Boeing ASB 747-53A2610: Revision 1, text

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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2610 Original Issue: May 10, 2007 Revision 1: December 04, 2012 ATA System: 5312 SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Tie Inspection, Repair, and Modification - Stretched Upper Deck (SUD) Special Freighters 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:

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner™, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management Company.

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 1 of 220

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Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 2 of 220 BOEING SERVICE BULLETIN 747-53A2610

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Table of Contents

Revision Transmittal Sheet5

Summary7

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

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 3 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 7 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1

1. Existing Data: ......................................... 2 1

2. Data Supplied with this Service Bulletin: ........................... 2 2

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 2 M. Software Accomplishment Summary ................................ 2 2

2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary for Each Airplane ................................. 2 3

1. Kits/Parts: ........................................... 2 3

2. Parts and Materials Supplied by the Operator: ........................ 3 1

3. Parts Modified and Reidentified: ............................... 3 2

4. Parts Removed and Not Replaced: .............................. 3 3 D. Parts Necessary to Change Spares ................................. 3 3 E. Special Tooling - Price and Availability ............................... 3 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 3

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: STA 1120, 1160, 1200, AND 1220 TENSION TIE DETAILED INSPECTION - TYPICAL - LEFT SIDE .............................................. 3 9 FIGURE 2: STA 1120, 1160, 1200, AND 1220 TENSION TIE DETAILED INSPECTION - TYPICAL - RIGHT SIDE .............................................. 4 2 FIGURE 3: STA 880 - STA 1100 TENSION TIE DETAILED INSPECTION - TYPICAL - LEFT SIDE . 44 FIGURE 4: STA 880 - STA 1100 TENSION TIE DETAILED INSPECTION - TYPICAL - RIGHT SIDE . 46 FIGURE 5: STA 880 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 4 8 FIGURE 6: STA 900 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 5 3 FIGURE 7: STA 920 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 5 8 FIGURE 8: STA 940 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 6 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 3 of 220 BOEING SERVICE BULLETIN 747-53A2610

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FIGURE 9: STA 960 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 6 8 FIGURE 10: STA 980 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 7 3 FIGURE 11: STA 1000 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 7 8 FIGURE 12: STA 1020 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 8 3 FIGURE 13: STA 1040 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 8 8 FIGURE 14: STA 1060 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 9 3 FIGURE 15: STA 1080 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ............ 9 8 FIGURE 16: STA 1100 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ........... 1 0 3 FIGURE 17: STA 1120 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ........... 1 0 8 FIGURE 18: STA 1160 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ........... 1 1 3 FIGURE 19: STA 1200 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ........... 1 1 8 FIGURE 20: STA 1220 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE ........... 1 2 3 FIGURE 21: STA 880 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE ........... 1 2 8 FIGURE 22: STA 900 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE ........... 1 3 3 FIGURE 23: STA 920 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE ........... 1 3 8 FIGURE 24: STA 940 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE ........... 1 4 3 FIGURE 25: STA 960 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE ........... 1 4 8 FIGURE 26: STA 980 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE ........... 1 5 3 FIGURE 27: STA 1000 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 5 8 FIGURE 28: STA 1020 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 6 3 FIGURE 29: STA 1040 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 6 8 FIGURE 30: STA 1060 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 7 3 FIGURE 31: STA 1080 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 7 8 FIGURE 32: STA 1100 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 8 3 FIGURE 33: STA 1120 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 8 8 FIGURE 34: STA 1160 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 9 3 FIGURE 35: STA 1200 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 1 9 8 FIGURE 36: STA 1220 TENSION TIE REPAIR OR MODIFICATION - RIGHT SIDE .......... 2 0 3 FIGURE 37: TENSION TIE HIGH FREQUENCY EDDY CURRENT INSPECTION AT BODY STATIONS 1120, 1160, 1200 AND 1220 - LEFT SIDE ......................... 2 0 8 FIGURE 38: TENSION TIE HIGH FREQUENCY EDDY CURRENT INSPECTION AT BODY STATIONS 1120, 1160, 1200 AND 1220 - RIGHT SIDE ......................... 2 1 1 FIGURE 39: TENSION TIE HIGH FREQUENCY EDDY CURRENT INSPECTION AT BODY STATIONS 880 THROUGH 1100 - LEFT SIDE ................................ 2 1 4 FIGURE 40: TENSION TIE HIGH FREQUENCY EDDY CURRENT INSPECTION AT BODY STATIONS 880 THROUGH 1100 - RIGHT SIDE ............................... 2 1 7 Appendix A: TENSION TIE DISCONNECTION .............................. 2 2 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 4 of 220 BOEING SERVICE BULLETIN 747-53A2610

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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2610Original Issue: May 10, 2007 Revision 1: December 04, 2012 ATA System: 5312 SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Tie Inspection, Repair, and Modification - Stretched Upper Deck (SUD) Special Freighters This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes that were not previously repaired or modified as given in the original issue of this of this service bulletin. At any tension tie location at body stations (STA) 880 - 1120, 1160, 1200, and 1220 where repair or modification has not previously been done, Boeing recommends that the modification be done at the time given in Paragraph 1.E., Compliance. In addition, Boeing also recommends that operators do a surface high frequency eddy current (HFEC) inspection of the tension tie channels during future inspections that are done as given in this service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-16-19 is related to this service bulletin.

REASON FOR REVISION This revision is sent to recommend that operators accomplish the modification given in this service bulletin from STA 880 to STA 1100, and incorporate HFEC inspections at all tension tie locations inspected by this service bulletin.

These sections were changed:

1. In the Summary: Updated Background and Action sections, revised Effectivity description, added reference to related AD 2007-16-19, and updated summary illustration.

2. In paragraph 1.C., Reason: Added reference to Service Related Problem 747-SRP-53-0403 and Service Letter 747-SL-53-088. Also, added Widespread Fatigue Damage information related to the service bulletin revision.

3. In paragraph 1.D., Description: Revised description of work to reflect new inspection and modification recommendations. Added Revision 1 "more work" statement.

4. In paragraph 1.E., Compliance: Added related AD statement for AD 2007-16-19. Revised Table 1 to make the grace period compliance time based from the effective date of the AD, and remove inspection for STA 1140 and STA 1180 tension ties, which were not changed during Special Freighter or Boeing Converted Freighter modification. Added new Table 2 for recommended compliance information related to high frequency eddy current inspection and modification.

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5. In paragraph 1.F., Approval: Added alternative method of compliance (AMOC) statement for AD 2007-16-19.

6. In paragraph 1.G., Manpower: Added task hours for new Figures 37 thru 40.

7. In paragraph 1.K., Publications Affected: Added statement for damage tolerance based structural inspections.

8. In paragraph 3.A., General Information: Incorporated current general information notes.

9. In paragraph 3.B., Work Instructions: In PART 1 and PART 2, added "no crack found" condition and specified that the inspections done in these sections are "detailed" inspections. In PART 3, clarified in some steps that the procedures are also for modification, not just repair. Also, PART 4 and PART 5 have been added for high frequency eddy current inspection procedures.

10. In Figure 1 and Figure 2: Clarified that inspection is only required at STA 1120, 1160, 1200, and 1220.

11. In Figure 3 and Figure 4: Revised footnote (a).

12. In Figure 11 and Figure 27: Changed "aft channel" to "forward channel" at two locations.

13. Figures 37 thru 40: These new figures are added for high frequency eddy current inspections.

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 May 10, 2007Original Issue:

December 04, 2012Revision 1:

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 6 of 220 BOEING SERVICE BULLETIN 747-53A2610

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2610Original Issue: May 10, 2007 Revision 1: December 04, 2012 ATA System: 5312 SUBJECT: FUSELAGE - Main Frame - Center Section - Tension Tie Inspection, Repair, and Modification - Stretched Upper Deck (SUD) Special Freighters

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin gives instructions to do inspections, repairs, and modifications to upper deck tension ties on stretched upper deck (SUD) airplanes that were modified to Special Freighter configuration. The affected tension ties are installed at body stations (STA) 880 - 1120, 1160, 1200, and 1220 aft of the upper deck floor beams. The tension ties at these locations are installed during Boeing modification to Special Freighter. Undetected cracks in tension ties will grow by fatigue due to cyclic cabin pressure loading, and could result in severed tension ties. Continued operation with severed tension ties will lead to fractured frames and rapid depressurization of the airplane.

One operator reported that six cracks were found in the aft tension tie channels at four station locations of one airplane. The largest crack was approximately 0.5 inches in length. The airplane on which the cracks were found had accumulated 4856 flight cycles since Boeing modification to Special Freighter. The cracks were found in the aft tension tie channels near the frame at a location where the flanges of the aft tension tie channels are machined down to a flat plate in order to attach to the frames.

Tension ties are considered to be structurally significant, in that they are critical to airplane structural integrity.

The failure of more than one tension tie can result in rapid depressurization of the airplane. This service bulletin provides instructions to inspect, and if necessary, repair the tension ties.

Boeing Service Related Problem (SRP) 747-SRP-53-0271 and 747-SRP-53-0403 are related to this service bulletin.

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 7 of 220

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Subsequent to the release of the original issue of this service bulletin, the upper deck tension ties have been determined to be structure that could develop Widespread Fatigue Damage (WFD). Due to the concern of WFD in the tension tie structure, Boeing now recommends that operators accomplish the modification given in this service bulletin at STA 880 to STA 1100. Previously, the modification was optional unless a crack was found during an inspection. Boeing recommends modification of STA 1120 to STA 1220 tension ties as given in Service Bulletin 747-53A2559.

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

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85901-120RS) Get access to the upper deck tension ties at STA 880 - 1120, 1160, 1200, and 1220. Do detailed and high frequency eddy current (HFEC) inspections for cracks in the channels of the tension ties where the aft channel is machined down to a flat plate. Inspect at the tension tie to frame joint within 2 inches inboard and outboard of the inner chord location of the frame at both the upper and lower flange of the tension tie.

If no cracks are found, repeat the detailed and HFEC inspections, and do modification of tension ties from STA 880 to STA 1100, at the times given in Paragraph 1.E., Compliance.

If cracks are found, repair as given in this service bulletin. Repeat inspections as given in this service bulletin are not required at locations where repair or modification has been done as given in this service bulletin. However, tension tie inspections given in the 747 Supplemental Structural Inspection Document (SSID) and Service Bulletin 747-53A2507 are still required.

EFFECTIVITY 747-200B/-300/-400 airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 8 of 220 BOEING SERVICE BULLETIN 747-53A2610

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COMPLIANCE Refer to Paragraph 1.E., Compliance.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-16-19 is related to this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of February 23, 2005. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

76.40145.40All

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 9 of 220 BOEING SERVICE BULLETIN 747-53A2610

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BOEING SERVICE BULLETIN 747-53A2610

ALERT ALERT STA 1220 STA 880 STA 1220 STA 880 TYPICAL:

DO DETAILED AND HIGH FREQUENCY EDDY CURRENT INSPECTIONS FOR CRACKS IN THE TENSION TIES AT STA 880-1120, 1160, 1200, AND 1220. IF CRACKS ARE FOUND, REPAIR AS THIS SERVICE BULLETIN. IF NO CRACKS ARE FOUND, REPEAT CRACKS ARE SHOWN IN

THE DETAILED AND HFEC INSPECTIONS, AND MODIFY THE STA 880 TO STA 1100 TENSION TIES AT THE TIMES SPECIFIED IN 1314060 PARAGRAPH 1.E., COMPLIANCE.

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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 Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below. Refer to PRR 85901-71RS and PRR 85901-120RS for data about this change.

DESCRIPTIONCONFIGURATIONGROUP 747-200B/-300 Stretched Upper Deck airplanes that have been modified by Boeing to Special Freighter configuration, and one 747-400 airplane that has been modified to Boeing Converted Freighter configuration.

-1 Airplane Models:

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GroupVariable Number 1RS762 1RS771 1RS786 1RT456

2. Spares Affected None.

B. Concurrent Requirements None.

C. Reason This service bulletin gives instructions to do inspections, repairs, and modifications to upper deck tension ties on stretched upper deck (SUD) airplanes that were modified to Special Freighter configuration. The affected tension ties are installed at body stations (STA) 880 - 1120, 1160, 1200, and 1220 aft of the upper deck floor beams. The tension ties at these locations are installed during Boeing modification to Special Freighter. Undetected cracks in tension ties will grow by fatigue due to cyclic cabin pressure loading, and could result in severed tension ties. Continued operation with severed tension ties will lead to fractured frames and rapid depressurization of the airplane.

The cracks were found in the aft tension tie channels near the frame at a location where the flanges of the aft tension tie channels are machined down to a flat plate in order to attach to the frames.

Tension ties are considered to be structurally significant, in that they are critical to airplane structural integrity. The failure of more than one tension tie can result in rapid depressurization of the airplane.

This service bulletin provides instructions to inspect, and if necessary, repair the tension ties.

Boeing Service Related Problem (SRP) 747-SRP-53-0271 and 747-SRP-53-0403 are related to this service bulletin.

Because of common access, the inspections given in Service Bulletin 747-53A2507 "FUSELAGE - Stretched Upper Deck Frame and Tension Tie - Inspection and Repair" can be done at the same time as the inspection and/or changes given in this service bulletin.

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

Original Issue: May 10, 2007 747-53A2610Revision 1: December 04, 2012 12 of 220 BOEING SERVICE BULLETIN 747-53A2610

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