are described in that service bulletin. The upper closure fittings installed in the airplanes affected

by this service bulletin were shot peened during production to increase fatigue resistance; however, subsequent

analysis has shown that the increase in fatigue resistance may not be sufficient to ensure that upper closure

fitting cracks will be found soon enough with existing inspections per the 747-400 MPD. While there have been

no upper closure fitting cracks found on the airplanes affected by this service bulletin, the potential for cracks

to initiate and grow in the upper closure fitting makes the inspections given in this service bulletin necessary. It

is necessary to do these inspections to make sure that cracks in the upper closure fitting will be found and

repaired before they can affect flight safety.

Boeing Service Related Problem (SRP) 747-SRP-53-0460 is related to this service bulletin.

The table below is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

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Planning Data Affected Reference

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected No Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

A Detailed inspection and a Surface High Frequency Eddy Current (HFEC) inspection for cracks in the upper

closure fitting and connected structure at the nose cargo door portal C-3 frame are to be accomplished. If any

crack is found with these inspections, a repair is to be done in accordance with this service bulletin. The repair

alternatives given in this service bulletin are an oversize fastener repair, a time limited repair, and a part

replacement repair. Repeat inspections are to be done within a compliance time that can be extended by

zero-timing specified fastener holes common to the upper closure fitting.

EFFECTIVITY

All 747-400F airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection and repair procedures given in this service bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2880

Original Issue: December 03, 2014

ATA System: 5311

SUBJECT: FUSELAGE - Nose Section - Nose Cargo Door Portal C-3 Frame Upper Closure Fitting

Inspection

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

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

Serial Number data.

This service bulletin is applicable to 747-400F airplanes in one group. The Variable Numbers and

Group Information for the applicable airplanes is given below.

GROUP CONFIGURATION DESCRIPTION

1 - All 747-400F Airplanes

Airplane Models:

747-400F

Variable Number Group

RL401 - RL403 1

RL411 - RL436 1

RL451 - RL456 1

RL461 - RL462 1

RL471 - RL481 1

RL491 - RL492 1

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Variable Number Group

RL501 - RL502 1

RL511 - RL516 1

RL521 - RL522 1

RL531 - RL534 1

RL551 1

RL561 - RL568 1

RL571 - RL572 1

RL576 - RL577 1

RL579 1

RL581 - RL586 1

RL651 - RL655 1

RL671 - RL675 1

RL681 - RL684 1

RL751 - RL752 1

RM851 - RM859 1

RM861 - RM863 1

RM871 - RM899 1

RM901 - RM906 1

RM911 1

RR701 1

RR721 - RR724 1

RR746 - RR748 1

RR851 - RR856 1

RR861 - RR862 1

RR951 - RR952 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

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ALERT ALERT
C. Reason

This service bulletin gives instruction to inspect the upper closure fitting and connected structure at the

nose cargo door portal C-3 frame for cracks. Cracks in the upper closure fitting that are not found and

repaired can grow with continued use of the airplane and cause a sudden decompression and loss of

structural integrity.

Boeing issued service bulletin 747-53A2495 in 2003 to give inspections for cracks in the C-3 frame

upper closure fittings of 747-200F and 747-200C airplanes. Service bulletin 747-53A2495 was issued

in response to crack reports which are described in that service bulletin. The upper closure fittings

installed in the airplanes affected by this service bulletin were shot peened during production to increase

fatigue resistance; however, subsequent analysis has shown that the increase in fatigue resistance

may not be sufficient to ensure that upper closure fitting cracks will be found soon enough with existing

inspections per the 747-400 MPD. While there have been no upper closure fitting cracks found on the

airplanes affected by this service bulletin, the potential for cracks to initiate and grow in the upper

closure fitting makes the inspections given in this service bulletin necessary. It is necessary to do these

inspections to make sure that cracks in the upper closure fitting will be found and repaired before they

can affect flight safety.

Boeing Service Related Problem (SRP) 747-SRP-53-0460 is related to this service bulletin.

D. Description

A Detailed inspection and a Surface High Frequency Eddy Current (HFEC) inspection for cracks in the

upper closure fitting and connected structure at the nose cargo door portal C-3 frame are to be

accomplished. If any crack is found with these inspections, a repair is to be done in accordance with

this service bulletin. The repair alternatives given in this service bulletin are an oversize fastener repair,

a time limited repair, and a part replacement repair. Repeat inspections are to be done within a

compliance time that can be extended by zero-timing specified fastener holes common to the upper

closure fitting.

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

Affected Maintenance Zones

Model Zone

747-400F 221, 222

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

A logic diagram showing compliance tasks and compliance times is included as an aid in Appendix A.

Do the required actions on both sides of the airplane in accordance with Paragraph 3. Accomplishment

Instructions.

When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When

more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION

numbers for that CONDITION number or OPTION number.

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ALERT ALERT
Table 1: C-3 Frame Upper Closure Fitting Inspection and Repair

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before 28,000 total -

flight cycles, or

2,000 flight cycles

after the original issue date of this

service bulletin,

whichever occurs

later.

Do PART 1: INSPECTION FOR CRACKS IN

UPPER CLOSURE FITTING AND CONNECTED

STRUCTURE. (g)

All airplanes.

Within 3,000 flight 3,000 flight cycles.

cycles after doing

the inspection.

OPTION 1: Repeat PART

1. (g)

CONDITION 1: NO

CRACK FOUND

Before further -

flight.

OPTION 2: Do PART 3:

INSURANCE OVERSIZE.

(b) (e) (f)

Within 20,000 flight 3,000 flight cycles.

cycles after doing

PART 3.

CONDITION 1.1: NO Repeat PART 1. (g)

CRACK FOUND AND

PART 3 ACCOMPLISHED

Before further -

flight.

Do a repair in accordance

with applicable repair instruction given in this

service bulletin. (a) (b)

CONDITION 2: ANY

CRACK FOUND

Before further -

flight.

Do PART 8: SPECIAL

INSTRUCTION REPAIR.

(d)

CONDITION 2.1: REMAINING CRACK IN STRAP (c)

Within 3,000 flight 3,000 flight cycles.

cycles after doing

PART 2 or PART

6.

CONDITION 2.2: ONLY Repeat PART 1. (g)

PART 2 AND/OR PART 6

ACCOMPLISHED

Within 20,000 flight 3,000 flight cycles.

cycles after doing

PART 2 or PART 6

and doing PART 3.

CONDITION 2.3: PART 2 Repeat PART 1. (g)

AND/OR PART 6 ACCOMPLISHED PLUS PART 3

ACCOMPLISHED

Within 10,000 flight -

cycles after doing

PART 4.

Do PART 5: REPLACE

UPPER CLOSURE FITTING.

CONDITION 2.4: PART 4

ACCOMPLISHED

Within 20,000 flight 3,000 flight cycles.

cycles after doing

PART 5.

CONDITION 2.5: PART 5 Repeat PART 1. (g)

ACCOMPLISHED

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ALERT ALERT
Table 1: C-3 Frame Upper Closure Fitting Inspection and Repair

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

(a) Instruction is given in this service bulletin for the following repairs:

– PART 2: OVERSIZE FASTENER REPAIR

– PART 3: INSURANCE OVERSIZE

– PART 4: TIME LIMITED REPAIR

– PART 5: REPLACE UPPER CLOSURE FITTING

– PART 6: REPLACE DOUBLER

– PART 8: SPECIAL INSTRUCTION REPAIR (applicable if a crack found in the strap

cannot be repaired in accordance with PART 2)

(b) PART 2 and PART 3 can be accomplished only if limits specified for maximum hole diameter and minimum edge margin can be maintained.

The minimum edge margin that applies at the strap can be reduced by fabricating and installing a new doubler in accordance with PART 7: FABRICATE / REPLACE DOUBLER.

Thus, accomplishment of PART 2 or PART 3 can include accomplishment of PART 7 also.

(c) CONDITION 2.1 applies if a crack is found in the strap and the crack cannot be removed

in accordance with PART 2.

(d) After a repair is accomplished in accordance with PART 8: SPECIAL INSTRUCTION

REPAIR, the post-repair inspections are specified in the repair instructions.

(e) PART 3 includes an Open Hole HFEC inspection for cracks. If any crack is found with this

inspection, CONDITION 1 is no longer applicable and CONDITION 2: ANY CRACK FOUND

becomes applicable. If this occurs, it may not be possible to complete a repair with existing

parts due to hole size and/or edge margin limits.

(f) Successful accomplishment of PART 3 extends the compliance time for the next inspection;

however, a need to access the same area to accomplish other inspections including those

given in service bulletins 747-53A2500 and 747-53A2753 could make the extension of

the compliance time less advantageous.

(g) PART 1 includes instruction to do a Detailed inspection for cracks in the upper closure

fitting and connected strap and doubler, and a Surface HFEC inspection for cracks in the

upper closure fitting.

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.

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ALERT ALERT
G. Manpower

The table below shows an estimate of the task hours necessary to do the inspection given in this service

bulletin for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust

the estimate with operator task hour data if necessary. The estimate does not include lost time. These

are some examples of lost time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 4.0 2.0

Inspect (FIGURE 1) 1 1.0 1.0

Close Access 2 4.0 2.0

TOTAL FOR EACH AIRPLANE 9.0 5.0

NOTE: More time will be necessary for repairs if cracks are found.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Boeing Service Bulletin 747-53A2495, 747-53A2500, 747-53A2753

b. Boeing Service Related Problem (SRP) 747-SRP-53-0460

c. Service Bulletin Index D6-30300

d. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-01

e. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Procedures 1, 4, 11, 16, 23

f. 747-400 Aircraft Maintenance Manual (AMM) 25-11-01, 25-15-00

g. 747-400 Maintenance Planning Data (MPD)

h. 747-400F Structural Repair Manual (SRM) 51-10-02, 51-20-07, 51-40

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BOEING SERVICE BULLETIN 747-53A2880

ALERT ALERT
2. Data Supplied with this Service Bulletin:

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

Time Limited Repair C-3 Upper Closure 1 A -

Fitting Freighter Nose Door

691U0144

2 A -

3 A -

4 - -

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

Drawing Number Title

65B12887 Frame Installation - Closure, Upper

65B12886 Beam Instl - Body Cab WL 331.5

The table above lists applicable drawings used to prepare this service bulletin. The drawings are

not necessary to make the specified changes, and are not supplied with this service bulletin. The

drawings may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

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

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

Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected

are contained in Paragraph 1.E., Compliance of this service bulletin.

L. Interchangeability and Intermixability of Parts

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

M. Software Accomplishment Summary

Not affected.

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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the parts shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

The parts are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the original issue

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Part Number Name

65B12886-503 Doubler 199 $136.00

65B12888-17 Fitting - Closure Frame, Upper (left side) 199 $21,465.00

65B12888-18 Fitting - Closure Frame, Upper, (right side) 199 $21,465.00

Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to

help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this

service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: A part shown below could be necessary to do a change given in this service bulletin. The

parts will be needed only as noted in the table.

Part Number / QTY Name Notes

Specification

65B12886-503 - Doubler (a)

Fitting - Closure Frame, Upper (left (b)

side)

65B12888-17 1

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ALERT ALERT
Part Number / QTY Name Notes

Specification

Fitting - Closure Frame, Upper, (right (b)

side)

65B12888-18 1

(a) The identified doubler will be needed only if a decision is made to accomplish Paragraph

3.B., Work Instructions, PART 6: REPLACE DOUBLER on either side of the airplane.

(b) The identified fitting will be needed only if a decision is made to accomplish Paragraph

3.B., Work Instructions, PART 5: REPLACE UPPER CLOSURE FITTING.

2. Parts and Materials Supplied by the Operator

The following parts could be necessary to do a change given in this service bulletin. Parts and

materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine

operator part and material supply to make sure all necessary parts and materials are available.

Part Number / QTY Name Notes

Specification

(a) (a) Bolts/Collars (b) (c)

(a) A fastener listed in FIGURE 2 will be needed if a crack is found and repaired in accordance

with Paragraph 3.B., Work Instructions, PART 2: OVERSIZE FASTENER REPAIR.

Fasteners identified in FIGURE 3 will be needed if Paragraph 3.B., Work Instructions,

PART 3: INSURANCE OVERSIZE is accomplished.

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

for supplier data.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternate fasteners.

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.

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BOEING SERVICE BULLETIN 747-53A2880

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 747 Structural Repair Manual,

Chapter 51.

— Non-standard torque values for maintenance tasks are included in the

applicable installation step.

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

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate

full threaded fasteners (screws) needed for installation in this service bulletin.

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.

7. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

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ALERT ALERT
8. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

9. Refer to Appendix A for a logic diagram. The Logic diagram is provided as an aid

only. Information contained in Paragraph 1.E., Compliance is the primary source for

compliance times. Information in Paragraph 3.B., Work Instructions is the primary

source for tasks required for compliance.

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

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

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

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

12. If shading is used, shaded areas in Figures are to separate the non-critical and

non-authoritative information from the critical and authoritative information.

13. Use of colors in Figures is based on guidance from the ATA e-Business Program

(ATA) iSpec 2200.

14. When more than one OPTION is given for a CONDITION, do only one of the OPTION

numbers. When more than one ACTION is given for a CONDITION number or an

OPTION number, do all of the ACTION numbers for that CONDITION number or

OPTION number.

15. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

16. The CONDITIONS, ACTIONS and OPTIONS shown apply to each side of the airplane

independently.

17. Some steps in the Work Instructions are identified as Required for Compliance (RC).

If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps

identified as RC must be done to comply with the AD. Alternative procedures for

steps not identified with RC can be used if the RC steps can still be done as specified,

and the airplane can be put back in a serviceable condition. An Alternative Method

of Compliance (AMOC) is not necessary for deviations to steps that are not identified

as RC.

18. Edge margin (EM) is the distance from the center of the fastener hole to the edge

of the part. The specified minimum value is given as a constant times the hole

diameter D

B. WORK INSTRUCTIONS

1. Remove flight deck sidewall lining and insulation to get access to the C-3 Frame Upper Closure

Fitting where the C-3 frame intersects the body frame at STA 287. Refer to 747-400 AMM 25-15-00

as an accepted procedure for removal of the sidewall lining and insulation. To get easier access

to the inspection area, remove the pilot and copilot seats. Refer to 747-400 AMM 25-11-01 as an

accepted procedure for removal of the seats.

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ALERT ALERT
2. RC - Do PART 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED

STRUCTURE.

3. RC - Do one of the OPTIONS given below that applies for the CONDITION found with the PART

1 inspection.

a. If CONDITION 1: NO CRACK FOUND applies:

(1) OPTION 1: Do steps 4-6 below.

CAUTION: IF OPTION 2 BELOW IS CHOSEN, REMOVE THE FASTENERS CAREFULLY

TO AVOID DAMAGING THE FASTENER HOLES WHEN ACCOMPLISHING

PART 3: INSURANCE OVERSIZE.

(2) OPTION 2: Do PART 3: INSURANCE OVERSIZE and then do steps 4-6 below.

NOTE: – Accomplishment of PART 3 is possible only if the insurance oversize can

be done within specified hole size and edge margin limits. Sufficient edge

margins should be verified before the fasteners are removed.

– PART 3 includes an Open Hole HFEC inspection. If any crack is found with

this inspection, CONDITION 1 is no longer applicable and CONDITION 2:

ANY CRACK FOUND becomes applicable. If this occurs, it may not be

possible to complete a repair with existing parts due to hole size and/or

edge margin limits.

– Successful accomplishment of PART 3 extends the compliance time for the

next inspection as shown in Paragraph 1.E., Compliance; however, a need

to access the same area to accomplish other inspections including those

given in service bulletins 747-53A2500 and 747-53A2753 could make the

extension of the compliance time less advantageous.

b. If CONDITION 2: ANY CRACK FOUND applies:

Accomplish a repair that removes the crack or replaces the cracked part in accordance with

one or more of the repairs listed in the table below and then do steps 4-6 below.

NOTE: Accomplishment of PART 2 is possible only if the crack indication can be

eliminated within specified hole size and edge margin limits.

–

– Accomplishment of PART 3 is possible only if the insurance oversize can be

done within specified hole size and edge margin limits. Accomplishment of PART

3 affects the compliance time for the repeat inspection.

– If accomplishment of PART 2 or PART 3 is prevented by a short edge margin

condition at the strap, a new doubler with increased edge margin can be

fabricated and installed in accordance with PART 7: FABRICATE / REPLACE

DOUBLER. Accomplishment of PART 7 will reduce the minimum edge margin

permitted for the strap; thus, accomplishment of PART 7 could allow for a PART

2, PART 3 repair that would otherwise be prevented.

Applicable Instruction Description

PART 2 (a) OVERSIZE FASTENER REPAIR

PART 2 plus PART 3 (a) OVERSIZE FASTENER REPAIR + INSURANCE OVERSIZE

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ALERT ALERT
Applicable Instruction Description

PART 4 TIME LIMITED REPAIR

PART 5 REPLACE UPPER CLOSURE FITTING

PART 6 REPLACE DOUBLER

PART 6 plus PART 3 (a) REPLACE DOUBLER + INSURANCE OVERSIZE

(a) PART 2 and PART 3 are applicable only if limits specified for maximum hole diameter and minimum edge

margin can be maintained.

The minimum edge margin that applies at the strap can be reduced by fabricating and installing a new

doubler in accordance with PART 7: FABRICATE / REPLACE DOUBLER. Thus, accomplishment of PART

2 or PART 3 can include accomplishment of PART 7 also.

c. CONDITION 2.1: REMAINING CRACK IN STRAP

If a crack is found in the strap that cannot be repaired in accordance with PART 2, do PART

8: SPECIAL INSTRUCTION REPAIR.

4. Install removed flight deck sidewall lining and insulation. Refer to 747-400 AMM 25-15-00 as an

accepted procedure for installation of the sidewall lining and insulation. If removed, reinstall the

pilot and copilot seats. Refer to 747-400 AMM 25-11-01 as an accepted procedure for installation

of the seats.

5. Put the airplane back to a serviceable condition.

6. RC - Repeat PART 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND

CONNECTED STRUCTURE in accordance with Paragraph 1.E., Compliance. Use the compliance

data in Paragraph 1.E., Compliance that applies for the applicable post-change CONDITION

identified in the table below.

Condition After Change Description

CONDITION 2.2: ONLY PART 2 AND/OR PART 6 ACCOMPLISHED

PART 2 AND/OR PART 6 ACCOMPLISHED PLUS

PART 3 ACCOMPLISHED

CONDITION 2.3:

CONDITION 2.4: PART 4 ACCOMPLISHED

CONDITION 2.5: PART 5 ACCOMPLISHED

CONDITION 2.1.1: PART 8 ACCOMPLISHED

PART 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED

STRUCTURE

1. Do a Detailed inspection and a Surface High Frequency Eddy Current (HFEC) inspection for cracks

in the upper closure fitting and connected structure at the nose cargo door portal C-3 frame in

accordance with FIGURE 1. Do these inspections on both sides of the airplane.

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ALERT ALERT
PART 2: OVERSIZE FASTENER REPAIR

1. Oversize the fastener hole to remove material containing the crack and inspect to confirm that no

detectable crack remains in the upper closure fitting or the connected strap and doubler in

accordance with FIGURE 2.

2. Install a new fastener at the oversized hole in accordance with FIGURE 2.

PART 3: INSURANCE OVERSIZE

1. Do an Open Hole HFEC inspection at two fastener holes common to the upper closure fitting in

accordance with FIGURE 3 to confirm there is no detectable crack in the upper closure fitting or

the connected strap and doubler at these locations.

2. Oversize the two inspected fastener holes common to the upper closure fitting and strap and

doubler in accordance with FIGURE 3 to remove material that could contain an undetected crack.

3. Install new fasteners at the oversized holes in accordance with FIGURE 3.

PART 4: TIME LIMITED REPAIR

1. Do a time limited repair in accordance with drawing 691U0144 except where drawing 691U0144

specifies sections of the 747-100/200/300 Structural Repair Manual (SRM), the equivalent section

of the 747-400 SRM is to be used as shown in the table below.

NOTE: After accomplishment of PART 4: TIME LIMITED REPAIR, PART 5: REPLACE

UPPER CLOSURE FITTING must be accomplished within the time given in Paragraph

1.E., Compliance.

–

– Drawing 691U0144 shows a stop drill repair (or a freeze plug repair for a small crack)

and new CRES doublers which must be installed if a stop drill or freeze plug repair

is done.

747-100/200/300 SRM Section 747-400F SRM Section

51-10-01 747-400F SRM 51-10-02

51-10-08 747-400F SRM 51-20-07

51-30 747-400F SRM 51-40

PART 5: REPLACE UPPER CLOSURE FITTING

1. Remove the damaged upper closure fitting and install a new upper closure fitting. Install fitting

65B12888-17 as a left side replacement. Install fitting 65B12888-18 as a right side replacement.

If the minimum edge margin at the strap fastener holes common to the upper closure fitting is 1.0D

or more but less than 1.7D, fabricate and install a replacement doubler along with the new upper

closure fitting in accordance with PART 7: FABRICATE / REPLACE DOUBLER. The edge margin

at fastener holes in the new upper closure fitting is to be 1.7D or more. The edge margin at fastener

holes in the new doubler is to be 2.0D or more.

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ALERT ALERT
NOTE: If there is a freeze plug installed in the strap, the edge margin calculation at the location

of the freeze plug is to be based on the diameter of the hole that holds the freeze plug,

not the fastener hole size.

If CONDITION 2.4: PART 4 ACCOMPLISHED is applicable and the minimum edge margin at the

strap fastener holes common to the upper closure fitting is 1.7D or more, install a new 65B12886-503

doubler along with the new upper closure fitting. The minimum permitted edge margin at fastener

holes in the new upper closure fitting and the new doubler is 1.7D.

For PART 5 the maximum permitted hole size for fasteners common to the new upper closure

fitting, new doubler and strap are as follows:

Maximum Hole DiameterFastener Location

The maximum diameter specified in FIGURE 2.Bottom two fasteners common to the upper closure fitting / doubler / strap.

Fasteners common to the upper closure fitting / doubler / strap other than the bottom 0.281 inch.

two fasteners.

Contact Boeing if additional instruction is needed to install a new upper closure fitting. If the new

fitting cannot be installed within the edge margin and fastener hole size limits given above, contact

Boeing to get special instruction and install the new fitting in accordance with the special instruction

from Boeing.

PART 6: REPLACE DOUBLER

1. Remove the damaged doubler and install a new 65B12886-503 doubler. The limits for fastener

hole size and edge margin given in this service bulletin apply for the installation of the new doubler.

PART 7: FABRICATE / REPLACE DOUBLER

1. Fabricate a new replacement doubler that is sized to give 2.0D or more edge margin at all fastener

locations. Make the doubler 0.090 inch thick from 7075-T6 Clad sheet per QQ-A-250/13.

NOTE: Accomplishment of PART 7 could allow for a PART 2 or PART 3 repair that would

otherwise be prevented by a short edge margin condition at the strap. If PART 7 is

accomplished, the minimum edge margin permitted for the strap changes from 1.7D to

1.0D.

2. Apply Chemical conversion coating to the surfaces of the doubler. Refer to SOPM 20-43-03 as an

accepted procedure.

3. Apply one layer of BMS 10-11, Type 1 primer. Refer to SOPM 20-41-02 as an accepted procedure.

4. Remove the existing doubler and install the replacement doubler with 2.0D or more edge margin

at all the fastener holes common to the doubler.

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BOEING SERVICE BULLETIN 747-53A2880

ALERT ALERT
PART 8: SPECIAL INSTRUCTION REPAIR

1. If a crack is found in the strap and the crack cannot be repaired in accordance with PART 2:

OVERSIZE FASTENER REPAIR, contact Boeing to get special repair and post-repair inspection

instruction and do the repair and post-repair inspections.

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ALERT ALERT
FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2880

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

Step Task Name Identification Qty More Data

Upper Closure Fitting / - - (a)

Strap / Doubler

1 Inspect

2 Inspect Upper Closure Fitting - - (b)

(a) Do a Detailed inspection for cracks. Inspect all visible parts of the upper closure fitting, strap and doubler

in the area shown.

FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE

(SHEET 2 OF 3)

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ALERT ALERT
Step Task Name Identification Qty More Data

(b) Do a Surface HFEC inspection of the upper closure fitting for cracks in accordance with 747 NDT Manual

Part 6, 51-00-00, Procedure 4 or 23. Inspect the surface of the upper closure fitting around the heads of

the two fasteners shown in Detail C of this figure.

FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 2: OVERSIZE FASTENER REPAIR

(SHEET 1 OF 4)

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

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

Step Task Name Identification Qty More Data

1 Drill / Ream Fastener Hole - - (a)

Upper Closure Fitting / - - (b)

Strap / Doubler

2 Inspect

3 Install (New) Fastener - - (c)

(a) The fastener hole is to be oversized to remove material containing the crack. There are two limitations

for this step as follows:

1. The oversized hole must not exceed the maximum diameter for the accomplishment of PART

2: OVERSIZE FASTENER REPAIR given in the table below. Note that accomplishment of PART

3: INSURANCE OVERSIZE will be possible only if the oversize is kept within the limit for accomplishment of PART 3 given in the table below.

2. The edge margin for the upper closure fitting, strap and doubler is not to be less than the value

specified in the table below.

(b) Do an Open Hole HFEC inspection for cracks in the upper closure fitting, strap and doubler in accordance

with 747 NDT Manual Part 6, 51-00-00, Figures 1, 11, or 16.

If the hole size is less than the maximum permitted size and a crack is indicated with this inspection, repeat

steps 1 and 2 as necessary/permitted.

(c) Install the fastener identified in the fastener table below that is applicable for the final hole size. This step

is not applicable if an additional oversize will be made to accomplish PART 3: INSURANCE OVERSIZE.

Maximum Hole Diameter that Permits Accomplishment of

PART 3: INSURANCE

OVERSIZE

Maximum Hole Diameter for Accomplishment of PART 2:

OVERSIZE FASTENER REPAIR

Initial Hole Size

3/16 0.281 0.219

FIGURE 2: OVERSIZE FASTENER REPAIR

(SHEET 2 OF 4)

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ALERT ALERT
Maximum Hole Diameter that Permits Accomplishment of

PART 3: INSURANCE

OVERSIZE

Maximum Hole Diameter for Accomplishment of PART 2:

OVERSIZE FASTENER REPAIR

Initial Hole Size

1/4 0.344 0.281

Part Minimum Edge Margin (a)

Upper Closure Fitting 1.7D

Doubler 1.7D

1.7D if the doubler edge margin is not 2.0D or more at

all fastener holes common to the strap and doubler.

Strap

1.0D if the doubler edge margin is 2.0D or more at all

fastener holes common to the strap and doubler. (b)

(a) Edge margin is the distance from the center of the fastener hole to the edge of the part. The specified

minimum value is given as a constant times the final hole diameter D.

(b) PART 7: FABRICATE / REPLACE DOUBLER gives instruction to fabricate and install a replacement

doubler that has 2.0D or more edge margin at all fastener holes common to the strap and doubler.

The code shown below agrees with the letter shown in the upper left corner of the fastener symbols in the figure.

The applicable fastener is the fastener that applies for the diameter of the fastener hole.

Code Name Identification Qty Hole Dia More Data

A Bolt BACB30NX6K6X - 0.200 - 0.203 -

Collar BACC30BH6 - - -

Bolt BACB30NX6K6Y - 0.216 - 0.219 -

Collar BACC30AC6 - - -

Bolt BACB30NX8K6 - 0.247 - 0.250 -

Collar BACC30BH8 - - -

Bolt BACB30NX8K6X - 0.263 - 0.266 -

Collar BACC30BH8 - - -

Bolt BACB30NX8K6Y - 0.278 - 0.281 -

Collar BACC30AC8 - -

FIGURE 2: OVERSIZE FASTENER REPAIR

(SHEET 3 OF 4)

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ALERT ALERT
Code Name Identification Qty Hole Dia More Data

B Bolt BACB30NX8K6X - 0.263 - 0.266

Collar BACC30BH8 - -

Bolt BACB30NX8K6Y - 0.278 - 0.281

Collar BACC30AC8 - -

Bolt BACB30NX10K6 - 0.309 - 0.313 -

Collar BACC30BH10 - -

Bolt BACB30NX10K6X - 0.325 - 0.328 -

Collar BACC30BH10 - - -

Bolt BACB30NX10K6Y - 0.341 - 0.344 -

Collar BACC30AC10 - - -

FIGURE 2: OVERSIZE FASTENER REPAIR

(SHEET 4 OF 4)

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ALERT ALERT
FIGURE 3: INSURANCE OVERSIZE

(SHEET 1 OF 3)

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

NOTE: If the work given in this figure is accomplished after a crack is removed in accordance with FIGURE 2,

the work given in step 1 and step 2 of this figure will already have been accomplished in accordance

with FIGURE 2 . The Open Hole HFEC inspection with no crack indication accomplished in accordance

with FIGURE 2 is a satisfactory inspection for step 2 of this figure.

Step Task Name Identification Qty More Data

1 Remove Fasteners - 2 -

Upper Closure Fitting / - - (a) (b)

Strap / Doubler

2 Inspect

3 Drill / Ream Fastener Hole - - (c)

4 Install (New) Fasteners - 2 (d)

(a) Do an Open Hole HFEC inspection for cracks in the upper closure fitting, strap and doubler in accordance

with 747 NDT Manual Part 6, 51-00-00, Figures 1, 11, or 16.

(b) If any crack is found with the inspection given in this step, the remainder of the work given in this figure

is not applicable.

(c) The diameter of the fastener hole that contains no detectable crack is to be increased by 1/16 inch to remove material that could contain an undetected crack. The hole size is not to exceed the maximum size

given in the table below and the edge margin is not to be less than the minimum value given in the table

below. The hole diameter is to be within the limits given in the fastener table for the fastener to be installed.

(d) Install the fastener identified in the fastener table below that is applicable for the final hole size.

Initial Hole Size Maximum Hole Diameter

3/16 0.281

1/4 0.344

Part Minimum Edge Margin (a)

Upper Closure Fitting 1.7D

FIGURE 3: INSURANCE OVERSIZE

(SHEET 2 OF 3)

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Part Minimum Edge Margin (a)

Doubler 1.7D

1.7D if the doubler edge margin is not 2.0D or more at

all fastener holes common to the strap and doubler.

Strap

1.0D if the doubler edge margin is 2.0D or more at all

fastener holes common to the strap and doubler. (b)

(a) Edge margin is the distance from the center of the fastener hole to the edge of the part. The specified

minimum value is given as a constant times the final hole diameter D.

(b) PART 7: FABRICATE / REPLACE DOUBLER gives instruction to fabricate and install a replacement

doubler that has 2.0D or more edge margin at all fastener holes common to the strap and doubler.

Code Name Identification Qty Hole Dia More Data

C Bolt BACB30NX8K6 - 0.247 - 0.250 -

Collar BACC30BH8 - - -

Bolt BACB30NX8K6X - 0.263 - 0.266 -

Collar BACC30BH8 - - -

Bolt BACB30NX8K6Y - 0.278 - 0.281 -

Collar BACC30AC8 - -

D Bolt BACB30NX10K6 - 0.309 - 0.313 -

Collar BACC30BH10 - -

Bolt BACB30NX10K6X - 0.325 - 0.328 -

Collar BACC30BH10 - - -

Bolt BACB30NX10K6Y - 0.341 - 0.344 -

Collar BACC30AC10 - - -

FIGURE 3: INSURANCE OVERSIZE

(SHEET 3 OF 3)

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ALERT ALERT
A description for each PART and CONDITION included in the logic diagram is given in the tables below. The

actions associated with each PART are to be done in accordance with Paragraph 3. Accomplishment Instructions.

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 1: C-3 FRAME UPPER

CLOSURE FITTING INSPECTION AND REPAIR

(SHEET 1 OF 2)

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ALERT ALERT
Part Description

INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED

STRUCTURE

PART 1:

PART 2: OVERSIZE FASTENER REPAIR (a) (c)

PART 3: INSURANCE OVERSIZE (b) (c)

PART 4: TIME LIMITED REPAIR

PART 5: REPLACE UPPER CLOSURE FITTING

PART 6: REPLACE DOUBLER (c)

PART 7: FABRICATE / REPLACE DOUBLER (c)

PART 8: SPECIAL INSTRUCTION REPAIR (d)

(a) Accomplishment of PART 2 is possible only if the crack indication can be eliminated within specified hole

size and edge margin limits.

(b) Accomplishment of PART 3 is possible only if the insurance oversize can be done within specified hole

size and edge margin limits.

(c) If accomplishment of PART 2 or PART 3 is prevented by a short edge margin condition at the strap, a

new doubler with increased edge margin can be fabricated and installed in accordance with PART 7 to

reduce the minimum edge margin permitted for the strap. Accomplishment of PART 7 with PART 2 or

PART 3 allows the PART 2 or PART 3 repair to be done with edge margin = 1.0D (versus 1.7D) at the

strap.

(d) Special instruction will be provided by Boeing to repair a crack in the strap that cannot be repaired in accordance with PART 2. Special instruction will also be provided for post-repair inspections that will apply

after the special repair is accomplished.

Condition Description

CONDITION 1: NO CRACK FOUND

CONDITION 1.1 NO CRACK FOUND AND PART 3 ACCOMPLISHED

CONDITION 2: ANY CRACK FOUND

CONDITION 2.1 REMAINING CRACK IN STRAP (a)

CONDITION 2.1.1 PART 8 ACCOMPLISHED

CONDITION 2.2 ONLY PART 2 AND/OR PART 6 ACCOMPLISHED

CONDITION 2.3 PART 2 AND/OR PART 6 ACCOMPLISHED PLUS PART 3 ACCOMPLISHED

CONDITION 2.4 PART 4 ACCOMPLISHED

CONDITION 2.5 PART 5 ACCOMPLISHED

(a) CONDITION 2.1 applies if a crack found in the strap cannot be repaired in accordance with PART 2.

APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 1: C-3 FRAME UPPER

CLOSURE FITTING INSPECTION AND REPAIR

(SHEET 2 OF 2)

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APPENDIX B: PART DEMAND INTENT

(SHEET 1 OF 1)

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ALERT ALERT