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ALERT ALERT Commercial Airplanes 747

ALERTALERT Service Bulletin Number: 747-53A2507 Original Issue: April 21, 2005 Revision 1: January 14, 2010 ATA System: 5310 SUBJECT: FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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 the Boeing livery 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.

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BLANK PAGE Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 114 BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

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Table of Contents Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 114 BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 32

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 33 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 33

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 36

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 37

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 FIGURE 1: DETAILED INSPECTION OF TENSIO N TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 2: Deleted (Revision 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2). . . . . . . . . . . . . . . 55 FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) . . . . . . . . . . 58 FIGURE 5: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES FROM STA 1120 TO STA 1220 (STAGE 2 ONLY) . . . . . . . . . . . . . . . . . . . . 61 FIGURE 6: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220 . . . . . . . . . . . . . . . . . . . . 67 FIGURE 7: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS . . . . . . . . . . 72 FIGURE 8: DETAILED INSPECTION OF TENSIO N TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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Table of Contents Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 114 BOEING SERVICE BULLETIN 747-53A2507

ALERT ALERT

FIGURE 9: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) . . . . . . . . . . . 80 FIGURE 10: HFEC AND DETAILED INSPECTIONS OF TENSION TIES, STEEL PLATES, AND FRAMES FROM STA 1120 TO STA 1220 (STAGE 2 ONLY) . . . . . . . . . . . . . . . . . . . . 83 FIGURE 11: OVERSIZE HOLE REPAIR STA 1120 TO STA 1220 . . . . . . . . . . . . . . . . . . . 89 FIGURE 12: HFEC INSPECTION OF HOLES FOR INSULATION BLANKET STUDS . . . . . . . . . 94 FIGURE 13: STA 1140 - INSPECTION FOR MISLOCATED ANGLE . . . . . . . . . . . . . . . . . . 97 FIGURE 14: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work) . . . . . . . . . . . . . . . . . . . . . . . . . 102 FIGURE 15: STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140 . . . . . . . . . . . . . . 109 APPENDIX A: Deleted (Revision 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 APPENDIX B: TENSION TIE DISCONNECTION METHODS. . . . . . . . . . . . . . . . . . . . . . 112 APPENDIX C: COMMON FASTENER TYPE REQUIREMENT . . . . . . . . . . . . . . . . . . . . 114

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ALERT ALERT Commercial Airplanes 747

ALERTALERT Service Bulletin Number: 747-53A2507 Revision Transmittal Sheet Original Issue: April 21, 2005 Revision 1: January 14, 2010 ATA System: 5310 SUBJECT: FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2007-23-18 is related to this service bulletin.

AD 2007-23-18 supersedes AD 2006-06-11.

Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 is related to this service bulletin.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2009-NM-024-AD, is related to this service bulletin.

More work is necessary on airplanes inspected as shown in the original issue of this service bulletin.

Compliance times for Stage 1 inspections have been revised to match the requirements of FAA AD 2007-23-

18. This revision also recommends new compliance times for Stage 2 inspections, which is not included in FAA AD 2007-23-18. For airplanes that are past the new compliance time for Stage 2 inspections, continue to do the Stage 1 inspection work at the repeat interval specified until the Stage 2 inspection work is started. Also, a requirement has been added to do eddy current inspection of twelve additional fastener holes in the tension tie inboard of the aluminum straps at STA 1140. Boeing recommends that operators incorporate this additional inspection requirement before 10,000 total flight cycles or within 3,000 flight cycles after the Revision 1 date of this service bulletin, whichever is later.

Group 1, Configuration 1: In addition, more work is necessary on airplanes that have not been modified to SF or BCF. A new inspection of the shear panels for a mislocated angle is recommended within 3,000 flight cycles after the Revision 1 date of this service bulletin.

Group 1, Configuration 2; Group 2-3: In addition, more work is necessary on airplanes that have been modified by Boeing to Special Freighter (SF) or Boeing Converted Freighter (BCF). A new inspection of fastener holes in the frames at locations where tension ties existed before freighter modification is recommended within 3,000 flight cycles after the Revision 1 date of this service bulletin.

For other clarifications or corrections to work instructions that are transmitted with this revision, Boeing recommends that operators incorporate the revised instructions at the next planned Stage 1 or Stage 2 inspection as given in this service bulletin.

No airplanes were added to this service bulletin effectivity.

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ALERT ALERT

REASON FOR REVISION This alert revision is sent to revise compliance times of Stage 1 inspections to match the requirements of AD 2007-23-18, and reduce the initial Stage 2 inspection compliance time. In addition, this revision adds references to Structural Repair Manual (SRM) repairs that were released after the original issue of this service bulletin, and adds new inspection requirements.

Many other changes have also been made in Revision 1. The following list describes important changes.

Changes to this service bulletin include:

— In Summary, Reason, and Description sections: Updated these sections with current data.

— In Paragraph 1.A., Effectivity: Revised effectivity to remove RT631, RT632, RT743, and RT876. These airplanes no longer have tension ties. Also, the Effectivity has been divided into three groups. Group 1 is for passenger airplanes. Groups 2 and 3 are for airplanes modified by Boeing to SF or BCF.

— In Paragraph 1.E., Compliance: This section is changed to recommend new compliance times for Stage 1 and Stage 2 inspections. Also, added compliance information for new inspections, updated existing AD callouts to 2004-07-22 R1, and added reference to AD 2007-23-18.

— In Paragraph 1.F., Approval: Updated this section with Alternative Method of Compliance (AMOC) information.

— In Paragraph 1.J., References: Added new SRM and AD references.

— In Paragraph 1.K., Publications Affected: This section has been revised to add Damage Tolerance Inspection information.

— In Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Updated table to reflect additional parts that may be necessary to support new inspections.

— In Paragraph 3.A., General Information: Some existing notes have been updated and new notes have been added.

— In Paragraph 3.B., Work Instructions: Added reference to SRM repairs. Revised to provide separate instructions for passenger airplanes and SF/BCF airplanes. Also, added instructions for new inspections and revised instructions for additional inspections when a severed tension tie is found.

— In Figure 1: Revised figure to clarify shear web information.

— In Figure 2: This figure is deleted. In previous revisions of this service bulletin, Figure 2 gave instructions for additional inspections that were required if a tension tie was found severed. Boeing now recommends instructions given in the Accomplishment Instructions section and Figure 5 for additional inspections if a tension tie is found severed.

— In Figure 5: Revised figure to clarify shear web information and to clarify the location of view E-E. Revised instructions to require that all removed fasteners be re-installed wet with BMS 3-27 or BMS 3-38 in close ream holes, instead of installed dry in transition fit holes. Note (g) has been revised to remove instruction to contact Boeing for repair instructions. Repair instructions are contained in the Accomplishment Instructions section. Also, some footnotes and footnote identifiers have been revised.

— In Figure 6: Revised figure to clarify shear web information, to remove instruction to contact Boeing for repair instructions, and to add instruction to repair as given in the Accomplishment Instructions. Revised instructions to require that all removed fasteners be re-installed wet with BMS 3-27 or BMS 3-38 in close ream holes, instead of installed dry in transition fit holes. Also, some footnotes and footnote identifiers have been revised.

— New Figure 8 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 8 is similar to Figure 1.

— New Figure 9 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 9 is similar to Figure 4.

— New Figure 10 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 10 is similar to Figure 5.

— New Figure 11 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 11 is similar to Figure 6.

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ALERT ALERT

— New Figure 12 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 12 is similar to Figure 7.

— New Figure 13 has been added for passenger airplanes (airplanes not modified by Boeing to SF or BCF).

Figure 13 is a one-time inspection for a mislocated angle common to the shear panel and tension tie at STA 1140.

— New Figure 14 has been added for airplanes that were modified by Boeing to SF or BCF. Figure 14 is a one-time inspection for cracks in frames at locations where tension ties existed before SF or BCF modification.

— New Figure 15 has been added for all airplanes to specify eddy current inspection of twelve additional fastener holes in the tension tie inboard of the aluminum straps at STA 1140.

— Appendix A has been deleted.

— Appendix B has been revised to delete Method 2 and Method 4 for disconnecting tension ties.

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.

REVISION HISTORY Original Issue: April 21, 2005 Revision 1: January 14, 2010

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ALERT ALERT

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ALERT ALERT Commercial Airplanes 747

ALERTALERT Service Bulletin Number: 747-53A2507 Summary Original Issue: April 21, 2005 Revision 1: January 14, 2010 ATA System: 5310 SUBJECT: FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair

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 for inspection and repair of upper deck tension ties and adjacent frame structure on stretched upper deck (SUD) airplanes. The tension ties have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). WFD could cause tension ties to become severed or disconnected from the frames. Severed or disconnected tension ties and/or frames at multiple locations could result in rapid in-flight decompression of the airplane.

For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.

Tension ties are installed just aft of the floor beams that support the upper deck. Tension ties are installed at Stations (STA) 1120, 1140, 1160, 1180, 1200, and 1220 and extend from the left side to the right side of the airplane.

During routine maintenance an operator found two severed upper deck tension ties at STA 1120 and STA 1140.

The cause of the severed tension ties was fatigue cracking due to an incorrect configuration. As a result of this report, Boeing released Service Bulletin 747-53-2483 which recommended a one time inspection to make sure proper configuration and a crack free condition.

During inspections per Service Bulletin 747-53-2483 one operator found severed tension ties at both STA 1120 and STA 1140 at approximately 14,000 total flight cycles, and a second operator found a severed tension tie at STA 1120 at approximately 28,000 total flight cycles. For these three additional severed tension tie reports, the tension tie configuration was as shown on Boeing Engineering Drawings.

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ALERT ALERT

In addition, before the original issue of this service bulletin, operators reported finding 10 cracks in tension ties, 10 broken fasteners, 9 cracks in frames adjacent to tension ties, and 8 cracks in the shear ties adjacent to the tension ties. The cracks and broken fasteners were at STA 1120, STA 1140, STA 1160, STA 1180, STA 1200, and STA 1220. There were also 4 reports of cracks in the shear web between the STA 1120 and STA 1140 tension ties. For these additional reports, the airplanes had between 7,000 and 28,000 total flight cycles.

Subsequent to the release of the original issue of this service bulletin, one operator reported that three adjacent tension ties were found severed on a 747-300 series airplane with approximately 18,400 flight cycles. Another operator reported that two adjacent tension ties were found severed on a 747-300 series airplane with approximately 14,000 flight cycles. In addition, multiple operators have reported finding cracks in tension ties and frames during inspections per the original issue of this service bulletin. Due to these reports, Boeing finds it necessary to reduce the compliance times and repeat intervals for the inspections recommended by this service bulletin.

In addition to receiving multiple crack reports after the release of the original issue of this service bulletin, Boeing has determined that Stage 2 inspections should include open hole eddy current inspection at twelve additional fastener locations in the STA 1140 tension tie inboard of the aluminum straps. The aluminum straps create load conditions in the STA 1140 tension tie that could cause cracks at these additional fastener locations, which are farther inboard than where eddy current inspections are done on other tension ties.

Also, due to operator reports of a mislocated angle common to the shear panel, a one-time inspection has been added to inspect for the mislocated angle and install a new angle in the correct location, as necessary. A mislocated angle could lead to cracks in the shear panel.

Also, Boeing has determined that it is necessary to add a one-time inspection of fastener holes in the frames of Boeing Special Freighter and Boeing Converted Freighter airplanes at locations where tension ties existed before freighter modification. These fastener holes were not inspected during modification at Boeing.

Inspection is necessary to ensure the fastener holes are crack free.

This service bulletin provides instructions for inspections and repair of the tension ties and frames at the aft end of the upper deck.

The tension ties and frames have been found to be structually significant in that they are critical to the structural integrity of the airplane. Tension tie and frame cracks not found before they reach critical crack lengths can cause in-flight depressurization.

Boeing Service Related Problem (SRP) 747-SRP-53-0215 is related to this service bulletin.

Modification Service Bulletin 747-53A2559 has been released to address Widespread Fatigue Damage (WFD) in the tension ties and adjacent frame structure. Accomplishment of Service Bulletin 74753A2559 will terminate the repeat inspection requirements of this service bulletin. For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.

ACTION Get access to the frame to tension tie joints at STA 1120 through STA 1220. Do Stage 1 or Stage 2 inspections for cracks, and broken, loose, or missing fasteners in the tension ties, the shear webs, and the attached frames.

If cracks are found, or if broken, loose, or missing fasteners are found, do the repairs given in this service bulletin before the airplane is returned to service. Repeat inspections at the specified intervals.

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ALERT ALERT

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 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 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes. Refer to paragraph 1.A.1, Effectivity.

NOTE: For 747-200B airplanes, only airplanes that have been modified to Stretched Upper Deck are affected.

COMPLIANCE Refer to paragraph 1.E, Compliance.

Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 is related to this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive 2007-23-18 is related to this service bulletin. AD 2007-23-18 supersedes AD 2006-06-11.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2009-NM-024-AD, is related to this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection or 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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ALERT ALERT

REPAIR IF NECESSARY AND LOOSE OR MISSING FASTENERS.

INSPECT TENSION TIES FOR CRACKS 1120 STA 1220 STA 1120 STA 1220 STA

REPAIR IF NECESSARY CRACKS AND LOOSE OR MISSING FASTENERS.

TO 2 STRINGERS BELOW TENSION TIES FOR INSPECT FRAMES FROM 2 STRINGERS ABOVE CRACKS. REPAIR IF NECESSARY

INSPECT SHEAR WEBS FOR 1140 STA FWD 466909

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