# Boeing Alert Service Bulletin 747-53A2610: Revision 1

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- Document: [Boeing Alert Service Bulletin 747-53A2610](https://openairdocs.org/service-documents/boeing/747-53a2610.md)
- Title as filed: U.S. DOT/FAA - Boeing Service Bulletin
- Pages: 220
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## Text

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### Page 1

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:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 2007 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner™,
BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing
liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection
with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management
Company.
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3.0

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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
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
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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
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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:
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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.
Export Controlled ECCN: 9E991 - BOEING
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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 Air-
plane 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.
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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.
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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.
Original Issue: May 10, 2007
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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
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:
747-200B, 747-300, 747-400
GroupVariable Number
1RD601 - RD602
1RS721 - RS722
1RS741
1RS743
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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.
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.
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.
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.
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ALERTALERT

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Revision 1 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.
D. Description
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.
Revision 1 - 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.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
243, 244747-200B, 747-300, 747-400
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-16-19 is related to this service
bulletin.
For each affected tension tie, accomplish the inspections given in Tables 1 and 2 until modification is
accomplished as given in Paragraph 3.B., Work Instructions, PART 3 (for STA 880 - 1100) and as
given in Service Bulletin 747-53A2559 (for STA 1120 - 1220).
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Table 1: Recommended Compliance for Tension Tie Detailed Inspections and Repairs
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs Later)ActionCondition
-Within 1,000 flight cy-
cles after August 28,
2007.
Before the accumula-
tion of 4,000 flight cy-
cles since Boeing
modification to Special
Freighter or Boeing
Converted Freighter.
Do detailed inspections
for cracks in the Tension
Ties at STA 1120, 1160,
1200, and 1220 as given
in the Accomplishment
Instructions, paragraph
3.B., Part 1.
All airplanes.
-Within 1,000 flight cy-
cles after August 28,
2007.
Before the accumula-
tion of 8,000 flight cy-
cles since Boeing
modification to Special
Freighter or Boeing
Converted Freighter.
Do detailed inspections
for cracks in the Tension
Ties from STA 880 to
STA 1100 as given in the
Accomplishment Instruc-
tions, paragraph 3.B.,
Part 2.
4,000 flight cycles.
(b)
--Repeat the detailed in-
spections for cracks in
the Tension Ties at STA
1120, 1160, 1200, and
1220 as given in the Ac-
complishment Instruc-
tions, paragraph 3.B.,
Part 1.
All airplanes:
No crack found.
4,000 flight cycles.
(b)
--Repeat the detailed in-
spections for cracks in
the Tension Ties from
STA 880 to STA 1100 as
given in the Accomplish-
ment Instructions, para-
graph 3.B., Part 2.
-Before further flight.Repair as given in the
Accomplishment Instruc-
tions, paragraph 3.B.,
Part 3. (a)
All airplanes:
Crack found in
Tension Tie.
-Before further flight.Contact Boeing for repair
instructions, and do the
repair.
All airplanes:
Crack found in
bolt hole.
(a) No further action is necessary as given in this service bulletin at tension tie locations where paragraph
3.B., Part 3 - Tension Tie Repair or Modification has been done as given in this service bulletin.
(b) As an option to the repeat inspections, operators can do the modification at all tension tie locations as
given in paragraph 3.B., Part 3 - Tension Tie Repair or Modification. Modification at all tension tie locations
terminates the repeat inspection requirements of this service bulletin.
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### Page 15

Table 2: Tension Tie High Frequency Eddy Current Inspection and Modification (More Work)
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever Occurs Later)ActionCondition
--Within 4,000 flight
cycles after the
Revision 1 date of
this service bul-
letin.
Concurrent with
the next sched-
uled detailed in-
spection as given
in paragraph 1.E.,
Compliance, Ta-
ble 1.
Do surface high
frequency eddy
current (HFEC) in-
spections for
cracks in the ten-
sion ties at STA
1120, 1160, 1200,
and 1220 as given
in paragraph 3.B.,
Work Instructions,
PART 4.
All airplanes.
-Within 4,000 flight
cycles after the
Revision 1 date of
this service bul-
letin.
Concurrent with
the next scheduled
detailed inspection
as given in para-
graph 1.E., Compli-
ance, Table 1.
Before the accu-
mulation of 8,000
flight cycles after
Boeing modifica-
tion to Special
Freighter or Boe-
ing Converted
Freighter.
Do surface high
frequency eddy
current (HFEC) in-
spections for
cracks in the ten-
sion ties from STA
880 to STA 1100
as given in para-
graph 3.B., Work
Instructions, PART
5.
4,000 flight cy-
cles. (b)
---Repeat the sur-
face high frequen-
cy eddy current
(HFEC) inspec-
tions for cracks in
the tension ties at
STA 1120, 1160,
1200, and 1220 as
given in paragraph
3.B., Work Instruc-
tions, PART 4.
No crack
found.
4,000 flight cy-
cles. (b)
---Repeat the sur-
face high frequen-
cy eddy current
(HFEC) inspec-
tions for cracks in
the tension ties
from STA 880 to
STA 1100 as giv-
en in paragraph
3.B., Work Instruc-
tions, PART 5.
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### Page 16

Table 2: Tension Tie High Frequency Eddy Current Inspection and Modification (More Work)
Repeat Inter-
val (Not to Ex-
ceed)
Compliance Time (Whichever Occurs Later)ActionCondition
---Before further
flight.
Repair the tension
tie as given in
paragraph 3.B.,
Work Instructions,
PART 3. (a)
Crack found.
--Within 2,000 flight
cycles after the
Revision 1 date on
this service bul-
letin.
Before the accu-
mulation of
20,000 flight cy-
cles since Boeing
modification to
Special Freighter
or Boeing Con-
verted Freighter
Unless previously
accomplished, do
the modification of
the Tension Ties
from STA 880 to
STA 1100 as giv-
en in the Accom-
plishment Instruc-
tions, paragraph
3.B., PART 3. (c)
All airplanes.
(a) No further action is necessary as given in this service bulletin at tension tie locations where paragraph
3.B., Part 3 - Tension Tie Repair or Modification has been done as given in this service bulletin.
(b) As an option to the repeat inspections, operators can do the modification at all tension tie locations as
given in paragraph 3.B., Part 3 - Tension Tie Repair or Modification. Modification at all tension tie locations
terminates the repeat inspection requirements of this service bulletin.
(c) Boeing recommends modification of STA 1120 - 1220 tension ties as given in Service Bulletin 747-53A2559,
instead of paragraph 3.B., Part 3.
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.
In addition, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the
accomplishment of the inspection, repair, and modification procedures with corresponding compliance
times given in Service Bulletin 747-53A2610, Revision 1, as an alternative method of compliance to
the inspection, repair, and optional terminating action requirements with corresponding compliance
times required by paragraphs (f) and (i) of AD 2007-16-19. All provisions of AD 2007-16-19 that are
not specifically referenced in this paragraph remain fully applicable and must be complied with
accordingly.
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### Page 17

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
— Time to find the tools.
Elapsed HoursTask-HoursNumber of Per-
sons
Task
8.2516.502Open Access
---Inspect Left Side
0.600.601Figure 1
1.101.101Figure 3
0.800.801Figure 37
1.201.201Figure 39
---Inspect Right Side
0.600.601Figure 2
1.101.101Figure 4
0.800.801Figure 38
1.201.201Figure 40
---Repair/Modification Left Side
1.753.502Figure 5
1.753.502Figure 6
1.753.502Figure 7
1.753.502Figure 8
1.753.502Figure 9
1.753.502Figure 10
1.753.502Figure 11
1.753.502Figure 12
1.753.502Figure 13
1.503.002Figure 14
1.503.002Figure 15
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### Page 18

Elapsed HoursTask-HoursNumber of Per-
sons
Task
1.503.002Figure 16
1.503.002Figure 17
1.503.002Figure 18
1.503.002Figure 19
1.503.002Figure 20
---Repair/Modification Right Side
1.753.502Figure 21
1.753.502Figure 22
1.753.502Figure 23
1.753.502Figure 24
1.753.502Figure 25
1.753.502Figure 26
1.753.502Figure 27
1.753.502Figure 28
1.753.502Figure 29
1.503.002Figure 30
1.503.002Figure 31
1.503.002Figure 32
1.503.002Figure 33
1.503.002Figure 34
1.503.002Figure 35
1.503.002Figure 36
8.2516.502Close Access
76.40145.40TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
For repairs at each tension tie location:
STA 880:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+264.0+0.3Repair at only one end of the tension tie
+528.0+0.6Repair at both ends of the tension tie
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### Page 19

STA 900:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+270.0+0.3Repair at only one end of the tension tie
+540.0+0.6Repair at both ends of the tension tie
STA 920:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+276.0+0.3Repair at only one end of the tension tie
+552.0+0.6Repair at both ends of the tension tie
STA 940:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+282.0+0.3Repair at only one end of the tension tie
+564.0+0.6Repair at both ends of the tension tie
STA 960:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+288.0+0.3Repair at only one end of the tension tie
+576.0+0.6Repair at both ends of the tension tie
STA 980:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+294.0+0.3Repair at only one end of the tension tie
+588.0+0.6Repair at both ends of the tension tie
STA 1000:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+300.0+0.3Repair at only one end of the tension tie
+600.0+0.6Repair at both ends of the tension tie
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### Page 20

STA 1020:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+306.0+0.3Repair at only one end of the tension tie
+612.0+0.6Repair at both ends of the tension tie
STA 1040:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+312.0+0.3Repair at only one end of the tension tie
+624.0+0.6Repair at both ends of the tension tie
STA 1060:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+318.0+0.3Repair at only one end of the tension tie
+636.0+0.6Repair at both ends of the tension tie
STA 1080:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+324.0+0.3Repair at only one end of the tension tie
+648.0+0.6Repair at both ends of the tension tie
STA 1100:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+330.0+0.3Repair at only one end of the tension tie
+660.0+0.6Repair at both ends of the tension tie
STA 1120:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+224.0+0.2Repair at only one end of the tension tie
+448.0+0.4Repair at both ends of the tension tie
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### Page 21

STA 1160:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+232.0+0.2Repair at only one end of the tension tie
+464.0+0.4Repair at both ends of the tension tie
STA 1200:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+240.0+0.2Repair at only one end of the tension tie
+480.0+0.4Repair at both ends of the tension tie
STA 1220:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+244.0+0.2Repair at only one end of the tension tie
+488.0+0.4Repair at both ends of the tension tie
Total if modification is done at all tension tie locations:
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+10080.0+9.6
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 85901-120RS and PRR 85901-71RS
b. Boeing Service Bulletin 747-53A2507, 747-53A2559
c. Boeing Service Letter 747-SL-51-048, 747-SL-53-088
d. Boeing Service Related Problem (SRP) 747-SRP-53-0271, 747-SRP-53-0403
e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2007-16-19
f. Standard Overhaul Practices Manual (SOPM) 20-41-05, 20-43-03, 20-50-19
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### Page 22

g. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00
h. 747-100/200/300 Aircraft Maintenance Manual (AMM) 24-22-00, 25-14-02, 25-22-04, 25-25-01
i. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 25-14-02, 25-22-04, 25-25-01
j. Supplemental Structural Inspection Document (SSID) D6-35022
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Tension Tie Rework Instl - STA 880 thru STA 1220814B9001
This drawing was used to prepare this service bulletin. This drawing is not necessary to make the
specified changes, and is not supplied with this service bulletin. This drawing 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 but no new DTIs are necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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### Page 23

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown
below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares.
More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the
date Boeing gets the purchase order.
Unit Price thru
Mar 31/07
ROLT
(Weeks)
QTYDateName015U1804 Number
$14,948.00391May 25/07TOPKIT - TENSION TIE
REPAIR/MODIFICA-
TION
015U1804-1
9Jul 24/07
$2,292.0062--OVERSIZE FASTENER
KIT
015U1804-101
B. Industry Support Information
Boeing warranty remedies are available for 747 airplanes in warranty as of February 23, 2005. For
inspection task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to
Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is
found during the inspection for airplanes in warranty as of that date and additional task hours parts are
required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to
this service bulletin number and reference the airplane variable number in your purchase order.
C. Parts Necessary for Each Airplane
1. Kits/Parts:
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane.
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
Figure Kit
13121110987651Top Kit
1111111111015U1804-1
Figure Kit
23222120191817161514Top Kit
1111111111015U1804-1
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### Page 24

Figure Kit
33323130292827262524Top Kit
1111111111015U1804-1
Figure Kit
363534Top Kit
111015U1804-1
Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
987651
Qty
DOUBLER11111-814B9001-33
BOLT, PROTRUD-
ING HD
-----1BACB30NX6K3X
BOLT, PROTRUD-
ING HD
-----5BACB30NX6K4X
BOLT, PROTRUD-
ING HD
-----4BACB30NX6K5X
BOLT, PROTRUD-
ING HD
4444411BACB30NX6K6X
BOLT, PROTRUD-
ING HD
6666615BACB30NX6K7X
BOLT, PROTRUD-
ING HD
5555510BACB30NX6K8X
HI LOK-----2BACB30NX8K5
BOLT-----9BACB30NX8K6
BOLT, PROTRUD-
ING HD
6666614BACB30NX8K6X
BOLT, HEX DRIVE-----3BACB30NX8K7
BOLT, PROTRUD-
ING HD
-----1BACB30NX8K7X
BOLT, 12 PT
HEAD
444448BACB30US4K10X
BOLT, 12 PT
HEAD
444449BACB30US4K12X
BOLT, 12 PT
HEAD
-----1BACB30US4K5X
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### Page 25

Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
987651
Qty
BOLT, 12 PT
HEAD
-----1BACB30US4K6X
BOLT, 12 PT
HEAD
-----1BACB30US4K7X
BOLT, 12 PT
HEAD
-----1BACB30US4K8X
COLLAR151515151530BACC30BH6
COLLAR6666618BACC30BH8
FILLER, FLAT111111BACF3F023J089AN
RADIUS FILLER222221BACF3H08JP008HN
NUT888887BACN10HR4CD
RIVET, UNIVER-
SAL HD
-----4BACR15BB6D7C
WASHER, PLAIN555554BACW10BP31DP
WASHER, 1/64
O.S.
88888-BACW10BP41APU
WASHER, PLAIN88888-BACW10BP41CD
WASHER, PLAIN22222-BACW10BP41DP
WASHER, PLAIN88888-BACW10BP41NAPU
Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
151413121110
Qty
DOUBLER-----1814B9001-33
DOUBLER1111--814B9001-34
DOUBLER----1-814B9001-40
BOLT, PROTRUD-
ING HD
4444-4BACB30NX6K6X
BOLT, PROTRUD-
ING HD
446686BACB30NX6K7X
BOLT, PROTRUD-
ING HD
777795BACB30NX6K8X
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### Page 26

Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
151413121110
Qty
BOLT, PROTRUD-
ING HD
666666BACB30NX8K6X
BOLT, 12 PT
HEAD
3444-4BACB30US4K10X
BOLT, 12 PT
HEAD
4344-4BACB30US4K12X
BOLT, 12 PT
HEAD
----1-BACB30US4K5X
BOLT, 12 PT
HEAD
----5-BACB30US4K6X
BOLT, 12 PT
HEAD
----2-BACB30US4K7X
BOLT, 12 PT
HEAD
----1-BACB30US4K8X
COLLAR151517171715BACC30BH6
COLLAR666666BACC30BH8
FILLER, FLAT111111BACF3F023J089AN
RADIUS FILLER1122-2BACF3H08JP008HN
NUT778898BACN10HR4CD
WASHER, PLAIN555555BACW10BP31DP
WASHER, 1/64
O.S.
778898BACW10BP41APU
WASHER, PLAIN778898BACW10BP41CD
WASHER, PLAIN222222BACW10BP41DP
WASHER, PLAIN778898BACW10BP41NAPU
Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
212019181716
Qty
DOUBLER1-----814B9001-33
DOUBLER-----1814B9001-35
DOUBLER----1-814B9001-36
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### Page 27

Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
212019181716
Qty
DOUBLER---1--814B9001-37
DOUBLER--1---814B9001-38
DOUBLER-1----814B9001-39
BOLT, PROTRUD-
ING HD
--11--BACB30NX6K3X
BOLT, PROTRUD-
ING HD
-6578-BACB30NX6K4X
BOLT, PROTRUD-
ING HD
-5463-BACB30NX6K5X
BOLT, PROTRUD-
ING HD
4-2-14BACB30NX6K6X
BOLT, PROTRUD-
ING HD
6----6BACB30NX6K7X
BOLT, PROTRUD-
ING HD
5----5BACB30NX6K8X
HI LOK-124--BACB30NX8K5
BOLT--6-2-BACB30NX8K6
BOLT, PROTRUD-
ING HD
6----6BACB30NX8K6X
BOLT, HEX DRIVE-8134-BACB30NX8K7
BOLT, PROTRUD-
ING HD
----3-BACB30NX8K7X
BOLT, 12 PT
HEAD
4----3BACB30US4K10X
BOLT, 12 PT
HEAD
4----4BACB30US4K12X
COLLAR151112141215BACC30BH6
COLLAR699796BACC30BH8
FILLER, FLAT111111BACF3F023J089AN
RADIUS FILLER2----2BACF3H08JP008HN
NUT8----7BACN10HR4CD
RIVET, UNIVER-
SAL HD
-8642-BACR15BB6D7C
WASHER, PLAIN-1111-BACW10BP31APU
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### Page 28

Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
212019181716
Qty
WASHER, PLAIN533345BACW10BP31DP
WASHER, 1/64
O.S.
8---17BACW10BP41APU
WASHER, PLAIN8----7BACW10BP41CD
WASHER, PLAIN2----2BACW10BP41DP
WASHER, PLAIN8----7BACW10BP41NAPU
WASHER-3332-BACW10BP4APU
Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
272625242322
Qty
DOUBLER-11111814B9001-33
DOUBLER1-----814B9001-40
BOLT, PROTRUD-
ING HD
-44444BACB30NX6K6X
BOLT, PROTRUD-
ING HD
866666BACB30NX6K7X
BOLT, PROTRUD-
ING HD
955555BACB30NX6K8X
BOLT, PROTRUD-
ING HD
666666BACB30NX8K6X
BOLT, 12 PT
HEAD
-44444BACB30US4K10X
BOLT, 12 PT
HEAD
-44444BACB30US4K12X
BOLT, 12 PT
HEAD
1-----BACB30US4K5X
BOLT, 12 PT
HEAD
5-----BACB30US4K6X
BOLT, 12 PT
HEAD
2-----BACB30US4K7X
BOLT, 12 PT
HEAD
1-----BACB30US4K8X
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Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
272625242322
Qty
COLLAR171515151515BACC30BH6
COLLAR666666BACC30BH8
FILLER, FLAT111111BACF3F023J089AN
RADIUS FILLER-22222BACF3H08JP008HN
NUT988888BACN10HR4CD
WASHER, PLAIN555555BACW10BP31DP
WASHER, 1/64
O.S.
988888BACW10BP41APU
WASHER, PLAIN988888BACW10BP41CD
WASHER, PLAIN222222BACW10BP41DP
WASHER, PLAIN988888BACW10BP41NAPU
Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
333231302928
Qty
DOUBLER--1111814B9001-34
DOUBLER-1----814B9001-35
DOUBLER1-----814B9001-36
BOLT, PROTRUD-
ING HD
8-----BACB30NX6K4X
BOLT, PROTRUD-
ING HD
3-----BACB30NX6K5X
BOLT, PROTRUD-
ING HD
144444BACB30NX6K6X
BOLT, PROTRUD-
ING HD
-64466BACB30NX6K7X
BOLT, PROTRUD-
ING HD
-57777BACB30NX6K8X
BOLT2-----BACB30NX8K6
BOLT, PROTRUD-
ING HD
-66666BACB30NX8K6X
BOLT, HEX DRIVE4-----BACB30NX8K7
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### Page 30

Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
333231302928
Qty
BOLT, PROTRUD-
ING HD
3-----BACB30NX8K7X
BOLT, 12 PT
HEAD
-33444BACB30US4K10X
BOLT, 12 PT
HEAD
-44344BACB30US4K12X
COLLAR121515151717BACC30BH6
COLLAR966666BACC30BH8
FILLER, FLAT111111BACF3F023J089AN
RADIUS FILLER-21122BACF3H08JP008HN
NUT-77788BACN10HR4CD
RIVET, UNIVER-
SAL HD
2-----BACR15BB6D7C
WASHER, PLAIN1-----BACW10BP31APU
WASHER, PLAIN455555BACW10BP31DP
WASHER, 1/64
O.S.
177788BACW10BP41APU
WASHER, PLAIN-77788BACW10BP41CD
WASHER, PLAIN-22222BACW10BP41DP
WASHER, PLAIN-77788BACW10BP41NAPU
WASHER2-----BACW10BP4APU
Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
363534
Qty
DOUBLER--1814B9001-37
DOUBLER-1-814B9001-38
DOUBLER1--814B9001-39
BOLT, PROTRUD-
ING HD
-11BACB30NX6K3X
BOLT, PROTRUD-
ING HD
657BACB30NX6K4X
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Kit 015U1804-1 - Group 1:
NotesExisting Part
Number
NameFigureNew Part Number
363534
Qty
BOLT, PROTRUD-
ING HD
546BACB30NX6K5X
BOLT, PROTRUD-
ING HD
-2-BACB30NX6K6X
HI LOK124BACB30NX8K5
BOLT-6-BACB30NX8K6
BOLT, HEX DRIVE813BACB30NX8K7
COLLAR111214BACC30BH6
COLLAR997BACC30BH8
FILLER, FLAT111BACF3F023J089AN
RIVET, UNIVER-
SAL HD
864BACR15BB6D7C
WASHER, PLAIN111BACW10BP31APU
WASHER, PLAIN333BACW10BP31DP
WASHER333BACW10BP4APU
2. Parts and Materials Supplied by the Operator:
NotesNameQTYPart Number /
Specification
(a)Chemical Conversion Coating6 ozAlodine
(b)Primer6 ozBMS 10-11, Type I
(c) (d)BOLT14BACB30NX10K6
(c) (d)BOLT2BACB30NX10K7
(c) (d)BOLT, PROTRUDING HD2BACB30NX6K3Y
(c) (d)BOLT, PROTRUDING HD10BACB30NX6K4Y
(c) (d)BOLT, PROTRUDING HD2BACB30NX6K5X
(c) (d)BOLT, PROTRUDING HD6BACB30NX6K5Y
(c) (d)BOLT, PROTRUDING HD18BACB30NX6K6Y
(c) (d)BOLT, PROTRUDING HD26BACB30NX6K7Y
(c) (d)BOLT, PROTRUDING HD28BACB30NX6K8Y
(c) (d)HI-LOK2BACB30NX8K3
(c) (d)HI-LOK5BACB30NX8K4
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NotesNameQTYPart Number /
Specification
(c) (d)HI LOK4BACB30NX8K5
(c) (d)BOLT, PROTRUDING HD4BACB30NX8K5X
(c) (d)BOLT, PROTRUDING HD2BACB30NX8K5Y
(c) (d)BOLT10BACB30NX8K6
(c) (d)BOLT, PROTRUDING HD28BACB30NX8K6Y
(c) (d)BOLT, HEX DRIVE13BACB30NX8K7
(c) (d)BOLT, PROTRUDING HD8BACB30NX8K7X
(c) (d)BOLT, PROTRUDING HD5BACB30NX8K7Y
(c) (d)BOLT14BACB30NX8K8
(c) (d)BOLT16BACB30US4K10Y
(c) (d)BOLT, 12 PT HEAD18BACB30US4K12Y
(c) (d)BOLT, 12 PT HEAD2BACB30US4K5Y
(c) (d)BOLT, 12 PT HEAD2BACB30US4K6Y
(c) (d)BOLT2BACB30US4K7Y
(c) (d)BOLT, 12 PT HEAD2BACB30US4K8Y
(c) (d)BOLT, 12 PT HEAD8BACB30US6K10
(c) (d)BOLT, 12 PT HEAD8BACB30US6K11
(c) (d)BOLT, 12 PT HEAD2BACB30US6K12
(c) (d)BOLT, 12 PT HEAD4BACB30US6K6
(c) (d)BOLT, 12 PT HEAD2BACB30US6K7
(c) (d)BOLT, 12 PT HEAD2BACB30US6K8
(c) (d)COLLAR20BACC30BH10
(a) Refer to SOPM 20-43-03 for material alternatives.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
(c) These are oversize fasteners that may be required if holes are damaged or small cracks
are found during repair/modification. Operators can order all oversize fasteners in oversize
fastener kit 015U1804-101.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
3. Parts Modified and Reidentified:
None.
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### Page 33

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.
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### Page 34

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BLANK PAGE

### Page 35

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 and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque limits to tighten nuts and bolts are in SRM Chapter 51
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet 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. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
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 in 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. Do not disconnect adjacent tension ties at the same time. Only disconnect every
other tension tie at one end, or both ends, as shown in Appendix A.
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### Page 36

9. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
10. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
11. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
12. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
B. WORK INSTRUCTIONS
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:
NOTE: PART 1 and PART 2 inspections have a different compliance time for initial inspection.
If only PART 1 inspection is being done, then access is only required from body station
(STA) 1120 to STA 1220.
a. Remove the seats as necessary between STA 880 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. Remove the main deck ceiling panels as necessary between STA 880 and STA 1220. Refer
to 747-100/200/300 AMM 25-22-04 or 747-400 AMM 25-22-04 as an accepted procedure.
c. Remove insulation as necessary between STA 880 and STA 1220. Refer to 747-100/200/300
AMM 25-14-02 or 747-400 AMM 25-14-02 as an accepted procedure.
PART 1 - Detailed Inspection of Tension Ties at Body Stations 1120, 1160, 1200, and 1220
1. Do detailed inspections for cracks in the tension ties on the left side of the airplane as given in
FIGURE 1.
2. Do detailed inspections for cracks in the tension ties on the right side of the airplane as given in
FIGURE 2.
3. If any cracks are found, repair as given in PART 3 - Tension Tie Repair or Modification.
4. If no cracks are found, repeat the detailed inspections for cracks at the time given in Paragraph
1.E., Compliance.
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### Page 37

PART 2 - Detailed Inspection of Tension Ties from Body Station 880 to Body Station 1100
1. Do detailed inspections for cracks in the tension ties on the left side of the airplane as given in
FIGURE 3.
2. Do detailed inspections for cracks in the tension ties on the right side of the airplane as given in
FIGURE 4.
3. If any cracks are found, repair as given in PART 3 - Tension Tie Repair or Modification.
4. If no cracks are found, repeat the detailed inspections for cracks at the time given in Paragraph
1.E., Compliance.
PART 3 - Tension Tie Repair or Modification
CAUTION: DO NOT DISCONNECT ADJACENT TENSION TIES AT THE SAME TIME. IF ADJACENT
TENSION TIES ARE DISCONNECTED AT THE SAME TIME, DAMAGE TO THE
AIRPLANE STRUCTURE CAN OCCUR. IF IT IS NECESSARY TO REPAIR OR MODIFY
ADJACENT TENSION TIES, ONLY DISCONNECT EVERY OTHER TENSION TIE AT
A TIME, AS SHOWN IN APPENDIX A. EACH TENSION TIE THAT IS DISCONNECTED
BY THIS METHOD CAN BE DISCONNECTED AT ONE END, OR BOTH ENDS, AS
NECESSARY.
1. For the left side of the airplane, do repairs or modifications as necessary, as given in Figures 5
through 20.
2. For the right side of the airplane, do repairs or modifications as necessary, as given in Figures 21
through 36.
3. As an option to repeat inspections, modification of all affected tension tie locations as given in
Figures 5 through 36 can be done as terminating action.
4. If any cracks are found in bolt holes during repair or modification, contact Boeing for repair
instructions.
PART 4 - High Frequency Eddy Current Inspection of Tension Ties at Body Stations 1120, 1160,
1200, and 1220
1. Do surface high frequency eddy current inspections for cracks in the tension ties on the left side
of the airplane as given in FIGURE 37.
2. Do surface high frequency eddy current inspections for cracks in the tension ties on the right side
of the airplane as given in FIGURE 38.
3. If any cracks are found, repair as given in PART 3 - Tension Tie Repair or Modification.
4. If no cracks are found, repeat the detailed inspections for cracks at the time given in Paragraph
1.E., Compliance.
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### Page 38

PART 5 - High Frequency Eddy Current Detailed Inspection of Tension Ties from Body Station
880 to Body Station 1100
1. Do surface high frequency eddy current inspections for cracks in the tension ties on the left side
of the airplane as given in FIGURE 39.
2. Do surface high frequency eddy current inspections for cracks in the tension ties on the right side
of the airplane as given in FIGURE 40.
3. If any cracks are found, repair as given in PART 3 - Tension Tie Repair or Modification.
4. If no cracks are found, repeat the detailed inspections for cracks at the time given in Paragraph
1.E., Compliance.
Restoration
1. Apply BMS 3-23, Type II, Corrosion Inhibiting Compound to all areas where repairs were done.
Refer to SOPM 20-41-05 as an accepted procedure.
2. Install insulation as necessary between STA 880 and STA 1220. Refer to 747-100/200/300 AMM
25-14-02 or 747-400 AMM 25-14-02 as an accepted procedure.
3. Install the main deck ceiling panels as necessary between STA 880 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. Install the seats as necessary between STA 880 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. Supply electrical power to the airplane. Refer to 747-100/200/300 AMM 24-22-00 or 747-400 AMM
24-22-00 as an accepted procedure.
6. Return the airplane to a serviceable condition.
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### Page 39 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
STA
1220
STA
880
VOOD
STA
1220~
1120 \
SEE A
STA
880
1313447
FIGURE 1: STA 1120, 1160, 1200, AND 1220 TENSION TIE DETAILED INSPECTION - TYPICAL - LEFT
SIDE
(SHEET 1 OF 3)
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### Page 40

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
in the area shown. (a)1-Aft Tension TieInspect1
(a) At each tension tie location, do a detailed inspection for cracks of the aft tension tie channel at the
radius where the flanges are machined down to a flat plate. Do this inspection on the left side of the
airplane at STA 1120, 1160, 1200, and 1220.
The parts shown in the table below are provided as extra parts for this service bulletin.
MORE DATAQTYIDENTIFICATIONNAME
1BACB30NX6K3XBolt
5BACB30NX6K4XBolt
4BACB30NX6K5XBolt
11BACB30NX6K6XBolt
15BACB30NX6K7XBolt
FIGURE 1: STA 1120, 1160, 1200, AND 1220 TENSION TIE DETAILED INSPECTION - TYPICAL - LEFT
SIDE
(SHEET 2 OF 3)
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### Page 41

MORE DATAQTYIDENTIFICATIONNAME
10BACB30NX6K8XBolt
2BACB30NX8K5Bolt
9BACB30NX8K6Bolt
14BACB30NX8K6XBolt
3BACB30NX8K7Bolt
1BACB30NX8K7XBolt
8BACB30US4K10XBolt
9BACB30US4K12XBolt
1BACB30US4K5XBolt
1BACB30US4K6XBolt
1BACB30US4K7XBolt
1BACB30US4K8XBolt
30BACC30BH6Collar
18BACC30BH8Collar
1BACF3F023J089ANFiller
1BACF3H08JP008HNFiller
7BACN10HR4CDNut
4BACR15BB6D7CRivet
4BACW10BP31DPWasher
FIGURE 1: STA 1120, 1160, 1200, AND 1220 TENSION TIE DETAILED INSPECTION - TYPICAL - LEFT
SIDE
(SHEET 3 OF 3)
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### Page 42 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
STA
1220
STA
880
SEE
\ STA
1220
\STA
1120
FWD -
STA
880  1313449
FIGURE 2: STA 1120, 1160, 1200, AND 1220 TENSION TIE DETAILED INSPECTION - TYPICAL - RIGHT
SIDE
(SHEET 1 OF 2)
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### Page 43

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
in the area shown. (a)1-Aft Tension TieInspect1
(a) At each tension tie location, do a detailed inspection for cracks of the aft tension tie channel at the
radius where the flanges are machined down to a flat plate. Do this inspection on the right side of the
airplane at STA 1120, 1160, 1200, and 1220.
FIGURE 2: STA 1120, 1160, 1200, AND 1220 TENSION TIE DETAILED INSPECTION - TYPICAL - RIGHT
SIDE
(SHEET 2 OF 2)
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### Page 44 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
STA
1220
STA
880
• STA
1220
STA
1100
STA
880  FWD  SEE M
1313451
FIGURE 3: STA 880 - STA 1100 TENSION TIE DETAILED INSPECTION - TYPICAL - LEFT SIDE
(SHEET 1 OF 2)
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### Page 45

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
in the area shown. (a)1-Aft Tension TieInspect1
(a) At each tension tie location, do a detailed inspection for cracks of the tension tie channel at the radius
where the flanges are machined down to a flat plate. Do this inspection on the left side of the airplane
at each tension tie location from STA 880 to STA 1100.
NOTE: At STA 1000 the forward tension tie channel is machined down to a flat plate. At all other sta-
tions, the aft tension tie channel is machined down to a flat plate.
FIGURE 3: STA 880 - STA 1100 TENSION TIE DETAILED INSPECTION - TYPICAL - LEFT SIDE
(SHEET 2 OF 2)
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
45 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

### Page 46 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
STA
1220
STA
880
SEE
STA
1100
_ STA
1220
STA  FWD C
880
1313453
FIGURE 4: STA 880 - STA 1100 TENSION TIE DETAILED INSPECTION - TYPICAL - RIGHT SIDE
(SHEET 1 OF 2)
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Revision 1 December 04, 2012  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-53A2610
Work - See page 1 for details.  46 of 220

### Page 47

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
in the area shown. (a)1-Aft Tension TieInspect1
(a) At each tension tie location, do a detailed inspection for cracks of the tension tie channel at the radius
where the flanges are machined down to a flat plate. Do this inspection on the right side of the airplane
at each tension tie location from STA 880 to STA 1100.
NOTE: At STA 1000 the forward tension tie channel is machined down to a flat plate. At all other sta-
tions, the aft tension tie channel is machined down to a flat plate.
FIGURE 4: STA 880 - STA 1100 TENSION TIE DETAILED INSPECTION - TYPICAL - RIGHT SIDE
(SHEET 2 OF 2)
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
47 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

### Page 48 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
STA
1220
STA
880
STA
1220
STA
880
FWD
TENSION TIE
STA 880  1313455
FIGURE 5: STA 880 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 1 OF 5)
Original Issue: May 10, 2007
Revision 1 December 04, 2012  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-53A2610
Work - See page 1 for details.  48 of 220

### Page 49 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
FRAME
FILLER 'A'
(29 LOCATIONS)
00Q
DOUBLER 'A'
0.45  18
• B
- 0.45
¿ FILLER 'B'
UP
→ INBD
STA 880
A-A
FILLER 'A'
DOUBLER 'A'
28  , FRAME
DOUBLER 'B'
EXISTING
STRAP
(AFTER REPAIR)  1313456
B-B
FIGURE 5: STA 880 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 2 OF 5)
Original Issue: May 10, 2007
Revision 1 December 04, 2012  PROPRIETARY - Copyright ® Unpublished  Export Controlled ECCN: 9E991 - BOEING  747-53A2610
Work - See page 1 for details.  49 of 220

### Page 50

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this Figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
29FastenersRemove1
1657U7314-17Doubler ARemove/Keep2
as shown. (a)1657U7314-( )Aft ChannelTrim3
from the airplane.Trimmed sectionRemove4 (not
shown)
to trimmed edges of aft channel.
Apply chemical conversion
coating as given in SOPM 20-
43-03. Apply primer as given in
SOPM 20-41-02.
AlodineChemical Conver-
sion Coating
Apply5
BMS 10-11, Type IPrimer
Refer to 747 NDT Part 6, 51-00-
00, Procedure 1, 11, or 16. (b)
29HolesInspect6
1814B9001-33Doubler BInstall (New)7
1BACF3F023J089ANFiller AInstall (New)
Use radius filler if required. Add
one grip length to fastener if
necessary.
2BACF3H08JP008HNFiller BInstall (New)
1657U7314-17Doubler AInstall (Kept)8
wet with BMS 5-95 sealant. Re-
fer to SOPM 20-50-19, Method
2.
29FastenersInstall9
(a) Maintain 0.45 inch minimum edge distance from nearest fastener holes. Maintain 63 Microinches Ra
surface roughness or better. Break sharp edges.
(b) If cracks are found, contact Boeing for repair instructions.
FIGURE 5: STA 880 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 3 OF 5)
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
50 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

### Page 51

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.
A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the
number of fasteners necessary for this figure.
If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than
indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute
fasteners may be supplied in Boeing kits.
MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE
0.2651-0.26614BACB30US4K10XBoltA
4BACW10BP41CDWasher (under head)
(a)4BACW10BP41NAPUWasher (under nut)
4BACN10HR4CDNut
0.2651-0.26614BACB30US4K12XBoltB
4BACW10BP41CDWasher (under head)
(a)4BACW10BP41NAPUWasher (under nut)
4BACN10HR4CDNut
0.2026-0.20364BACB30NX6K6XBoltC
(b)4BACC30BH6Collar
0.2026-0.20366BACB30NX6K7XBoltD
(b)6BACC30BH6Collar
0.2026-0.20365BACB30NX6K8XBoltE
(b)5BACC30BH6Collar
FIGURE 5: STA 880 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 4 OF 5)
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
51 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

### Page 52

MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE
0.2651-0.26616BACB30NX8K6XBoltF
(c)6BACC30BH8Collar
(a) Use BACW10BP41APU if necessary for grip adjustment.
(b) Install one BACW10BP31DP under the collar as necessary for grip adjustment.
(c) Install one BACW10BP41DP under the collar as necessary for grip adjustment.
The parts shown in the table below are provided as extra parts for this figure.
MORE DATAQTYIDENTIFICATIONNAME
(a)8BACW10BP41APUWasher
(a)5BACW10BP31DPWasher
(a)2BACW10BP41DPWasher
(a) If not used, keep the extra parts for use in other Figures.
FIGURE 5: STA 880 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 5 OF 5)
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
52 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

### Page 53 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
STA
1220
STA
880
VOOD
STA
1220
STA
900
STA
880-
FUDD
TENSION TIE  STA 900  1313458
FIGURE 6: STA 900 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 1 OF 5)
Original Issue: May 10, 2007
Revision 1 December 04, 2012  PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  747-53A2610
Work - See page 1 for details.  53 of 220

### Page 54 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
FILLER 'A'  FRAME
(29 LOCATIONS)
169
DOUBLER 'A'
0.45  28
•  - 0.45
) FILLER 'B'
UP
→ INBD
STA 900
A-A
FILLER 'A'
DOUBLER 'A'
• FRAME
DOUBLER 'B'
EXISTING
STRAP
(AFTER REPAIR)  1313459
B-B
FIGURE 6: STA 900 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 2 OF 5)
Original Issue: May 10, 2007
Revision 1 December 04, 2012  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-53A2610
Work - See page 1 for details.  54 of 220

### Page 55

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this Figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
29FastenersRemove1
1657U7314-17Doubler ARemove/Keep2
as shown. (a)1657U7314-( )Aft ChannelTrim3
from the airplane.Trimmed sectionRemove4 (not
shown)
to trimmed edges of aft channel.
Apply chemical conversion
coating as given in SOPM 20-
43-03. Apply primer as given in
SOPM 20-41-02.
AlodineChemical Conver-
sion Coating
Apply5
BMS 10-11, Type IPrimer
Refer to 747 NDT Part 6, 51-00-
00, Procedure 1, 11, or 16. (b)
29HolesInspect6
1814B9001-33Doubler BInstall (New)7
1BACF3F023J089ANFiller AInstall (New)
Use radius filler if required. Add
one grip length to fastener if
necessary.
2BACF3H08JP008HNFiller BInstall (New)
1657U7314-17Doubler AInstall (Kept)8
wet with BMS 5-95 sealant. Re-
fer to SOPM 20-50-19, Method
2.
29FastenersInstall9
(a) Maintain 0.45 inch minimum edge distance from nearest fastener holes. Maintain 63 Microinches Ra
surface roughness or better. Break sharp edges.
(b) If cracks are found, contact Boeing for repair instructions.
FIGURE 6: STA 900 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 3 OF 5)
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
55 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

### Page 56 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
FASTENER
DIAMETER
(OPTIONAL)
LETTER CODE  HEAD LOCATION
N = NEAR SIDE
D  6F  F = FAR SIDE
(OPTIONAL)
C
COUNTERSINK  FASTENER
LENGTH/GRIP
(OPTIONAL)
EXAMPLE OF FASTENER SYMBOL
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.
A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the
number of fasteners necessary for this figure.
If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than
indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute
fasteners may be supplied in Boeing kits.
CODE  NAME  IDENTIFICATION  QTY  HOLE DIA  MORE DATA
Bolt  BACB30US4K10X  4  0.2651-0.2661
Washer (under head)  BACW10BP41CD  4
Washer (under nut)  BACW10BP41NAPU  4  (a)
Nut  BACN10HR4CD  4
Bolt  BACB30US4K12X  4  0.2651-0.2661
Washer (under head)  BACW10BP41CD  4
Washer (under nut)  BACW10BP41NAPU  4  (a)
Nut  BACN10HR4CD  4
C  Bolt  BACB30NX6K6X  4  0.2026-0.2036
Collar  BACC30BH6  4  (b)
D  Bolt  BACB30NX6K7X  6  0.2026-0.2036
Collar  BACC30BH6  6  (b)
Bolt  BACB30NX6K8X  5  0.2026-0.2036
Collar  BACC30BH6  5  (b)
FIGURE 6: STA 900 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 4 OF 5)
Original Issue: May 10, 2007
Revision 1 December 04, 2012  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-53A2610
Work - See page 1 for details.  56 of 220

### Page 57

MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE
0.2651-0.26616BACB30NX8K6XBoltF
(c)6BACC30BH8Collar
(a) Use BACW10BP41APU if necessary for grip adjustment.
(b) Install one BACW10BP31DP under the collar as necessary for grip adjustment.
(c) Install one BACW10BP41DP under the collar as necessary for grip adjustment.
The parts shown in the table below are provided as extra parts for this figure.
MORE DATAQTYIDENTIFICATIONNAME
(a)8BACW10BP41APUWasher
(a)5BACW10BP31DPWasher
(a)2BACW10BP41DPWasher
(a) If not used, keep the extra parts for use in other Figures.
FIGURE 6: STA 900 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 5 OF 5)
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
57 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

### Page 58 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
STA
1220
STA
880
STA
1220
STA
920
STA
FWD <  880
TENSION TIE
STA 920  1313460
FIGURE 7: STA 920 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 1 OF 5)
Original Issue: May 10, 2007
Revision 1 December 04, 2012  Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-53A2610
Work - See page 1 for details.  58 of 220

### Page 59 (OCR)

BOEING SERVICE BULLETIN 747-53A2610
ALERT  ALERT
FRAME  FILLER 'A'
(29 LOCATIONS)
00Q
DOUBLER 'A'
,0.45  18
- 0.45
7 FILLER 'B'
UP
—INBD
STA 920
A-A
FILLER 'A'
DOUBLER 'A'
28  • FRAME
DOUBLER 'B'
EXISTING
STRAP
(AFTER REPAIR)  1313461
B-B
FIGURE 7: STA 920 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 2 OF 5)
Original Issue: May 10, 2007
Revision 1 December 04, 2012  PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  747-53A2610
Work - See page 1 for details.  59 of 220

### Page 60

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this Figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
29FastenersRemove1
1657U7314-17Doubler ARemove/Keep2
as shown. (a)1657U7314-( )Aft ChannelTrim3
from the airplane.Trimmed sectionRemove4 (not
shown)
to trimmed edges of aft channel.
Apply chemical conversion
coating as given in SOPM 20-
43-03. Apply primer as given in
SOPM 20-41-02.
AlodineChemical Conver-
sion Coating
Apply5
BMS 10-11, Type IPrimer
Refer to 747 NDT Part 6, 51-00-
00, Procedure 1, 11, or 16. (b)
29HolesInspect6
1814B9001-33Doubler BInstall (New)7
1BACF3F023J089ANFiller AInstall (New)
Use radius filler if required. Add
one grip length to fastener if
necessary.
2BACF3H08JP008HNFiller BInstall (New)
1657U7314-17Doubler AInstall (Kept)8
wet with BMS 5-95 sealant. Re-
fer to SOPM 20-50-19, Method
2.
29FastenersInstall9
(a) Maintain 0.45 inch minimum edge distance from nearest fastener holes. Maintain 63 Microinches Ra
surface roughness or better. Break sharp edges.
(b) If cracks are found, contact Boeing for repair instructions.
FIGURE 7: STA 920 TENSION TIE REPAIR OR MODIFICATION - LEFT SIDE
(SHEET 3 OF 5)
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
60 of 220
BOEING SERVICE BULLETIN 747-53A2610
ALERTALERT

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