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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2605 Original Issue: October 08, 2009 Revision 3: July 10, 2013 ATA System: 5312 SUBJECT: FUSELAGE - Center Section - Tension Ties and Frames - Modification and Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2009 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 1 of 203
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 2 of 203 BOEING SERVICE BULLETIN 747-53A2605
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 2 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 3 D. Description .............................................. 2 3 E. Compliance .............................................. 2 5 F. Approval ............................................... 3 0 G. Manpower .............................................. 3 1 H. Weight and Balance Changes .................................... 4 1 I. Electrical Load Data ......................................... 4 2 J. References .............................................. 4 2
1. Existing Data: ......................................... 4 2
2. Data Supplied with this Service Bulletin: ........................... 4 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 9 K. Publications Affected ........................................ 4 9 L. Interchangeability and Intermixability of Parts ........................... 5 0 M. Software Accomplishment Summary ................................ 5 0
2. MATERIAL INFORMATION ........................................ 5 1 A. Material - Price and Availability ................................... 5 1 B. Industry Support Information .................................... 5 2 C. Parts Necessary for Each Airplane ................................. 5 2
1. Kits/Parts: ........................................... 5 2
2. Parts and Materials Supplied by the Operator: ....................... 1 6 2
3. Parts Modified and Reidentified: ............................... 1 6 3
4. Parts Removed and Not Replaced: ............................. 1 6 3 D. Parts Necessary to Change Spares ................................ 1 6 3 E. Special Tooling - Price and Availability .............................. 1 6 3 F. Special Tooling Necessary to do this Service Bulletin ...................... 1 6 4
3. ACCOMPLISHMENT INSTRUCTIONS ................................. 1 6 5 A. GENERAL INFORMATION .................................... 1 6 5 B. WORK INSTRUCTIONS ...................................... 1 6 6 FIGURE 1: SURFACE HFEC INSPECTION OF TENSION TIE CENTER SECTIONS (STA 760 - STA 940) [Group 1-3, 13-14] ....................................... 1 7 7 FIGURE 2: SURFACE HFEC INSPECTION OF TENSION TIE CENTER SECTIONS (STA 800 - STA 940) [Group 4, 9] .......................................... 1 7 9 FIGURE 3: SURFACE HFEC INSPECTION OF TENSION TIE CENTER SECTIONS (STA 800 - STA 880, STA 920, AND STA 940) [Group 5, 16] ........................... 1 8 1 FIGURE 4: SURFACE HFEC INSPECTION OF TENSION TIE CENTER SECTIONS (STA 840 - STA 940) [Group 6] ............................................ 1 8 3 FIGURE 5: SURFACE HFEC INSPECTION OF TENSION TIE CENTER SECTIONS (STA 840 - STA 880, STA 920, AND STA 940) [Group 7] ............................. 1 8 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 3 of 203 BOEING SERVICE BULLETIN 747-53A2605
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FIGURE 6: SURFACE HFEC INSPECTION OF TENSION TIE CENTER SECTIONS (STA 780 - STA 880, STA 920, AND STA 940) [Group 8, 11-12, 15] ....................... 1 8 7 FIGURE 7: SURFACE HFEC INSPECTION OF TENSION TIE CENTER SECTIONS (STA 720 - STA 940) [Group 10] ........................................... 1 8 9 FIGURE 8: EDDY CURRENT INSPECTIONS OF ALL AREAS OF TENSION TIES - LEFT SIDE [Group 1-16] .............................................. 1 9 2 FIGURE 9: EDDY CURRENT INSPECTIONS OF ALL AREAS OF TENSION TIES - RIGHT SIDE [Group 1-16] .............................................. 1 9 7 APPENDIX A: TENSION TIE DISCONNECTION METHODS ....................... 2 0 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 4 of 203 BOEING SERVICE BULLETIN 747-53A2605
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2605Original Issue: October 08, 2009 Revision 3: July 10, 2013 ATA System: 5312 SUBJECT: FUSELAGE - Center Section - Tension Ties and Frames - Modification and Inspection This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes modified in accordance with the original issue, Revision 1, or Revision 2 of this service bulletin. Airplanes previously modified in accordance with this service bulletin will require surface high frequency eddy current (HFEC) inspection for cracks in the forward and aft tension tie channels around fasteners in unmodified areas where fastener holes were not zero-timed during modification. Refer to paragraph
1.E., Compliance for the compliance time of this additional inspection. However, no additional modification is necessary.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-13-08 is related to this service bulletin.
Airplanes RG001-RG009, RG091-RG091, RG095-RG095, RG101-RG104, RG121-RG126, RG141-RG142, RG161-RG164, RG171-RG174, RG191-RG193, RG211-RG213, RG221-RG222, RH111-RH112, RH121-RH122 were added to the service bulletin effectivity as Group 17.
Airplanes RH101 and RH102 were added to the service bulletin effectivity as Group 18.
REASON FOR REVISION This revision is sent to add the requirement to do surface high frequency eddy current (HFEC) inspection where fastener holes are not zero-timed during modification on Group 1-16 airplanes. Revision 3 also adds instructions for post-modification inspection of the entire tension tie for Group 1-16 airplanes, and adds effectivity and modification instructions for 747SP (Group 17-18) airplanes.
These sections were changed:
1. In the Summary: Updated the Background and Action sections to reflect new inspection requirements.
Also, updated Compliance section with current Airworthiness Directive (AD) information.
2. In Paragraph 1.A., Effectivity: Added 747SP airplanes as Group 17 and Group 18. Also, revised the Group/Configuration table to specify configurations for airplanes that have and have not already had the tension tie and frame modification accomplished.
3. In Paragraph 1.C., Reason: Added reason for Revision 3.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 5 of 203
4. In Paragraph 1.D., Description: Updated the description of service bulletin actions and added "more work" statement related to Revision 3.
5. In Paragraph 1.E., Compliance: Updated Airworthiness Directive information. Revised compliance Table 1 to apply only to initial inspection and modification. Added new compliance Tables 2, 3, and 4 for Post-Modification inspections. Added new compliance Table 5 for additional (more work) inspection requirements on airplanes that had the tension tie and frame modification accomplished in accordance with a previous revision of this service bulletin. Added new compliance Tables 6 and 7 for Group 17 and 18 airplanes.
6. In Paragraph 1.F., Approval: Updated Alternative Method of Compliance (AMOC) statements for AD 2004-07-22 R1, 84-19-01, and 94-13-06. Added new AMOC statements for AD 2012-13-08 (which superseded AD 2006-01-07).
7. In Paragraph 1.G., Manpower: Added task hour estimates for tension tie center section inspections and post-modification inspections.
8. In Paragraph 1.J.2., Data Supplied with this Service Bulletin: Added drawings required for post-modification inspections of Group 1-16 airplanes and added drawings required for modification of Group 17-18 airplanes. Also added KPL data previously not listed.
9. In Paragraph 3.A., General Information: Added note 15.
10. In Paragraph 3.B., Work Instructions: Added PART 3 to give instructions for new post-modification inspection requirements, and added PART 4 to give instructions for inspection of the unmodified tension tie center sections. PART 4 is a "more work" requirement for airplanes that had the tension tie and frame modification accomplished in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin. Also in the Work Instructions, added PART 5 and PART 6 for modification of Group 17-18 airplanes.
11. In Figures 1 - 7: These new figures have been added to give inspection instructions for the unmodified tension tie center sections on Group 1-16 airplanes.
12. In Figures 8 and 9: These new figure have been added to give post-modification inspection instructions not previously included in the service bulletin for Group 1-16 airplanes.
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 October 08, 2009Original Issue:
May 27, 2010Revision 1:
December 09, 2011Revision 2:
July 10, 2013Revision 3:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 6 of 203 BOEING SERVICE BULLETIN 747-53A2605
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2605Original Issue: October 08, 2009 Revision 3: July 10, 2013 ATA System: 5312 SUBJECT: FUSELAGE - Center Section - Tension Ties and Frames - Modification and Inspection
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions for modification of upper deck tension ties and adjacent frame structure on non stretched upper deck (Non-SUD) airplanes. The tension ties have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). WFD can 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.
For more information about WFD, refer to Boeing Service Letter 747-SL-53-088.
Service Bulletin 747-53A2502 recommends initial and repeat inspections of Non-SUD airplane tension ties from body station (STA) 760 to STA 940 (STA 1040 to STA 1140 for 747SP). Service Bulletin 747-53A2502 was issued to address multiple reports of cracks found in tension ties and adjacent frame structure.
Group 1-16:
Accomplishment of the modification in this service bulletin terminates the repeat inspection requirement of Service Bulletin 747-53A2502.
Group 17-18:
Accomplishment of the modification in this service bulletin does not terminate the repeat inspection requirement of Service Bulletin 747-53A2502, but a new inspection threshold is provided.
Boeing Service Related Problem (SRP) 747-SRP-53-0200 and 747-SRP-53-0438 are related to this service bulletin.
As a part of a service bulletin validation program, this modification and inspection was completed on airplane RD041 by Service Bulletin 747-53A2605, Original Issue. The modification and inspection completed on airplane RD041 by Service Bulletin 747-53A2605, Original Issue is equivalent to the Revision 2 of this service bulletin.
Airplane RD041 has the configuration of a Group 5 airplane.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 7 of 203
Subsequent to the release of Revision 2 of this service bulletin, Boeing has determined that additional inspections are required in the center sections of the tension ties where the tension tie channels are not replaced and where fastener holes are not zero-timed during modification.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION (PRR 85901-68RS) Get access to the Frame to Tension Tie joints in Section 42. At each station, disconnect and remove a section of the tension tie between the frame and approximate Buttock Line (BL) 36. For each frame, remove a specified section of the frame above and below the tension tie attach point. After the existing frame and tension tie structure has been removed and discarded, install new frame and tension tie structure. Do the modification on both sides of the airplane.
Group 1-16:
Do surface high frequency eddy current (HFEC) inspection of the tension ties at fastener locations where the holes were not zero-timed during modification. If cracks are found, contact Boeing for repair instructions and do the repair.
Group 1-16:
After modification, do initial and repeat detailed, high frequency eddy current (HFEC), and low frequency eddy current (LFEC) inspections of the tension ties at the compliance time specified in paragraph 1.E., Compliance.
If cracks are found, contact Boeing for repair instructions and do the repair.
Group 17-18:
After modification, do initial and repeat detailed and HFEC inspections for cracks in all tension ties, adjacent frame structure, and adjacent structure that attaches to the tension ties. If cracks are found, contact Boeing for repair instructions and do the repair.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ALERTALERT
EFFECTIVITY 747-100, 747-100B, 747-200B, 747-200C, 747-200F, 747-400F, 747SR, and 747SP airplanes. Refer to Paragraph
1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 84-19-01, AD 94-13-06, AD 2004-07-22 R1, and AD 2012-13-08 are related to this service bulletin.
Refer to paragraph 1.E, Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the modification and inspections given in this service bulletin.
MANPOWER Refer to paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 9 of 203 BOEING SERVICE BULLETIN 747-53A2605
ALERTALERT
BOEING SERVICE BULLETIN 747-53A2605
ALERT ALERT STA STA 940 720
FRAME (TYPICAL)
TENSION TIE (TYPICAL) STA 720
MODIFY /INSPECT
TENSION TIES AND FRAMES NOTE: TENSION TIES ON 747SP AIRPLANES ARE FROM STA 1040 TO STA 1140
FWD STA 940 1732168 Original Issue: October 08, 2009 Revision 3: July 10, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2605 Work - See page 1 for details. 10 of 203
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2605 Original Issue: October 08, 2009 Revision 3: July 10, 2013 ATA System: 5312 SUBJECT: FUSELAGE - Center Section - Tension Ties and Frames - Modification and Inspection
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below. Refer to PRR 85901-68RS 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.
DESCRIPTIONCONFIGURATIONGROUP 747-100 and -200B airplanes with tension ties from STA 760 to STA 940, and a combination of tension ties at STA 760 and STA 940 that is unique. The Group 1 tension tie modification is similar to Group 2, except at STA 760. The Group 1 tension tie modification similar to Group 13, except at STA 940. This group requires 142U0102-233 tension tie modification kit.
-1 Group 1 airplanes not modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
1 Group 1 airplanes that were modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 11 of 203
DESCRIPTIONCONFIGURATIONGROUP 747-100 airplanes with tension ties from STA 760 to STA 940, and a combination of tension ties at STA 760 and STA 940 that is unique.
The Group 2 tension tie modification is similar to Group 1, except at STA 760. The Group 2 tension tie modification similar to Group 14, except at STA 940. This group requires 142U0102-233 tension tie modification kit.
-2 Group 2 airplanes not modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
1 Group 2 airplanes that were modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
2 -100 and -200B airplanes with tension ties from STA 760 to STA 940, and a unique tension tie configuration at STA 760.
-3 Group 3 airplanes not modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
1 Group 3 airplanes that were modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
2 747-100, -100B, -200B and SR airplanes with tension ties from STA 800 to STA 940, and a unique combination of tension ties at STA 900, 920, and 940.
-4 Group 4 airplanes not modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
1 Group 4 airplanes that were modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
2 747-200B and SR airplanes with tension ties from STA 800 to STA 940, and a unique frame configuration.
-5 Group 5 airplanes not modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
1 Group 5 airplanes that were modified in accordance with the Original Issue, Revision 1, or Revision 2 of this service bulletin.
2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2009 747-53A2605Revision 3: July 10, 2013 12 of 203 BOEING SERVICE BULLETIN 747-53A2605