# Boeing Alert Service Bulletin 747-53A2507: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2009-0607; AD 2012-15-13 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-53A2507](https://openairdocs.org/service-documents/boeing/747-53a2507.md) - Title as filed: U.S. DOT/FAA - Service Bulletin - Pages: 114 - PDF: https://openairdocs.org/files/sha256/3b/40/3b407e2f47288908998b7731af607e27fe444cc3d5a3e9eb13fd9e1e79d57950 - Page: https://openairdocs.org/service-documents/boeing/747-53a2507/file/3b407e2f4728 ## Text Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 114 ALERT ALERT Commercial Airplanes 747 ALERTALERT Service Bulletin Number: 747-53A2507 Original Issue: April 21, 2005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Tie - Inspection and Repair BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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. ### Page 2 BLANK PAGE Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT BLANK PAGE ### Page 3 Table of Contents Original Issue: April 21, 2005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 ### Page 4 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 ### Page 5 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 114 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. ### Page 6 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 114 BOEING SERVICE BULLETIN 747-53A2507 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. ### Page 7 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 114 BOEING SERVICE BULLETIN 747-53A2507 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 ### Page 8 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT BLANK PAGE ### Page 9 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 114 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. ### Page 10 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 114 BOEING SERVICE BULLETIN 747-53A2507 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. ### Page 11 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 114 BOEING SERVICE BULLETIN 747-53A2507 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. ### Page 12 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 114 BOEING SERVICE BULLETIN 747-53A2507 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 ### Page 13 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 114 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 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 airplanes shown below. Refer to PRR 85901-53RS for data about this change. Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. ### Page 14 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT NOTE: Some airplanes were delivered with Extended Upper Deck Modifications that installed floor beams aft of Station 740. These airplanes are not the same as airplanes delivered with a Stretched Upper Deck (SUD), which includes 747-300, 747-400 passenger airplanes, and some 747-100 and 747-200 airplanes that have been modified to SUD. NOTE: Revision 1 changed the effectivity to remove RT631, RT632, RT743, and RT876. These airplanes have been modified to Large Cargo Freighter (LCF) configuration and no longer have tension ties. Airplane models: 747-100B SUD 747-200B 747-300 747-400 747-400D IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AEROLINEAS ARGENTINAS (ARG) 1 RT701–RT702 RT704 AEROSUR (REO) 1R M 3 5 4 R S 2 3 5 AIR ATLANTA ICELANDIC (AID) 1 RS211 RS233 RS237 RS332–RS333 RT515 RT777 RT834 3 RT776 AIR CARGO GERMANY (CGU) 1 RT633–RT634 AIR CHINA (BEJ) 1 RM341 RM811–RM813 RT034–RT035 RT878–RT880 3 RT033 GROUP CONFIGURATION DESCRIPTION 1 - 747-100B/-200B/-300/-400/-400D airplanes, built in a Stretched Upper Deck (SUD) configuration, or modified to SUD by Boeing, except airplanes modified by Boeing to Special Freighter (SF) or Boeing Converted Freighter (BCF) configuration before Revision 1. 1 Group 1 airplane that have not been modified by Boeing to SF or BCF. 2 Group 1 airplanes that are modified to BCF configuration after release of Revision 1 of this service bulletin. 2 - 747-200B SUD and -300 airplanes that have been modified by Boeing to SF configuration. 3 - 747-400 airplanes that have been modified by Boeing to BCF configuration before release of Revision 1 of this service bulletin. ### Page 15 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT AIR CHINA CARGO (CGC) 1 RT101 RT103 3 RT031–RT032 AIR FRANCE (AFA) 1 RM401–RM403 RT073–RT074 RT121 RT591 RT711–RT716 3 RT071–RT072 RT075 RT751 AIR INDIA (AIN) 1 RS781–RS782 RU001–RU006 AIR NEW ZEALAND (ANZ) 1 RM082 RM191–RM192 RT671–RT673 RT703 RT932 AIR PACIFIC (APC) 1 RT502 RT504 AIR PULLMANTUR (PUL) 1 RT523 RT525 RT749 AIRBRIDGE CARGO (ABM) 2 RS762 AL WAFEER (WFR) 1 RU016 ALL NIPPON AIRWAYS (ANA) 1 RT753–RT755 RU831 RU833–RU841 ASIANA AIRLINES (AAR) 1 RM071 RT131–RT136 RU032 ATLAS AIR (TLS) 1 RM232–RM233 2 RS722 3 RT752 BAHRAIN ROYAL FLIGHT (BHR) 1R M 4 2 6 BRITISH AIRWAYS (BAB) 1 RM096–RM097 RM136–RM145 RM261–RM264 RT471–RT499 RU121–RU132 CATHAY PACIFIC AIRWAYS (CAT) 1 RT451–RT455 RT457–RT460 RT462–RT469 RT511–RT512 RT514 RT517 RT522 RT529 3 RT456 RT461 RT508 RT518–RT519 RT524 RT528 RT781–RT782 RT837 ### Page 16 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT CHINA AIRLINES (CHI) 1 RM021–RM024 RM441–RM443 RM445 RT636–RT640 CORSAIR (COR) 1 RS239–RS240 RT613–RT614 RT616 RT618–RT619 RT621 DRAGONAIR (DRG) 3 RT510 RT513 RT516 DUBAI AIR WING (DAW) 1 RM167–RM168 RT102 EAGLE AVIATION EUROPE (EAU) 1 RT831 EL AL ISRAEL AIRLINES (ELA) 1 RM091 RT527 RU081–RU083 EVA AIR (EVA) 1 RM116–RM117 RT162–RT163 RT165–RT168 RT951–RT955 EXPORT RESTRICTED AIRPLANES (YWV) 1 RS751–RS752 RT602 RT606 RT620 FINOVA (GRB) 1R S 7 6 1 GARUDA INDONESIA (GIA) 1 RT931 RU061–RU062 GECAS (GEF) 1 RT412 RT615 RT622 GENERIC CUSTOMER/SUPPLIER (XXX) 1 RD382 RS331 GOVERNMENT OF JAPAN (JAG) 1 RT681–RT682 GREAT WALL AIRLINES (GWL) 3 RT520 HIS MAJESTY THE SULTAN'S FLIGHT (BWN) 1 RT440 JAL INTERNATIONAL (JAL) 1 RM126–RM127 RM129–RM132 RM316–RM318 RS251–RS252 RS259 RT641 RT643–RT654 RT861–RT864 RT966 RU801–RU809 3 RM128 RT642 RT655–RT657 RT967 ### Page 17 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT KALITTA AIR (KAC) 3 RT021–RT022 KINGDOM HOLDING COMPANY (KBA) 1 RT877 KLM - ROYAL DUTCH AIRLINES (KLM) 1 RM801–RM803 RT001–RT014 RT531–RT535 KOREAN AIR (KAL) 1 RM011–RM013 RT061 RT571 RT577–RT588 RT590 RT811–RT814 3 RT572–RT576 KUWAIT AIRWAYS (KUW) 1 RT151 LION AIR (MLI) 1 RT503 RT505 LUFTHANSA GERMAN AIRLINES (DLH) 1 RM001–RM007 RT041–RT047 RT431–RT439 RT441–RT447 MALAYSIA AIRLINES (MAS) 1 RM036–RM040 RM366–RM367 RT744 RT746 RT748 RT750 RU017 MARTINAIR HOLLAND (MTH) 3 RT501 RT506–RT507 RT509 MAX AIR (MXE) 1 RS266–RS267 NORTHWEST AIRLINES (NWA) 1 RM241–RM246 RT401–RT410 OMAN ROYAL FLIGHT (RFO) 1R M 0 1 0 ORIENT THAI AIRLINES (OTH) 1 RS001–RS002 RS253–RS254 RS257 PAKISTAN INT'L AIRLINES (PIA) 1 RS301–RS303 RS305–RS306 PHILIPPINE AIRLINES (PAL) 1 RT152 RU051–RU052 RU059–RU060 PHUKET AIRLINES (PHK) 1 RD381 RD605 RS238 RS241 RS711 ### Page 18 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT PRESIDENTIAL FLIGHT (ABD) 1 RM084 RT137 QANTAS (QAN) 1 RF001–RF006 RM331–RM333 RS273–RS274 RS276 RT551–RT568 RT741–RT742 RU031 ROYAL AIR MAROC (RAM) 1 RT717 SATAIR (SAI) 1 RD606 SAUDI ARABIAN AIRLINES (SVA) 1 RM156–RM157 RS311–RS320 RU101–RU102 SAUDI ROYAL FLIGHT (SRF) 1R M 1 5 8 R S 6 9 9 SINGAPORE AIRLINES (SIA) 1 RM041–RM045 RT521 RT530 RT833 RT835 3 RT526 SKYTECH-AIC (SKC) 1 RT832 SONAIR (SON) 1R M 2 3 1 SOUTH AFRICAN AIRWAYS (SAA) 1 RM081 RM083 RM147 RS212 RS232 RS236 SOUTHERN AIR (SOF) 2 RD601–RD602 RS721 RS786 SURINAM AIRWAYS (SUR) 1R S 7 1 3 TAAG (ANGOLA AIRLINES) (ANG) 1R S 7 0 3 R S 7 4 2 THAI AIRWAYS INTERNATIONAL (TII) 1 RM026–RM030 RM431 RT691–RT699 RT801–RT803 TRANSAERO AIRLINES (TRX) 1 RM146 RS255 RS258 RS263 RS268 RS271 RT783–RT784 UNICAL AVIATION (UNL) 1 RS341–RS342 ### Page 19 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT UNITED AIR LINES (UAL) 1 RM166 RM169–RM177 RT411 RT601 RT603–RT605 RT607–RT612 RT617 RT623–RT630 UPS (UPS) 3 RT161 RT164 VIRGIN ATLANTIC AIRWAYS (VAA) 1 RM051–RM053 RM351–RM353 RM355 RT945–RT949 WORLD AIRWAYS, INC. (WLD) 1 RT745 RT747 YANGTZE RIVER EXPRESS (YTH) 1 RT756–RT757 IDENTIFICATION BY VARIABLE NUMBER Variable Group RD381–RD383 1 RD601–RD602 2 RD603–RD607 1 RD721–RD722 1 RF001–RF006 1 RM001–RM007 1 RM010–RM013 1 RM021–RM024 1 RM026–RM030 1 RM036–RM045 1 RM051–RM053 1 RM071 1 RM081–RM084 1 RM091 1 RM096–RM097 1 RM116–RM117 1 RM126–RM127 1 RM128 3 RM129–RM132 1 RM136–RM147 1 RM156–RM158 1 RM166–RM177 1 RM191–RM192 1 RM231–RM233 1 RM241–RM246 1 ### Page 20 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT RM261–RM264 1 RM316–RM318 1 RM331–RM333 1 RM341 1 RM351–RM355 1 RM366–RM367 1 RM401–RM403 1 RM426 1 RM431 1 RM441–RM443 1 RM445 1 RM801–RM803 1 RM811–RM813 1 RS001–RS002 1 RS201 1 RS211–RS212 1 RS221–RS222 1 RS231–RS241 1 RS251–RS259 1 RS263 1 RS265–RS268 1 RS271–RS276 1 RS291–RS292 1 RS301–RS306 1 RS311–RS320 1 RS331–RS333 1 RS341–RS342 1 RS699 1 RS701–RS703 1 RS711–RS713 1 RS721–RS722 2 RS731–RS732 1 RS741 2 RS742 1 RS743 2 RS751–RS752 1 RS761 1 RS762 2 RS771 2 Variable Group ### Page 21 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT RS781–RS782 1 RS786 2 RT001–RT014 1 RT021–RT022 3 RT031–RT033 3 RT034–RT035 1 RT041–RT047 1 RT061 1 RT071–RT072 3 RT073–RT074 1 RT075 3 RT101–RT103 1 RT121 1 RT131–RT137 1 RT151–RT152 1 RT161 3 RT162–RT163 1 RT164 3 RT165–RT168 1 RT401–RT412 1 RT431–RT447 1 RT451–RT455 1 RT456 3 RT457–RT460 1 RT461 3 RT462–RT469 1 RT471–RT499 1 RT501 3 RT502–RT505 1 RT506–RT510 3 RT511–RT512 1 RT513 3 RT514–RT515 1 RT516 3 RT517 1 RT518–RT520 3 RT521–RT523 1 RT524 3 RT525 1 Variable Group ### Page 22 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT RT526 3 RT527 1 RT528 3 RT529–RT535 1 RT551–RT568 1 RT571 1 RT572–RT576 3 RT577–RT591 1 RT601–RT630 1 RT633–RT641 1 RT642 3 RT643–RT654 1 RT655–RT657 3 RT671–RT673 1 RT681–RT682 1 RT691–RT699 1 RT701–RT704 1 RT711–RT717 1 RT741–RT742 1 RT744–RT750 1 RT751–RT752 3 RT753–RT757 1 RT776 3 RT777 1 RT781–RT782 3 RT783–RT784 1 RT801–RT803 1 RT811–RT814 1 RT831–RT836 1 RT837 3 RT861–RT864 1 RT877–RT880 1 RT931–RT932 1 RT945–RT949 1 RT951–RT955 1 RT966 1 RT967 3 RU001–RU006 1 RU016–RU017 1 Variable Group ### Page 23 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 2. Spares Affected None. B. Concurrent Requirements None. C. Reason 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. 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. RU031–RU032 1 RU051–RU052 1 RU059–RU062 1 RU081–RU083 1 RU101–RU102 1 RU121–RU132 1 RU801–RU809 1 RU831–RU841 1 Variable Group ### Page 24 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 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 structurally 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. Revision 1 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. A list of Revision 1 changes can be found on the Revision Transmittal Sheet for Revision 1. D. Description 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. ### Page 25 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 114 BOEING SERVICE BULLETIN 747-53A2507 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. Revision 1 includes the following work: 1. 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. 2. 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. 3. 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. NOTE: For other clarifications or corrections to work instructions that are transmitted with Revision 1, Boeing recommends that operators incorporate the revised instructions at the next planned Stage 1 or Stage 2 inspection as given in this service bulletin. NOTE: If the damaged area is more than the specified limits, contact Boeing for repair instructions. Give the size and location of the damage. When possible, send sketches and photographs. If the damage includes corrosion, send data on the length, width, and largest depth of clean up. PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION RESULTS WHEN EACH INSPECTION IS COMPLETE. Send your report to: BOEING COMMERCIAL AIRPLANES GROUP ATTENTION: MANAGER, AIRLINE SUPPORT ### Page 26 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT Because of common access, the inspections specified in Service Bulletin 747-53-2483 "FUSELAGE - Frame to Tension Tie Joint Inspection - Body Station 1120 to 1220" can be done at the same time as the changes specified in this service bulletin. ### Page 27 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT E. Compliance Table 1: Compliance Time for STAGE 1 and STAGE 2 Inspection Condition Action Compliance Time (Whichever is earlier) Repeat Interval (Not to Exceed) Airplanes that accumulated less than 12,000 total flight cycles as of November 28, 2007. (and DID NOT do a STAGE 1 inspection prior to November 28,2007) Do detailed inspections for damage as given in the STAGE 1 INSPECTION section of the Work Instructions, Paragraph 3.B. (b)(c)(d) At the earlier of the following: Before 8,000 total flight cycles, or within 1,500 flight cycles after April 26, 2006, or within 4,000 flight cycles since inspection per Service Bulletin 747- 53A2483, whichever occurs later, -OR- Before 10,000 total flight cycles, or within 250 flight cycles after November 28, 2007, whichever occurs later. At the later of the following: Before 12,000 total flight cycles, -OR- Within 50 flight cycles or 20 days after November 28, 2007, whichever is earlier. Do the next inspection before 10,000 total flight cycles or within 250 flight cycles after the initial STAGE 1 inspection, whichever occurs later, -AND- Do inspections thereafter every 250 flight cycles. Airplanes that accumulated less than 12,000 total flight cycles as of November 28, 2007. (and DID do a STAGE 1 inspection prior to November 28, 2007) Do detailed inspections for damage as given in the STAGE 1 INSPECTION section of the Work Instructions, Paragraph 3.B. (b)(c)(d) - - Do the next inspection before 10,000 total flight cycles or within 250 flight cycles after November 28, 2007, whichever occurs later, -AND- Do inspections thereafter every 250 flight cycles. Airplanes that accumulated 12,000 total flight cycles or more as of November 28, 2007. (and DID NOT do a STAGE 1 inspection prior to November 28,2007) Do detailed inspections for damage as given in the STAGE 1 INSPECTION section of the Work Instructions, Paragraph 3.B. (b)(c)(d) Within 50 flight cycles after November 28, 2007. Within 20 days after November 28, 2007. 250 flight cycles. ### Page 28 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT Airplanes that accumulated 12,000 total flight cycles or more as of November 28, 2007. (and DID do a STAGE 1 inspection prior to November 28,2007) Do detailed inspections for damage as given in the STAGE 1 INSPECTION section of the Work Instructions, Paragraph 3.B. (b)(c)(d) - - At the later of the following: Within 250 flight cycles after last STAGE 1 inspection -OR- Within 50 flight cycles or 20 days after November 28, 2007, whichever is earlier. -AND- Do inspections thereafter every 250 flight cycles. All airplanes. Do detailed and HFEC inspections for damage as given in the STAGE 2 INSPECTION section of the Work Instructions, Paragraph 3.B. (a)(b)(c)(d) Before 10,000 total flight cycles or within 1,000 flight cycles after the Revision 1 date of this service bulletin, whichever is later. 3,000 flight cycles. All airplanes. Do a HFEC inspection for cracks in the tension tie as given in the STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140 section of the Work Instructions, Paragraph 3.B. Before 10,000 total flight cycles or within 3,000 flight cycles after the Revision 1 date of this service bulletin, whichever is later. 3,000 flight cycles. No damage found, or damage has been repaired. Repeat the STAGE 1 or STAGE 2 inspection as given in this compliance table. At the times given in this compliance table. - Damage found. (d) Repair as given in the Work Instructions, paragraph 3.B. Before further flight. - (a) Revision 1 of this service bulletin reduces the initial inspection threshold for STAGE 2 inspection work. Continue to do STAGE 1 inspection work at the times specified until the STAGE 2 inspection work is started. Table 1: Compliance Time for STAGE 1 and STAGE 2 Inspection Condition Action Compliance Time (Whichever is earlier) Repeat Interval (Not to Exceed) ### Page 29 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 is related to this service bulletin. (b) The requirement to do the STAGE 1 INSPECTION ends when the STAGE 2 INSPECTION work is started. (c) Once the STAGE 2 INSPECTION work is started, continue doing the STAGE 2 inspections. Do not do the STAGE 1 inspections after the STAGE 2 inspections are started. (d) For this table, damage is defined as: Any crack, broken fastener, loose fastener, or fastener that is missing. Group 1, Configuration 1: One-Time Inspection for Mislocated Angles (Revision 1 - More Work) Condition Action Compliance Time All airplanes. Do the ONE-TIME INSPECTION FOR MISLOCATED ANGLES as given in the Work Instructions, Paragraph 3.B. Within 3,000 flight cycles after the Revision 1 date of this service bulletin. (a) No mislocated angle found. No further action. - Mislocated angle found. Correctly install a new angle as given in the Work Instructions, Paragraph 3.B. Before further flight. All airplanes. After inspection and rework as necessary, continue STAGE 1 or STAGE 2 inspections as applicable at the times shown in Table 1. - (a) Due to common access the inspection can be done concurrent with the next planned Stage 2 inspection as given in this service bulletin. Group 1, Configuration 2; Group 2-3: One-Time Inspection of Frames at Previous Tension Tie Locations (Revision 1 - More Work) Condition Action Compliance Time All airplanes. Do the ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS as given in the Work Instructions, Paragraph 3.B. Within 3,000 flight cycles after the Revision 1 date of this service bulletin. (a) No crack found, or crack has been repaired. No further action. - Any crack found. Repair as given in the Work Instructions, paragraph 3.B. Before further flight. All airplanes. After inspection and rework as necessary, continue STAGE 1 or STAGE 2 inspections as applicable at the times shown in Table 1. - (a) Due to common access the inspection can be done concurrent with the next planned Stage 2 inspection as given in this service bulletin. Table 1: Compliance Time for STAGE 1 and STAGE 2 Inspection Condition Action Compliance Time (Whichever is earlier) Repeat Interval (Not to Exceed) ### Page 30 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 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. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/ JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspection and repair procedures with the corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance" of Service Bulletin 747- 53A2507, Revision 1, as an AMOC to the inspections and repairs required by paragraphs (h), (i), and (j) of AD 2004-07-22 R1, for the inspection of Structural Significant Item (SSI) F-19A of Supplemental Structural Inspection Document (SSID) D6-35022, Revision G. This AMOC only applies to the areas inspected by this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph, including the initial inspection threshold per paragraph (i) of AD 2004-07-22 R1, remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspection and repair procedures with corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance" of Service Bulletin 747-53A2507, Revision 1, as an AMOC to the inspection and repair procedures specified in Table 1, under paragraph 1.E., "Compliance" of Service Bulletin 747- 53A2507, dated April 21, 2005, with the corresponding compliance times required by paragraphs (f), (g), (h) and (i) of AD 2007-23-18. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD 2007-23-18 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. G. Manpower The table below shows an estimate of the task-hours necessary to do 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 examine the work — Time to cure the materials — Time to make the parts ### Page 31 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT — Time to find the tools. Group 1, Configuration 1: Task Number of Persons Task-Hours Elapsed Hours Open Access (Stage 1 and 2) 2 12.00 6.00 Figure 1 (Stage 1) 2 8.00 4.00 Figure 3 (Stage 1 and 2) 2 1.00 0.50 Figure 4 (Stage 1 and 2) 2 10.00 5.00 Figure 5 (Stage 2) 2 72.00 36.00 Figure 6 (a) (b) 1 0.50 0.50 Figure 7 (b) 1 0.15 0.15 Figure 13 (c) 1 0.10 0.10 Figure 15 (Stage 2) 2 3.00 1.50 Close Access (Stage 1 and 2) 2 14 7 TOTAL FOR EACH AIRPLANE (Stage 1 only) 45.1 22.6 TOTAL FOR EACH AIRPLANE (Stage 2 only) 112.1 56.1 (a) If required. Not included in total. (b) Estimate given is for repair/inspection of one hole location. Actual task-hours necessary will depend on the number of holes that need to be repaired/inspected. (c) One-time inspection. Hours will not be required after inspection is done the first time. Estimate given is for inspection only. Time for part fabrication and replacement is not included. Group 1, Configuration 2; Group 2-3: Task Number of Persons Task-Hours Elapsed Hours Open Access (Stage 1 and 2) 2 12.00 6.00 Figure 8 (Stage 1) 2 8.00 4.00 Figure 9 (Stage 1 and 2) 2 10.00 5.00 Figure 10 (Stage 2) 2 72.00 36.00 Figure 11 (a) (b) 1 0.50 0.50 Figure 12 (b) 1 0.15 0.15 Figure 14 (c) 2 9.00 4.50 Figure 15 (Stage 2) 2 3.00 1.50 Close Access (Stage 1 and 2) 2 14 7 TOTAL FOR EACH AIRPLANE (Stage 1 only) 53.0 26.5 TOTAL FOR EACH AIRPLANE (Stage 2 only) 120.0 60.0 (a) If required. Not included in total. (b) Estimate given is for repair/inspection of one hole location. Actual task-hours necessary will depend on the number of holes that need to be repaired/inspected. (c) One-time inspection. Hours will not be required after inspection is done the first time. ### Page 32 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT The times for any additional repairs that are found because of the inspections are listed within the SRM. The times shown for the Figures above are for the tension ties at six station locations, both left side and right side. H. Weight and Balance Changes None. NOTE: No significant weight and balance changes are expected due to inspection or fastener replacement procedures in this service bulletin. However, SRM repairs and/or use of substitute fasteners could cause a significant weight and balance change. I. Electrical Load Data Not changed. J. References 1. Existing Data: a. 747-100/200/300 Aircraft Maintenance Manual (AMM) 24-22-00, 25-14-02, 25-22-04, 25-24-00, 25-25-01, 25-59-01, 25-59-05 b. 747-100/200/300 Structural Repair Manual (SRM) 51-30-02, 51-30-03, 51-30-05, 53-10-04, 53-10-11, 53-30-03, Chapter 51 c. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 25-22-00, 25-22-04, 25-24-00, 25-25-01, 25-59-01, 25-59-05 d. 747-400 Structural Repair Manual (SRM) 51-40-02, 51-40-03, 51-40-05, 53-40-01, 53-40-07, 53-40-30, Chapter 51 e. 747-400SF Structural Repair Manual (SRM) 53-40-01, Chapter 51 f. 747 Non-Destructive Testing (NDT) Manual, Part 6, 51-00-00 g. FAA Airworthiness Directive 2004-07-22 R1 h. FAA Airworthiness Directive 2007-23-18 i. FAA Notice of Proposed Rule Making 2009-NM-024-AD j. Standard Overhaul Practices Manual (SOPM) 20-41-05, 20-50-19 2. Data supplied with this Service Bulletin: None. ### Page 33 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 3. Installation Drawings Used in the Preparation of this Service Bulletin: These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 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 and new 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. Drawing Number Title 65B01749 FRAME INSTALLATION - BODY STA 1120 65B18703 FRAME INSTALLATION - BODY STA 1140 65B01751 FRAME INSTALLATION - BODY STA 1160 65B01752 FRAME INSTALLATION - BODY STA 1180 65B01753 FRAME INSTALLATION - BODY STA 1200 65B01754 FRAME INSTALLATION - BODY STA 1220 65B09631 TENSION TIE INSTALLATION - AFT OF UPPER DECK FLOOR 657U7304 TENSION TIE INSTALLATION - STA 880 - STA 1220, MOD ### Page 34 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT BLANK PAGE ### Page 35 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 2. MATERIAL INFORMATION A. Material - Price and Availability The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary For Each Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin does not show the Boeing price and supply data. B. Industry Support Information Boeing warranty remedies are not available for the inspection or repair procedures given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts: None. ### Page 36 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 2. Parts and Materials Supplied by the Operator: Part Number / Specification QTY Name Notes BACB30MY6K4Y 2 Hex Drive Bolt (a) BACB30MY6K5X 2 Hex Drive Bolt (a) BACB30NX( )K( ) 380 Hex Drive Bolt (a) (c) (d) (e) (f) BACB30VT6K3X 2 Hex Drive Bolt (a) (g) BACB30VT8K3 4 Hex Drive Bolt (a) (d) (e) BACC30BL6 2 Collar (a) (g) BACC30BL8 4 Collar (a) (d) (e) BACC30M6 2 Collar (a) (j) BACC30R6 2 Collar (a) (j) BACN10YT( )CD 380 Nut (a) (c) (d) (e) (f) BACR15BB6D( ) 24 Rivet (a) (j) BACR15BB7D( ) 28 Rivet (a) (j) BACR15FT5D( )C 10 Rivet (a) (g) (h) BACR15FT6D( ) 36 Rivet (a) (j) BACW10BP( )DP 380 Washer (a) (c) (d) (e) BMS 3-23, Type II 16 Ounces Corrosion Inhibiting Compound (b) (e) BMS 3-27 (BMS 3-38 optional) 8 Ounces Corrosion Inhibiting Compound (b) (e) BMS 10-11, Type 1 8 Ounces Primer (b) (e) Alodine as required Chemical Conversion Coating (b) (e) (i) 65B09631-139/-140 as required Angle (g) (a) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners. (b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) Operators should have access to 3/16 inch and 1/4 inch fasteners in the first and second oversize diameters. Operators should also have access to 5/16 inch standard diameter fasteners. Grip lengths from - 3 to -8 could be required. (d) Quantities are approximate, operators may need more or less fasteners, but these quantities are to be used as a guide and are for the total number of fasteners including all the grip lengths specified. (e) The quantity required will depend on the inspection results and if any repairs are necessary. (f) To allow for easier removal during repeat inspections, it is optional to install BACB30MR( )K( ) bolts and BACW10BP( )CD washers, with BACN11Z( )CD nuts and BACW10BP( )DP washers at fastener locations common to the steel plates. However, availability of BACB30MR( )K( ) bolts is limited. Also, if fasteners are substituted, the same type of fastener should be used throughout each joint, as shown in Appendix C, Figure F. (g) Group 1, Configuration 1: These parts may be necessary if it is necessary to re-install a mislocated angle. Refer to the "INSPECTION FOR MISLOCATED ANGLE" section of the paragraph 3.B., Work Instructions. Make from BAC1503-100031 extrusion, 7075-T6511 per QQ-A-200/11. (h) Grip lengths -5 and -6 are expected, but grip length -7 could be necessary. (i) Refer to SOPM 20-43-03 for material alternatives. (j) This part is only needed for Group 1, Configuration 2; Group 2-3. For rivets, grip length as required. ### Page 37 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 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. ### Page 38 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT BLANK PAGE ### Page 39 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 114 BOEING SERVICE BULLETIN 747-53A2507 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 are given in 747 SRM, Chapter 51 — Torque limits to tighten nuts and bolts are given in 747 SRM, Chapter 51. 4. For approved fastener and process material substitutions, refer to 747 SRM, Chapter 51 or Boeing Drawing 012W6100. Alternate fasteners are given in 747 SRM Chapter 51 and Boeing Drawing 65B88700. 5. If the length of any fastener specified in this service bulletin does not meet the 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. 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 on 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 "as given in" are included in the instruction, the procedure in the Boeing document must be used. 8. In the instructions and figures, the tension tie to frame joint configuration shown is a typical representative view. Actual configurations vary depending on location. 9. In the following work instructions, it is structurally satisfactory to substitute fasteners per 747-100/200/300 SRM 51-30-03 or 747-400 SRM 51-40-03. However, if fasteners are substituted, the same type fasteners should be used throughout each joint, as shown in Appendix C. ### Page 40 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 10. Airplanes that have been modified by Boeing to Special Freighter (SF) or Boeing Converted Freighter (BCF) configuration have tension ties installed from Station (STA) 880 to STA 1220. However, only tension ties from STA 1120 to STA 1220 need to be inspected as given in this Service Bulletin. Inspection per Supplemental Structural Inspection Document (SSID), Revision G, are still required for tension ties at STA 880 through STA 1100. 11. Do not remove the fasteners from adjacent tension tie to frame joints at the same time. Refer to Appendix B for allowable methods to disconnect the tension ties. 12. In Figures 1, 2, 5, and 6 of this Service Bulletin Right Buttock Line (RBL) 26, and Left Buttock Line (LBL) 26 are used as reference points. RBL 26 is defined as the perpendicular distance 26 inches right of the fuselage vertical center line. LBL 26 is defined as the perpendicular distance 26 inches left of the fuselage center line. 13. Airplanes that have been modified by Boeing to SF or BCF configuration have had the shear panel removed by trimming. The STA 1120 tension tie is replaced during modification. The only remaining part of the shear panel is a strip common to the lower flange of the STA 1140 forward tension tie channel. 14. 747-300 and 747-400 airplanes that have been modified by Boeing to SF or BCF do not have an Aluminum Channel attached to the tension tie at STA 1220. 747-200 SUD airplanes that have been modified by Boeing to SF configuration do have an Aluminum Channel attached to the tension tie at STA 1220. 15. Tension tie configurations created by "non-Boeing" modifications are not shown in this service bulletin. Operators of airplanes with non-Boeing tension tie configurations should seek approval of alternate inspection plans from their local regulatory agency. 16. If previous frame repairs are found during accomplishment of detailed inspections given in this service bulletin, also do a detailed inspection of the entire repaired area. 17. 747 SRM repairs for frame cracks include the following: — 747-100/200/300 SRM 53-10-04, Figures 123 through 131. — 747-400 SRM 53-40-07, Repairs 1 through 9. 18. 747 SRM repairs for tension tie cracks include the following: — 747-100/200/300 SRM 53-10-04 — 747-400 SRM 53-40-07Repair 1. 19. For airplanes that have been modified by Boeing to BCF, equivalent tension tie and frame structure repairs have not yet been added to the 747-400SF SRM. It is acceptable to use the referenced 747-400 SRM repairs for repair of the tension tie and frame structure on BCF airplanes until the 747-400SF SRM is updated. B. WORK INSTRUCTIONS Do the Stage 1 or Stage 2 Inspections at the compliance times specified in paragraph 1.E. of this service bulletin. ### Page 41 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT ACCESS 1. Remove electrical power and ground the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM 24-22-00 as an accepted procedure. 2. Get access to the tension ties and frames: a. Group 1, Configuration 1: Remove the seats as necessary between STA 1120 and STA 1220. Refer to 747-100/200/300 AMM 25-25-01 or 747-400 AMM 25-25-01 as an accepted procedure. b. Group 1, Configuration 1: Remove the main deck ceiling panels as necessary between STA 1120 and STA 1220 to get access to the tension ties and frames. Refer to 747-100/200/300 AMM 25-22-04 or 747-400 AMM 25-22-04 as an accepted procedure. c. Group 1, Configuration 1: Remove insulation as necessary to get access to the tension ties and frames. Refer to 747-100/200/300 AMM 25-14-02 or 747-400 AMM 25-22-00 as an accepted procedure. NOTE: Additional access to the STA 1120 tension tie joints can be obtained through the upper deck aft partition or closet(s). Refer to 747-100/200/300 AMM 25-24-00 or 747-400 AMM 25-24-00. However, this access is not required to accomplish the inspections as given in this service bulletin. d. Group 1, Configuration 2; Group 2-3: Remove main deck cargo compartment lining panels as necessary to get access to the tension ties and frames from STA 1120 to STA 1220. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure. e. Group 1, Configuration 2; Group 2-3: Remove main deck cargo compartment insulation as necessary to get access to the tension ties and frames from STA 1120 to STA 1220. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure. STAGE 1 INSPECTION CAUTION: IF FASTENER REMOVAL IS NECESSARY, DO NOT REMOVE THE FASTENERS FROM ADJACENT TENSION TIE TO FRAME JOINTS AT THE SAME TIME. IF FASTENERS ARE REMOVED FROM ADJACENT TENSION TIES, DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR. REFER TO APPENDIX B FOR ALLOWABLE METHODS TO DISCONNECT THE TENSION TIES. 1. Do the ACCESS steps as given in this service bulletin. 2. Group 1, Configuration 1: Do a detailed inspection of the tension ties and steel plates from STA 1120 to STA 1220 as given in Figure 1. 3. Group 1, Configuration 2; Group 2-3: Do a detailed inspection of the tension ties and steel plates from STA 1120 to STA 1220 as given in Figure 8. 4. Group 1, Configuration 1: Do a detailed inspection of the shear web components that attach to the tension ties as given in Figure 3. ### Page 42 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 5. Group 1, Configuration 1: Do a detailed inspection of each of the frames from 2 stringers above to 2 stringers below the tension ties, as given in Figure 4. 6. Group 1, Configuration 2; Group 2-3: Do a detailed inspection of each of the frames from 2 stringers above to 2 stringers below the tension ties, as given in Figure 9. 7. If no cracks are found, and there are no broken, loose, or missing fasteners, do the RESTORATION steps as given in this service bulletin. 8. If a severed tension tie is found, do the following before further flight: a. Do a detailed inspection of the frame web, frame inner chord, fail-safe chord, shear ties, and fasteners from stringer 3 to stringer 18, for cracks and broken, loose, or missing fasteners. Do this inspection on both sides of the frame, and on both sides of the airplane, for the severed tension tie only. b. Group 1, Configuration 1: Do the additional inspections (Open Hole HFEC, Surface HFEC, and Detailed) as given in Figure 5. Do the Figure 5 inspections at the severed tension tie and at the tension ties adjacent to the severed tension tie. If one of the inspected tension ties is at STA 1140, also do the open hole HFEC inspections as given in Figure 15. c. Group 1, Configuration 2; Group 2-3: Do the additional inspections (Open Hole HFEC, Surface HFEC, and Detailed) as given in Figure 10. Do the Figure 10 inspections at the severed tension tie and at the tension ties adjacent to the severed tension tie. If one of the inspected tension ties is at STA 1140, also do the open hole HFEC inspections as given in Figure 15. d. If no more cracks are found, and there are no broken, loose, or missing fasteners, repair the severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30. e. If more cracks are found, or if there are broken, loose, or missing fasteners, do the following: (1) Repair the severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30. (2) Do the STRUCTURE REPAIR steps as given in this service bulletin, as necessary. f. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 1140, also install fasteners as given in Figure 15, as necessary. g. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 10. At STA 1140, also install fasteners as given in Figure 15, as necessary. h. Do the RESTORATION steps as given in this service bulletin. 9. If cracks are found in a tension tie, steel plate, frame or shear web components (and the tension tie is NOT severed), or if there are broken, loose, or missing fasteners, do the following before further flight: a. Do the STRUCTURE REPAIR steps as given in this service bulletin, as necessary. b. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 1140, also install fasteners as given in Figure 15, as necessary. ### Page 43 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT c. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 10. At STA 1140, also install fasteners as given in Figure 15, as necessary. d. Do the RESTORATION steps as given in this service bulletin. 10. Repeat the inspections at the intervals specified in paragraph 1.E., Compliance. 11. Report all inspection findings to Boeing. STAGE 2 INSPECTION CAUTION: DO NOT REMOVE THE FASTENERS FROM ADJACENT TENSION TIE TO FRAME JOINTS AT THE SAME TIME. IF FASTENERS ARE REMOVED FROM ADJACENT TENSION TIES, DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR. REFER TO APPENDIX B FOR ALLOWABLE METHODS TO DISCONNECT THE TENSION TIES. 1. Do the ACCESS steps as given in this service bulletin. 2. Group 1, Configuration 1: Do HFEC and detailed inspections of the tension ties, frames, and steel plates as given in Figure 5. 3. Group 1, Configuration 2; Group 2-3: Do HFEC and detailed inspections of the tension ties, frames, and steel plates as given in Figure 10. 4. Group 1, Configuration 1: Do a detailed inspection of the shear web components that attach to the tension ties as given in Figure 3. 5. Group 1, Configuration 1: Do a detailed inspection of each of the frames from 2 stringers above to 2 stringers below the tension ties, as given in Figure 4. NOTE: If there are insulation blanket studs attached to the frames in the inspection area, check to see if the studs are bonded on to the frames, or if they go through holes in the frames. At locations where the studs go through holes in the frames, remove the stud and inspect the hole as given in Figure 7. 6. Group 1, Configuration 2; Group 2-3: Do a detailed inspection of each of the frames from 2 stringers above to 2 stringers below the tension ties, as given in Figure 9. NOTE: If there are insulation blanket studs attached to the frames in the inspection area, check to see if the studs are bonded on to the frames, or if they go through holes in the frames. At locations where the studs go through holes in the frames, remove the stud and inspect the hole as given in Figure 12. 7. Group 1, Configuration 1: If no cracks are found, and there are no broken, loose, or missing fasteners, install steel plates and fasteners as given in Figure 5, then do the RESTORATION steps. 8. Group 1, Configuration 2; Group 2-3: If no cracks are found, and there are no broken, loose, or missing fasteners, install steel plates and fasteners as given in Figure 10, then do the RESTORATION steps. 9. If a severed tension tie is found, do the following before further flight: ### Page 44 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT a. Do a detailed inspection of the frame web, frame inner chord, fail-safe chord, shear ties, and fasteners from stringer 3 to stringer 18, for cracks and broken, loose, or missing fasteners. Do this inspection on both sides of the frame, and on both sides of the airplane, for the severed tension tie only. b. If no more cracks are found and there are no more broken, loose, or missing fasteners, repair the severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30. c. If more cracks or broken, loose, or missing fasteners are found, do the following: (1) Repair the severed tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30. (2) Do the STRUCTURE REPAIR steps specified in this service bulletin, as necessary. d. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 1140, also install fasteners as given in Figure 15, as necessary. e. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 10. At STA 1140, also install fasteners as given in Figure 15, as necessary. f. Do the RESTORATION steps as given in this service bulletin. 10. If cracks are found in a tension tie, steel plate, frame or shear web components (and the tension tie is NOT severed), or if there are broken, loose, or missing fasteners, do the following before further flight: a. Do the STRUCTURE REPAIR steps as given in this service bulletin, as necessary. b. Group 1, Configuration 1: Install steel plates and fasteners as given in Figure 5. At STA 1140, also install fasteners as given in Figure 15, as necessary. c. Group 1, Configuration 2; Group 2-3: Install steel plates and fasteners as given in Figure 10. At STA 1140, also install fasteners as given in Figure 15, as necessary. d. Do the RESTORATION steps as given in this service bulletin. 11. Repeat the inspections at the intervals specified in paragraph 1.E., Compliance. 12. Report all inspection findings to Boeing. STAGE 2 INSPECTION - ADDITIONAL WORK at STA 1140 (Revision 1 - More Work) 1. Do an open hole HFEC inspection for cracks in the forward and aft tension tie channels at twelve fastener locations (six left side and six right side) inboard of the aluminum straps as given in Figure 15. ### Page 45 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT NOTE: Group 1, Configuration 1: When possible, Figure 15 is intended to be done concurrently with Figure 5 during accomplishment of STAGE 2 inspections. NOTE: Group 1, Configuration 2; Group 2-3: When possible, Figure 15 is intended to be done concurrently with Figure 10 during accomplishment of STAGE 2 inspections. 2. If any crack is found, remove the crack by doing OVERSIZE HOLE REPAIR, or repair the tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30. 3. If no crack is found, repeat the open hole HFEC inspection for cracks in the forward and aft tension tie channels at twelve fastener locations (six left side and six right side) inboard of the aluminum straps at the interval specified in paragraph 1.E., Compliance. 4. Repeat the inspection at the interval specified in paragraph 1.E., Compliance. 5. Report all inspection findings to Boeing. STRUCTURE REPAIR 1. If there are broken, loose, or missing fasteners common to the tension tie to frame joint, do the following before further flight: a. Group 1, Configuration 1: If the fasteners common to the steel plate, and three rows inboard of the steel plate have not already been removed, then remove them as given in Figure 5. b. Group 1, Configuration 2; Group 2-3: If the fasteners common to the steel plate, and three rows inboard of the steel plate have not already been removed, then remove them as given in Figure 10. c. Group 1, Configuration 1: If the fastener holes common to the steel plate, and three rows inboard of the steel plate have not already been open hole HFEC inspected per Figure 5, then do an open hole HFEC inspection, as given in Figure 5, at all locations where fasteners were removed. d. Group 1, Configuration 2; Group 2-3: If the fastener holes common to the steel plate, and three rows inboard of the steel plate have not already been open hole HFEC inspected per Figure 10, then do an open hole HFEC inspection, as given in Figure 10, at all locations where fasteners were removed. e. At STA 1140, if the fastener holes three rows inboard of the aluminum straps have not already been open hole HFEC inspected per Figure 15, then do an open hole HFEC inspection as given in Figure 15. f. If cracks are found, see STRUCTURE REPAIR steps 3 through 10 for repair instructions. 2. If there are broken, loose, or missing fasteners at any other location (not common to the tension tie to frame joint), contact Boeing for repair instructions before further flight. 3. If a crack is found in a shear tie at the flange common to the skin, do the following: a. Remove all fasteners common to the cracked shear tie and skin. ### Page 46 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT b. Do an Open Hole HFEC inspection of the skin at all fastener locations common to the cracked shear tie as given in 747 NDT, Part 6, 51-00-00, Figure 16. c. If a crack is found in the skin, repair the skin as given in 747-100/200/300 SRM 53-30-03 or 747-400 SRM 53-40-01, or 747-400SF SRM 53-40-01. Repair the shear tie as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07. d. If no cracks are found in the skin, repair the shear tie as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07. Install new fasteners as given in 747-100/200/300 SRM Chapter 51, or 747-400 SRM Chapter 51, or 747-400SF SRM Chapter 51, as applicable. 4. If a crack is found at a bolt, hilok, or rivet hole common to a frame, shear tie, failsafe chord, shear web component, tension tie, or steel plate, do the OVERSIZE HOLE REPAIR steps given in this service bulletin. If a crack is found at an insulation blanket stud hole common to a frame, contact Boeing for repair instructions. 5. If a crack is found in a shear tie and cannot be removed by doing the OVERSIZE HOLE REPAIR, repair the shear tie as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07. 6. If a crack is found in a frame and cannot be removed by doing the OVERSIZE HOLE REPAIR, repair as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07. 7. If a crack is found in the failsafe chord and cannot be removed by doing the OVERSIZE HOLE REPAIR, then repair the failsafe chord by splicing in a new segment as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07. The dimensions of the new Chord should be increased to maintain a 2D minimum edge margin. 8. If a crack is found in a shear web component and cannot be removed by doing the OVERSIZE HOLE REPAIR, contact Boeing for repair instructions. 9. If a crack is found in a tension tie and cannot be removed by doing the OVERSIZE HOLE REPAIR, repair the tension tie as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30. 10. If a crack is found in a steel plate and cannot be removed by doing OVERSIZE HOLE REPAIR, repair as given in 747-100/200/300 SRM 53-10-11 or 747-400 SRM 53-40-30 or replace the steel plate with a new steel plate as given in one of the following two options: a. Option 1: Replace the steel plate with a new steel plate made by Boeing, or b. Option 2: If required, fabricate a new steel plate per Boeing engineering drawing requirements same as existing steel plate, except make the new steel plate wider as required to maintain minimum 1.5D fastener edge margins in the steel plate. Make from the same material as existing steel plate, or it is also acceptable to make from alternative material 15-5 CRES per AMS5659, with heat treat to 150-170 ksi. Make sure that wider steel plates do not interfere with the flanges of the tension tie forward channel when installed. 11. If any other crack is found that cannot be repaired per the instructions above, contact Boeing for repair instructions. ### Page 47 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT OVERSIZE HOLE REPAIR 1. Group 1, Configuration 1: Remove cracks and install new fasteners as shown in Figure 6. 2. Group 1, Configuration 2; Group 2-3: Remove cracks and install new fasteners as shown in Figure 11. Group 1, Configuration 1: ONE-TIME INSPECTION FOR MISLOCATED ANGLES (Revision 1 - More Work) 1. On both sides of the airplane, do the ANGLE INSPECTION steps as shown in Figure 13. 2. If any angle has the incorrect installation, do the ANGLE REPLACEMENT steps as shown in Figure 13. 3. If both angles have the correct installation, no more work is required for the mislocated angles. 4. Continue STAGE 1 or STAGE 2 inspections, as applicable, as given in paragraph 1.E., Compliance. Group 1, Configuration 2; Group 2-3: ONE-TIME INSPECTION FOR CRACKS IN FRAMES AT PREVIOUS TENSION TIE LOCATIONS (Revision 1 - More Work) 1. At STA 1120, 1160, 1200, and 1220, do open hole HFEC inspections at the fastener locations where the tension tie was previously attached to the frame prior to modification to SF or BCF configuration. Do the inspection as given in Figure 14. 2. If any crack is found, remove the crack by doing OVERSIZE HOLE REPAIR, or repair the frame as given in 747-100/200/300 SRM 53-10-04 or 747-400 SRM 53-40-07. 3. If no crack is found, no more work is required for inspection of frames at previous tension tie locations. 4. Continue STAGE 1 or STAGE 2 inspections, as applicable, as given in paragraph 1.E., Compliance. RESTORATION 1. Apply BMS 3-23, Type II, Corrosion Inhibiting Compound to all areas where fasteners were removed, and where repairs were done. Refer to SOPM 20-41-05 as an accepted procedure. 2. Group 1, Configuration 1: Install insulation between STA 1120 and STA 1220. Refer to 747-100/ 200/300 AMM 25-14-02 or 747-400 AMM 25-22-00 as an accepted procedure. 3. Group 1, Configuration 1: Install ceiling panels between STA 1120 and STA 1220. Refer to 747-100/200/300 AMM 25-22-04 or 747-400 AMM 25-22-04 as an accepted procedure. 4. Group 1, Configuration 1: Install seats between STA 1120 and STA 1220. Refer to 747-100/200/ 300 AMM 25-25-01 or 747-400 AMM 25-25-01 as an accepted procedure. 5. Group 1, Configuration 1: If additional access to STA 1120 tension tie joints was obtained through the upper deck aft partition or closet(s) close the access. Refer to 747-100/200/300 AMM 25-24-00 or 747-400 AMM 25-24-00 as an accepted procedure. ### Page 48 Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT NOTE: This access was not required to accomplish the inspections as given in this Service Bulletin. 6. Group 1, Configuration 2; Group 2-3: Install main deck cargo compartment insulation as necessary from STA 1120 to STA 1220. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure. 7. Group 1, Configuration 2; Group 2-3: Install main deck cargo compartment lining panels as necessary from STA 1120 to STA 1220. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure. 8. Return airplane to a Serviceable Condition. ### Page 49 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) STA 1120 STA 1220 STA 1120 STA 1220 ASEE SEE B FWD 480026 (SHEET 1 OF 5) ### Page 50 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT TENSION TIE AFT CHANNEL VERTICAL POST ATTACHMENT C C D D E E AA G G BL26 VIEW LOOKING AFT (STA 1120 SHOWN, OTHER STATIONS SIMILAR) A-A STEEL PLATE NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION VARIES DEPENDING ON LOCATION. NOTE: SLOPING AND HORIZONTAL SHEAR WEB ONLY AT STA 1120 AND STA 1140. SHEAR WEB ATTACHES TO THE BOTOM OF THE TENSION CHANNEL AT STA 1140. (VIEW G-G SHOWN FOR STA 1120 AND STA 1140 ONLY) UP INBD A TENSION TIE FORWARD CHANNEL FRAME 1 2 STRINGERS FRAME FAILSAFE CHORD 1 1 1 1 482472 (SHEET 2 OF 5) ### Page 51 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT C C D D F FB B G G BL26 STRINGERS FRAME FAILSAFE CHORD B-B NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION VARIES DEPENDING ON LOCATION. VERTICAL POST ATTACHMENT STEEL PLATE NOTE: SLOPING AND HORIZONTAL SHEAR WEB ONLY AT STA 1120 AND STA 1140. SHEAR WEB ATTACHES TO THE BOTTOM OF THE TENSION TIE CHANNEL AT STA 1140. VIEW LOOKING AFT (STA 1120 SHOWN, OTHER STATIONS SIMILAR) (VIEW G-G SHOWN FOR STA 1120 AND STA 1140 ONLY) UP INBD 2 B TENSION TIE FORWARD CHANNEL FRAMETENSION TIE AFT CHANNEL 11 1 1 1 482473 (SHEET 3 OF 5) ### Page 52 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT FRAME ALUMINUM CHANNEL HORIZONTAL SHEAR WEB TENSION TIE AFT CHANNEL TENSION TIE FORWARD CHANNEL STEEL PLATE HORIZONTAL SHEAR WEB C-C E-E F-F (STA 1220) (STA 1140) (AT ALL OTHER STATIONS) D-D G-G D-D (STA 1120) G-G (TYPICAL) (TYPICAL) (TYPICAL) 2 22 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 482474 (SHEET 4 OF 5) ### Page 53 FIGURE 1: DETAILED INSPECTION OF TENSION TIES FROM STA 1120 TO STA 1220 (STAGE 1 ONLY) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT This Figure applies to Group 1, Configuration 1: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. STEP TASK NAME PROCEDURE REFERENCES MORE DATA 1 Inspect Tension Tie and Steel Plate Detailed Inspection 65B09631-( ) 65B09614-( ) (a) (c) 2 Inspect Fasteners Detailed Inspection -( b ) (a) Inspect for cracks in the forward and aft channels of the tension tie from Buttock Line (BL) 26 outboard to side of body on the left and right side of the airplane. Inspect for cracks in the steel plate on the left and right side of the airplane. Pay special attention to the tension tie at the frame joint, at all fastener locations common to the steel plate and 3 fastener rows inboard of the steel plate. Also, pay special attention to the tension tie at the vertical post attachments. At STA 1120 and STA 1140, pay special attention to the tension ties where they attach to the sloping shear web and horizontal shear web. (b) Inspect the fasteners common to the steel plate and 3 fastener rows inboard of the steel plate, for broken, loose, or missing fasteners. At STA 1220, also inspect all fasteners common to the aluminum channel on the underside of the tension tie in the area under the steel plate. (c) The sloping and horizontal shear web are only at STA 1120 and STA 1140. (SHEET 5 OF 5) ### Page 54 FIGURE 2: Deleted (Revision 1) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT FIGURE 2: Deleted (Revision 1) THIS FIGURE IS DELETED. D38438 (SHEET 1 OF 1) ### Page 55 FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2) STA 1120 STA 1140 STA 1120 STA 1140 ASEE SEE B FWD 482133 (SHEET 1 OF 3) ### Page 56 FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT 1120 STA 1140 STA SHEAR WEB HORIZONTAL INBD 1120 STA 1140 STA SHEAR WEB HORIZONTAL INBD WEB SHEAR SLOPING VIEW LOOKING UP VIEW LOOKING UP WEB SHEAR SLOPING 213 A 2 1 3 B 482181 (SHEET 2 OF 3) ### Page 57 FIGURE 3: SHEAR WEB COMPONENT INSPECTION (STAGE 1 AND 2) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT This Figure applies to Group 1, Configuration 1: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. STEP TASK NAME PROCEDURE REFERENCES MORE DATA 1 Inspect Sloping and Horizontal Shear Webs and Fasteners Detailed Inspection -( a ) ( b ) 2 Inspect Bends in Sloping Shear Web Detailed Inspection -( a ) 3 Inspect Sloping Shear Web to Supporting Structure (Gussets) and Fasteners Detailed Inspection -( a ) ( b ) (a) Inspect for cracks. (b) Inspect for broken, loose, or missing fasteners. (SHEET 3 OF 3) ### Page 58 FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) STA 1120 STA 1220 STA 1120 STA 1220 ASEE SEE B STA 1140 FWD 482449 (SHEET 1 OF 3) ### Page 59 FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 59 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT TRIPLER DOUBLER, AND FRAME WEB, CHORD FAILSAFE VIEW LOOKING AFT STRINGERS CHORD FAILSAFE VIEW LOOKING AFT TIE (TYP) SHEAR CHORD INNER TIE (TYP) SHEAR TRIPLER DOUBLER, AND FRAME WEB, CHORD INNER VARIES DEPENDING ON LOCATION. NOTE: TYPICAL CONFIGURATION. ACTUAL FASTENER PATTERN AND CONFIGURATION 4 UP INBD A 321 65 4 UP INBD B 321 65 STRINGERS 482493 (SHEET 2 OF 3) ### Page 60 FIGURE 4: FRAME INSPECTIONS - STA 1120 TO STA 1220 (STAGE 1 AND 2) Original Issue: April 21, 2005 Revision 1: January 14, 2010 747-53A2507 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 60 of 114 BOEING SERVICE BULLETIN 747-53A2507 ALERT ALERT This Figure applies to Group 1, Configuration 1: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. STEP TASK NAME PROCEDURE REFERENCES MORE DATA 1 Inspect Frame Web Detailed Inspection (a) (c) (d) 2 Inspect Frame Doubler Detailed Inspection (a) (c) (d) 3 Inspect Frame Tripler Detailed Inspection (a) (c) (d) 4 Inspect Inner chord Detailed Inspection (a) (c) (d) 5 Inspect Fail Safe Chord Detailed Inspection (a) (c) (d) 6 Inspect Shear Tie Detailed Inspection (a) (b) (c) (d) (a) Pay special attention to the corners of the stringer cut outs and fastener locations common to the tension ties. (b) Pay special attention to the bends in the shear ties common to the skin. (c) Inspect for cracks. (d) Inspect for broken, loose, or missing fasteners. (SHEET 3 OF 3) The text continues at https://openairdocs.org/service-documents/boeing/747-53a2507/file/3b407e2f4728.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. 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