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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2371 Original Issue: July 29, 1993 Revision 2: December 11, 2012 ATA System: 5300 SUBJECT: FUSELAGE - Center Section - STA 780 to STA 940 Upper Deck Tension Tie Inspection, Repair, and 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 © 1993 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Unpublished Work.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: July 29, 1993 747-53A2371Revision 2: December 11, 2012 1 of 59
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 2 of 59 BOEING SERVICE BULLETIN 747-53A2371
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 7 F. Approval ............................................... 1 9 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 1 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 5
3. Parts Modified and Reidentified ................................ 2 6
4. Parts Removed and Not Replaced .............................. 2 6 D. Parts Necessary to Change Spares ................................. 2 6 E. Special Tooling - Price and Availability ............................... 2 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 6
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 8 FIGURE 1: THIS FIGURE IS DELETED (REVISION 2) .......................... 3 1 FIGURE 2: TENSION TIE DETAILED INSPECTION ........................... 3 2 FIGURE 3: REPAIR OR MODIFICATION ................................. 3 4 FIGURE 4: THIS FIGURE IS DELETED (REVISION 2) .......................... 4 8 FIGURE 5: THIS FIGURE IS DELETED (REVISION 2) .......................... 4 9 FIGURE 6: AFTER MODIFICATION INSPECTION ............................ 5 0 FIGURE 7: REPAIR STRAP FABRICATION ............................... 5 2 FIGURE 8: TENSION TIE HIGH FREQUENCY EDDY CURRENT INSPECTION ............ 5 5 APPENDIX A: FLIGHT SAFETY SECTION .................................. 5 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 3 of 59 BOEING SERVICE BULLETIN 747-53A2371
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 4 of 59 BOEING SERVICE BULLETIN 747-53A2371
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2371Original Issue: July 29, 1993 Revision 2: December 11, 2012 ATA System: 5300 SUBJECT: FUSELAGE - Center Section - STA 780 to STA 940 Upper Deck Tension Tie Inspection, Repair, and Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed as given in the original issue or Revision 1 of this of this service bulletin. If the modification given in this service bulletin has not previously been done on all affected tension ties, then Boeing recommends that the modification be done at the time given in Paragraph 1.E., Compliance. In addition, Boeing also recommends that operators do a surface high frequency eddy current (HFEC) inspection of the unmodified aft tension tie channels during the next inspection that is scheduled to be done as given in this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 94-13-06 is related to this service bulletin.
REASON FOR REVISION This revision is sent to recommend that operators accomplish the modification given in this service bulletin.
These sections were changed:
1. In the Summary: Added new Background information related to the revision. Updated Action section to reflect new requirements. Added 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 affected maintenance zones.
4. In paragraph 1.E., Compliance: Added compliance Tables 1, 2, and 3. In previous revisions of this service bulletin, compliance information was given in Figure 1 and Figure 5.
5. In paragraph 1.F., Approval: Updated standard approval paragraphs and added alternative method of compliance statement for AD 94-13-06.
6. In paragraph 1.J., References: Added new references related to this revision.
7. In paragraph 1.K., Publications Affected: Added statement for damage tolerance inspections.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 5 of 59
8. In paragraph 2.B., Added Industry Support Information.
9. In paragraph 3.A., General Information: Updated general notes to current requirements.
10. In paragraph 3.B., Work Instructions, PART 1 - Tension Tie Inspection: Added reference to paragraph
1.E. for compliance information. Deleted the option to defer repair of cracked tension tie aft channels if additional eddy current inspections find that parts are crack free in other areas.
11. In paragraph 3.B., Work Instructions, PART 2 - After Modification Inspection Program: Added reference to paragraph 1.E. for compliance information.
12. In paragraph 3.B., Work Instructions, PART 4 and PART 5: These new sections have been added.
13. Figure 1: This figure (logic diagram) has been deleted. Compliance information is now found in the compliance tables of paragraph 1.E., Compliance.
14. Figure 3: Added example fastener symbol illustration.
15. Figure 4: This figure has been deleted. In previous revisions of this service bulletin, Figure 4 was an inspection needed to defer repair of cracked tension tie aft channels. The option to defer repair of cracked tension ties is no longer allowed.
16. Figure 5: This figure (logic diagram) has been deleted. Compliance information is now found in the compliance tables of paragraph 1.E., Compliance.
17. Figure 8: This new figure is added for high frequency eddy current inspection.
18. Appendix A: This appendix has been updated to reflect revised compliance information.
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 July 29, 1993Original Issue:
April 27, 1995Revision 1:
December 11, 2012Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 6 of 59 BOEING SERVICE BULLETIN 747-53A2371
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2371Original Issue: July 29, 1993 Revision 2: December 11, 2012 ATA System: 5300 SUBJECT: FUSELAGE - Center Section - STA 780 to STA 940 Upper Deck Tension Tie Inspection, Repair, and 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 This service bulletin gives instructions to do inspections, repairs, and modifications to upper deck tension ties.
The affected tension ties are installed from STA 780 to STA 940 aft of the upper deck floor beams. The failure of more than one tension tie can result in rapid depressurization of the airplane.
Six operators have reported 47 tension tie cracks on 13 airplanes. Forty-six of the cracks were in the aft channel of the tension tie. Only one crack was in the forward channel of the tension tie. Cracks usually occur in the upper flange of the aft channel of the tension tie. These fatigue cracks occur because the tension ties bend under cabin pressurization loads.
Boeing Service Bulletin 747-53-2088 gives instructions to change the STA 760 tension tie on passenger airplanes.
That service bulletin also gives instructions to change the STA 780 tension tie on 747-200F airplanes.
At line number 204, the tension tie configuration was changed in production.
A structural reassessment of the 747 airplane was 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 safe operation of 747 airplanes throughout their operational life. From this requirement, the tension ties from STA 780 to 940 were determined to be significant, in that they are critical to airplane structural integrity. The failure of more than one tension tie can result in rapid depressurization of the airplane. Therefore, a flight safety inspection program which will continue throughout the operational life of the airplane is described in this service bulletin.
Subsequent to the release of Revision 1 of this service bulletin, the upper deck tension ties have been determined to be structure that could develop Widespread Fatigue Damage (WFD). Due to the concern of WFD in the tension tie structure, Boeing now recommends that operators accomplish the modification given in this service bulletin.
Previously, the modification was optional unless a crack was found during an inspection.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 7 of 59
For more information about WFD, refer to Boeing Service Letter 747-SL-53-088.
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., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications 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/PartsNoBoeing supplied Kits/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) Do detailed and surface high frequency eddy current (HFEC) inspections for cracks in the outboard ends of each affected tension tie. If cracks are found, repair before any more flights. At tension tie locations where no cracks are found, repeat the inspections until the tension tie is repaired or modified. At tension tie locations that have been repaired or modified, do detailed inspections as given in the After Modification Inspection Program.
If cracks are found in a repaired or modified tension tie, contact Boeing for repair instructions.
This service bulletin contains a flight safety inspection program. The flight safety inspection program is the minimum inspection program to maintain the structural integrity of the affected area of the airplane. An optional economics based inspection, to be done earlier than the flight safety inspection, would usually be included in this type of service bulletin. However, for this area there is no economics based inspection program. The repair necessary when a crack is found in the flight safety inspection is the same as the repair necessary if a crack is found earlier.
EFFECTIVITY 747-100/-200B/-200F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directive AD 94-13-06 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 8 of 59 BOEING SERVICE BULLETIN 747-53A2371
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2371
ALERT ALERT
INDUSTRY SUPPORT INFORMATION This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether you ever filed a warranty claim with Boeing on this service bulletin.
MANPOWER Airplanes Total Task Hours Elapsed Hours Group 1 and 2 113.5 30.5 Group 3 and 7 101.25 27.25 Group 4 89 24 Group 5 and 6 77 21
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.C., Parts Necessary for Each Airplane.
_ SEE DETAIL I DO DETAILED AND HIGH
FREQUENCY EDDY CURRENT
INSPECTIONS FOR CRACKS IN
THE SPECIFIED TENSION TIES STA FROM STATION 780 TO STATION 940
940. IF CRACKS ARE FOUND,
STA REPAIR AS GIVEN IN THIS 780 SERVICE BULLETIN. REPEAT
THE INSPECTIONS AND DO THE
STA TENSION TIE MODIFICATION AT 780 THE TIMES SPECIFIED IN PARAGRAPH 1.E., COMPLIANCE.
STA 940 UP
FWD DETAIL I
VIEW FROM BELOW GROUP 1 AIRPLANE SHOWN C37776
OTHER GROUPS SIMILAR Original Issue: July 29, 1993 Revision 2: December 11, 2012 Export Controlled ECCN: 9E991 - BOEING 747-53A2371 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 59
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 10 of 59 BOEING SERVICE BULLETIN 747-53A2371
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2371 Original Issue: July 29, 1993 Revision 2: December 11, 2012 ATA System: 5300 SUBJECT: FUSELAGE - Center Section - STA 780 to STA 940 Upper Deck Tension Tie Inspection, Repair, and 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplane(s) shown below. Refer to PRR 85901-120RS for data about this change.
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
NOTE: Group 2 airplanes changed as given in Boeing Service Bulletin 747-25-2692, "Equipment/Furnishings - Upper Deck Passenger Compartment Conversion - Upper Deck Extension Station 710 - Station 780 Modification," should be considered Group 3 airplanes for the purposes of this service bulletin.
DESCRIPTIONCONFIGURATIONGROUP 747 airplanes prior to line number 204 with affected tension ties installed from STA 780 to 940. The fasteners used to attach the STA 940 tension tie on Group 1 airplanes is different than on Group 2 airplanes.
-1 747 airplanes prior to line number 204 with affected tension ties installed from STA 780 to 940. The fasteners used to attach the STA 940 tension tie on Group 2 airplanes is different than on Group 1 airplanes.
-2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 11 of 59
DESCRIPTIONCONFIGURATIONGROUP 747 airplanes prior to line number 204, except Group 7 airplanes, with affected tension ties installed only from STA 800 to 940. There is no tension tie at STA 780.
-3 747 airplanes prior to line number 204 with affected tension ties installed only from STA 820 to 940. The tension ties at STA 780 and 800 were removed during a modification at Boeing.
-4 747 airplanes prior to line number 204 with affected tension ties installed only from STA 840 to 940. The tension ties at STA 780, 800, and 820 were removed during a modification at Boeing. The fasteners used to attach the STA 940 tension tie on Group 5 airplanes is different than on Group 6 airplanes.
-5 747 airplanes prior to line number 204 with affected tension ties installed only from STA 840 to 940. The tension ties at STA 780, 800, and 820 were removed during a modification at Boeing. The fasteners used to attach the STA 940 tension tie on Group 6 airplanes is different than on Group 5 airplanes.
-6 747 airplanes prior to line number 204, except Group 3 airplanes, with affected tension ties installed only from STA 800 to STA 940.
On 747-200F airplane line number 168, Service Bulletin 747-53-2088 gives instructions to change the STA 780 tension tie. On all other Group 7 airplanes, there is no tension tie at STA 780.
-7 Airplane Models:
747-100, 747-200B, 747-200F GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA162 2RA163 - RA164 1RA201 - RA203 1RA216 2RA217 4RA245 - RA246 1RA251 - RA255 2RA256 - RA261 5RA301 - RA306 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 1993 747-53A2371Revision 2: December 11, 2012 12 of 59 BOEING SERVICE BULLETIN 747-53A2371