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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2088 Original Issue: March 08, 1974 Revision 4: January 11, 2013 ATA System: 5300 SUBJECT: FUSELAGE - Body Station 760 or 780 - Frame to Tension Tie Joint - Inspection / Modification 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.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 1989 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner™, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management Company.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 1 of 62
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 2 of 62 BOEING SERVICE BULLETIN 747-53A2088
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F. Approval ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data Supplied with this Service Bulletin: ........................... 2 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 3 M. Software Accomplishment Summary ................................ 2 3
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary for Each Airplane ................................. 2 5
1. Kits/Parts ............................................ 2 5
2. Parts and Materials Supplied by the Operator ........................ 2 6
3. Parts Modified and Reidentified ................................ 2 7
4. Parts Removed and Not Replaced .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 0 FIGURE 1: UNMODIFIED TENSION TIE INSPECTION ......................... 3 3 FIGURE 2: MODIFIED TENSION TIE INSPECTION ........................... 3 6 FIGURE 3: FRAME TENSION TIE MODIFICATION ........................... 3 8 FIGURE 4: THIS FIGURE IS DELETED (REVISION 4) ......................... 4 3 FIGURE 5: THIS FIGURE IS DELETED (REVISION 4) ......................... 4 4 FIGURE 6: THIS FIGURE IS DELETED (REVISION 4) ......................... 4 5 FIGURE 7: ALTERNATIVE MODIFICATION [Group 1] .......................... 4 6 FIGURE 8: ALTERNATIVE MODIFICATION [Group 2] .......................... 5 1 FIGURE 9: ALTERNATIVE MODIFICATION [Group 3] .......................... 5 6 APPENDIX A: ADDENDUM - FLIGHT SAFETY SECTION .......................... 6 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 3 of 62 BOEING SERVICE BULLETIN 747-53A2088
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 4 of 62 BOEING SERVICE BULLETIN 747-53A2088
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2088Original Issue: March 08, 1974 Revision 4: January 11, 2013 ATA System: 5300 SUBJECT: FUSELAGE - Body Station 760 or 780 - Frame to Tension Tie Joint - Inspection / Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on all airplanes that have not been modified in accordance with the original issue, Revision 1, Revision 2 or Revision 3 of this service bulletin. Do a surface High Frequency Eddy Current (HFEC) inspection of the radius common to the aft channel of the tension tie at the next inspection that is scheduled to be done in accordance with Paragraph 1.E., Compliance and accomplish the tension tie modification at the time given in Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directive AD 84-19-01 is related to this service bulletin.
REASON FOR REVISION This revision is sent to add a surface High Frequency Eddy Current (HFEC) inspection of the upper and lower radius common to the aft channel of the tension tie and to add a compliance time for the accomplishment of the tension tie modification.
These sections were changed:
1. Summary Section: Added new Background information related to the revision. Updated Action section to reflect new requirements. Added Federal Aviation Administration (FAA) Airworthiness Directive information to the compliance section. Added new industry support information. Revised Summary illustration text to reflect changed actions.
2. In Paragraph 1.C., Reason: Added new background information related to the revision.
3. In Paragraph 1.D., Description: Updated the action descriptions to reflect new requirements, added "More work" statement and added maintenance zone tables.
4. In Paragraph 1.E., Compliance: Updated compliance times and added new compliance tables.
5. In Paragraph 1.F., Approval: Is updated and a new approval statement added.
6. In Paragraph 1.G., Manpower: Updated manpower estimate.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 5 of 62
7. In Paragraph 1.H., Weight and Balance Changes: Updated weight and balance and added new weight and balance tables.
8. In Paragraph 1.J., References: Added new references related to this revision.
9. In Paragraph 1.K., Publications Affected: Added statement for damage tolerance inspections.
10. In Paragraph 2.B., Industry Support Information: Added new industry support information.
11. In Paragraph 3.A., General Information: Updated general notes to current requirements.
12. In Paragraph 3.B., Work Instructions, PART I - Flight Safety Inspection Program: Added a new surface High Frequency Eddy Current (HFEC) inspection of tension ties. Removed compliance times and removed the reference to report any discrepancies in the Flight Safety Addendum.
13. Figure 1: Added a new detailed inspection and surface High Frequency Eddy Current (HFEC) inspection of tension ties.
14. Figure 2: Updated the AMM reference for ceiling panel removal. Removed the word optional from the view A-A illustration. Changed close visual inspection to a detailed inspection.
15. Figure 3: Added a new section view to the illustration.
16. Figure 4, Figure 5 and Figure 6 logic diagrams have been deleted. The flight safety and economic based inspection program information can be found in Paragraph 1.E., Compliance.
17. Figure 7, Figure 8 and Figure 9: Added and removed typical measurements from the illustrations.
18. APPENDIX A: In table 1 the inspection method and repeat inspection threshold times have been updated.
19. ADDENDUM: Removed the evaluation form from the addendum section.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY March 08, 1974Original Issue:
May 01, 1974Revision 1:
August 26, 1983Revision 2:
September 08, 1994Revision 3:
January 11, 2013Revision 4:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 6 of 62 BOEING SERVICE BULLETIN 747-53A2088
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2088Original Issue: March 08, 1974 Revision 4: January 11, 2013 ATA System: 5300 SUBJECT: FUSELAGE - Body Station 760 or 780 - Frame to Tension Tie Joint - Inspection / Modification
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 Accomplishment of the inspection program detailed in this bulletin will make sure the structural integrity of the Body Station 760 or 780 (as applicable) tension tie throughout the operational life of the airplane. Undetected tension tie cracking could eventually result in in-flight depressurization of the airplane and the inability to withstand current regulatory failsafe loads.
Inspection of the fatigue test airplane after the equivalent of 12,000 flight-cycles revealed a crack in the BS 760 tension tie as a result of bending due to cabin pressurization.
Structural reassessment of the 747 airplane has been conducted under the requirements of Federal Aviation Administration (FAA) Advisory Circular 91-56, in accordance with Federal Aviation Regulation (FAR) 25.571 as amended in 1978, to ensure the safe operation of 747 airplanes throughout their operational life. As a result of this reassessment, the BS 760 or 780 (as applicable) tension tie has been determined to be structurally significant in that it is critical to the structural integrity of the airplane. Tension tie cracking not detected prior to it reaching critical crack length may result in in-flight depressurization of the airplane and the inability to withstand current regulatory failsafe loads.
Therefore, a flight-safety inspection program which will continue throughout the operational life of the airplane is defined in this service bulletin.
The upper deck tension ties have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
For more information about WFD, refer to Boeing Service Letter 747-SL-53-088.
Boeing Fleet Team Digest (FTD) 747 FTD 53-03005 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 7 of 62
Boeing Service Related Problem (SRP) 747-SRP-53-0403 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-120RS) This bulletin contains a flight safety inspection, an economics based inspection, and a modification. The flight safety inspection is the minimum inspection program to maintain the structural integrity of the affected area of the airplane. The economics based inspection, applicable to airplanes on which the modification described herein has not been incorporated, may be used in lieu of the flight safety inspection, at operator's option, until the modification is incorporated. The modification described herein will improve the resistance to cracking of the tension tie but does not alter the structural environment of the tension tie such that a flight safety inspection is not required. It does enable the initiation of the flight safety inspection to be deferred and increases the reinspection interval.
Flight Safety Inspection Program - Do a detailed inspection and a surface High Frequency Eddy Current (HFEC) inspection for cracking in the outboard ends of each affected tension tie. If any cracking is found within specified limits, do the modification. If any cracking is found out of specified limits, contact Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found, repeat the inspections until the tension tie is repaired or modified.
Do the tension tie modification at the time in accordance with Paragraph 1.E., Compliance. The modification consists of replacing the existing tension tie doubler with a longer doubler.
At tension tie locations that have been repaired or modified, do a detailed inspection for any cracking. If any cracking is found in a repaired or modified tension tie, contact Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found, repeat the inspections at the times in accordance with Paragraph
1.E., Compliance.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 8 of 62 BOEING SERVICE BULLETIN 747-53A2088
ALERTALERT
Economic Inspection Program - The economics based inspections (detailed and surface HFEC inspections at operator's option) are used to detect cracking at an earlier stage. If any cracking is found within specified limits do the modification. If cracking is found out of specified limits, contact Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found, repeat the inspections until the tension tie is repaired or modified.
EFFECTIVITY 747-100, 747-200B, 747-200F Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directive AD 84-19-01 is related to this service bulletin.
INDUSTRY SUPPORT INFORMATION This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether the operator previously filed a warranty claim with Boeing on this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
2.505.00Inspection
16.0032.00Modification
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 9 of 62 BOEING SERVICE BULLETIN 747-53A2088
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 10 of 62 BOEING SERVICE BULLETIN 747-53A2088
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2088
ALERT ALERT
DO A DETAILED INSPECTION AND A HIGH
FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE TENSION TIE FOR ANY CRACKING. IF ANY
CRACKING IS FOUND WITHIN SPECIFIED LIMITS, DO THE MODIFICATION. IF CRACKING IS FOUND
OUT OF SPECIFIED LIMITS, CONTACT BOEING FOR
REPAIR INSTRUCTIONS AND DO THE WORK STA 760 (GROUP 1 AND 2) INSTRUCTED BY BOEING. IF NO CRACKING IS STA 780 (GROUP 3) FOUND, DO THE TENSION TIE MODIFICATION IN FRAME ACCORDANCE WITH PARAGRAPH 1.E.,COMPLIANCE
FATIGUE TEST CRACK \ +++++++ + T SUP
INSPECTION AREA INBD <
VIEW A-A
EXISTING CONFIGURATION
DO A POST MODIFICATION DETAILED INSPECTION OF THE TENSION TIE FOR ANY CRACKING. IF ANY CRACKING IS FOUND
CONTACT BOEING FOR REPAIR INSTRUCTIONS AND DO THE WORK INSTRUCTED BY BOEING. IF NO CRACKING IS FOUND, REPEAT THE INSPECTIONS IN ACCORDANCE WITH PARAGRAPH 1.E., COMPLIANCE.
INSPECTION AREA ADD NEW. VIEW A-A
DOUBLER
MODIFIED CONFIGURATION R09726 Original Issue: March 08, 1974 Revision 4: January 11, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2088 Work - See page 1 for details. 11 of 62
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 08, 1974 747-53A2088Revision 4: January 11, 2013 12 of 62 BOEING SERVICE BULLETIN 747-53A2088