### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Number: 747-53A2866**  Original Issue: December 04, 2013 ATA System: 5312 **SUBJECT:** FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and Replacement 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2013 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: December 04, 2013 747-53A2866 1 of 46 3.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 2 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F. Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 24 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 24 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 25 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 26 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100) [Group 1, Configuration 2; Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA 880 - STA 1100) [Group 1, Configuration 2; Group 2]. . . . . . . . . . . . . . . . . 38 FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100) [Group 1, Configuration 2; Group 2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT [Group 1, Configuration 2; Group 2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 APPENDIX B: LOGIC DIAGRAM 2 - POST-REPLACEMENT TENSION TIE INSPECTION AND REPAIR [Group 1, Configuration 2; Group 2]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 3 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 4 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Summary**  **Number: 747-53A2866** Original Issue: December 04, 2013 ATA System: 5312 **SUBJECT:** FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** This service bulletin gives instructions for inspection, repair, and replacement of the upper deck tension ties on stretched upper deck (SUD) airplanes that have been converted to Boeing Special Freighter (SF) or Boeing Converted Freighter (BCF). Severed or disconnected tension ties at multiple locations could result in rapid decompression and loss of structural integrity. This service bulletin is for station locations from 880 to 1100 where floor beams were replaced with tension ties during conversion to SF or BCF. Tension ties have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). WFD could cause multiple adjacent tension ties to become severed or disconnected from the frames. For more information about WFD, refer to Boeing Service Letter 747-SL-53-088. Accomplishment of the inspection and replacement actions in this service bulletin will ensure that tension tie cracks are detected, and that cracked tension ties are repaired or replaced before they become severed. Service Bulletin 747-53A2507 and 747-53A2559 are for inspection, repair, and modification of tension tie and frame structure at station locations from 1120 to 1220 where tension ties were installed in production on the same airplanes. Boeing Service Related Problem (SRP) 747-SRP-53-0435 is related to this service bulletin. Fleet Team Digest article 747 FTD 53-13006 is related to this service bulletin. The following table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 5 of 46**Reference Affected**  **Planning Data** Paragraph 1.E., Compliance Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Materials Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**ACTION** No action is required for airplanes that have not been converted by Boeing to SF or BCF configuration. For airplanes that have been converted by Boeing to SF or BCF configuration, do the following actions: INSPECTIONS: – Get access to the tension tie structure from station 880 to station 1100. Do initial and repetitive detailed inspections for cracks in the tension tie structure at each station location. For a longer repeat inspection interval, also do HFEC inspection for cracks in the forward and aft tension tie channels around the fasteners. If any cracks are found, get access to the frame structure at stations where tension ties were found cracked and do a detailed inspection of the frame structure between stringer 3 and stringer 12 on both sides of the airplane. Repair or replace any cracked structure. REPLACEMENT: – At each station from 880 to 1100, remove and discard the existing tension tie channels. Also, remove and discard the existing straps and fillers at the outboard ends of the tension tie where the tension tie attaches to the frame. Do HFEC inspection of all open holes in the frame structure where the tension tie was removed. If a crack is found in a frame, contact Boeing for repair instructions and do the repair. Install new tension tie channels, straps, and fillers. Before installation of permanent fasteners at the outboard ends of the tension ties, cold work the fastener holes common to the frames and straps. POST-REPLACEMENT INSPECTIONS: – After replacement, restart initial and repetitive detailed (or detailed and HFEC) inspections beginning at the post-replacement inspection threshold in accordance with this service bulletin. **EFFECTIVITY** 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes. Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 6 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT COMPLIANCE**  Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspections, repairs, or replacement procedures given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 7 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 8 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Number: 747-53A2866**  Original Issue: December 04, 2013 ATA System: 5312 **SUBJECT:** FUSELAGE - Main Frame - Center Section - Tension Ties - Inspection, Repair, and Replacement 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 D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplane(s) shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 747-100B, 747-200B, 747-300, 747-400, and 747-400D airplanes, built in a Stretched Upper Deck (SUD) configuration, or modified to SUD by Boeing, except airplanes modified by Boeing to Special Freighter (SF) or Boeing Converted Freighter (BCF) configuration before release of the Original Issue of this service bulletin. - 1

Airplanes that have not been modified by Boeing to SF or BCF. 1 Airplanes that are modified by Boeing to SF or BCF configuration after release of the Original Issue of this service bulletin. 2
747-200B, 747-300, and 747-400 airplanes that have been modified by Boeing to SF or BCF configuration before release of the Original Issue of this service bulletin. - 2

Airplane Models: 747-100B SUD, 747-200B, 747-300, 747-400, 747-400D

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 9 of 46**Group Variable Number**  1 RD381 - RD383 2 RD601 - RD602 1 RD603 - RD607 1 RD721 - RD722 1 RF001 - RF006 1 RM001 - RM007 1 RM010 - RM013 1 RM021 - RM022 1 RM024 1 RM026 - RM030 1 RM036 - RM045 1 RM051 - RM053 1 RM071 1 RM081 - RM084 1 RM091 1 RM096 - RM097 1 RM116 - RM117 1 RM126 - RM127 2 RM128 1 RM129 - RM132 1 RM136 - RM147 1 RM156 - RM158 1 RM166 - RM177 1 RM191 - RM192 1 RM231 - RM233 1 RM241 - RM246 1 RM261 - RM264 1 RM316 - RM318 1 RM331 - RM333 1 RM341 1 RM351 - RM355 1 RM366 - RM367

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 10 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group**  **Variable Number** 1 RM401 - RM403 1 RM426 1 RM431 1 RM441 - RM443 1 RM445 1 RM801 - RM803 1 RM811 - RM813 1 RS001 - RS002 1 RS201 1 RS211 - RS212 1 RS221 - RS222 1 RS231 - RS241 1 RS251 - RS259 1 RS263 1 RS265 - RS268 1 RS271 - RS276 1 RS291 - RS292 1 RS301 - RS306 1 RS311 - RS320 1 RS331 - RS333 1 RS341 - RS342 1 RS699 1 RS701 - RS703 1 RS711 - RS713 2 RS721 - RS722 1 RS731 - RS732 2 RS741 1 RS742 2 RS743 1 RS751 - RS752 1 RS761 2 RS762 2 RS771

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 11 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group**  **Variable Number** 1 RS781 - RS782 2 RS786 1 RT001 - RT014 2 RT021 - RT022 2 RT031 - RT033 1 RT034 - RT035 1 RT041 - RT047 2 RT061 2 RT071 - RT072 1 RT073 - RT074 2 RT075 1 RT101 - RT103 1 RT121 1 RT131 - RT137 1 RT151 - RT152 2 RT161 1 RT162 - RT163 2 RT164 1 RT165 - RT168 1 RT401 - RT412 1 RT431 - RT447 1 RT451 - RT455 2 RT456 1 RT457 - RT460 2 RT461 1 RT462 - RT469 1 RT471 - RT499 2 RT501 1 RT502 - RT505 2 RT506 - RT510 1 RT511 - RT512 2 RT513 1 RT514 - RT515

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 12 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group**  **Variable Number** 2 RT516 1 RT517 2 RT518 - RT520 1 RT521 - RT523 2 RT524 1 RT525 2 RT526 1 RT527 2 RT528 1 RT529 2 RT530 1 RT531 - RT535 1 RT551 - RT568 1 RT571 2 RT572 - RT579 1 RT580 - RT591 1 RT601 - RT630 1 RT633 - RT641 2 RT642 1 RT643 - RT653 2 RT654 - RT657 1 RT671 - RT673 1 RT681 - RT682 2 RT691 - RT692 1 RT693 - RT699 1 RT701 - RT704 1 RT711 - RT717 1 RT741 - RT742 1 RT744 - RT750 2 RT751 - RT752 1 RT753 - RT757 1 RT776 - RT777 2 RT781 - RT782

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 13 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group**  **Variable Number** 1 RT783 - RT784 1 RT801 - RT803 1 RT811 - RT814 1 RT831 - RT836 2 RT837 1 RT861 - RT864 1 RT877 - RT880 1 RT931 - RT932 1 RT945 - RT949 1 RT951 - RT955 1 RT966 2 RT967 1 RU001 - RU006 1 RU016 - RU017 1 RU031 - RU032 1 RU051 - RU052 1 RU060 - RU062 1 RU081 - RU083 1 RU101 - RU102 1 RU121 - RU132 1 RU801 - RU809 1 RU831 - RU841 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** This service bulletin gives instructions for inspection, repair, and replacement of the upper deck tension ties on stretched upper deck (SUD) airplanes that have been converted to Boeing Special Freighter (SF) or Boeing Converted Freighter (BCF). Severed or disconnected tension ties at multiple locations could result in rapid decompression and loss of structural integrity.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 14 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**This service bulletin is for station locations from 880 to 1100 where floor beams were replaced with tension ties during conversion to SF or BCF. Tension ties have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). WFD could cause multiple adjacent tension ties to become severed or disconnected from the frames. For more information about WFD, refer to Boeing Service Letter 747-SL-53-088. Accomplishment of the inspection and replacement actions in this service bulletin will ensure that tension tie cracks are detected, and that cracked tension ties are repaired or replaced before they become severed. Service Bulletin 747-53A2507 and 747-53A2559 are for inspection, repair, and modification of tension tie and frame structure at station locations from 1120 to 1220 where tension ties were installed in production on the same airplanes. Boeing Service Related Problem (SRP) 747-SRP-53-0435 is related to this service bulletin. Fleet Team Digest article 747 FTD 53-13006 is related to this service bulletin. **D. Description** No action is required for airplanes that have not been converted by Boeing to SF or BCF configuration. For airplanes that have been converted by Boeing to SF or BCF configuration, do the following actions: INSPECTIONS: – Get access to the tension tie structure from station 880 to station 1100. Do initial and repetitive detailed inspections for cracks in the tension tie structure at each station location. For a longer repeat inspection interval, also do HFEC inspection for cracks in the forward and aft tension tie channels around the fasteners. If any cracks are found, get access to the frame structure at stations where tension ties were found cracked and do a detailed inspection of the frame structure between stringer 3 and stringer 12 on both sides of the airplane. Repair or replace any cracked structure. REPLACEMENT: – At each station from 880 to 1100, remove and discard the existing tension tie channels. Also, remove and discard the existing straps and fillers at the outboard ends of the tension tie where the tension tie attaches to the frame. Do HFEC inspection of all open holes in the frame structure where the tension tie was removed. If a crack is found in a frame, contact Boeing for repair instructions and do the repair. Install new tension tie channels, straps, and fillers. Before installation of permanent fasteners at the outboard ends of the tension ties, cold work the fastener holes common to the frames and straps. POST-REPLACEMENT INSPECTIONS: – After replacement, restart initial and repetitive detailed (or detailed and HFEC) inspections beginning at the post-replacement inspection threshold in accordance with this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 15 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group 1:** 
**Affected Maintenance Zones Zone**  **Model** 225, 226 747-100B SUD, 747-200B, 747- 300, 747-400, 747-400D **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 225, 226 747-200B, 747-300, 747-400 **E. Compliance** Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. Logic diagrams corresponding to each compliance table are included in APPENDIX A. The logic diagrams only show the conditions and actions, and are for reference only. **Group 1, Configuration 1:** No action is required. If a Group 1, Configuration 1 airplane is converted to BCF in the future, then it becomes a Configuration 2 airplane and the actions in the following tables will apply. **Group 1, Configuration 2; Group 2: Table 1: Tension Tie Inspection, Repair, and Replacement**  **Repeat Interval (Not to Exceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 

- Within 2,000flight cycles after the Original Issue date ofthis service bulletin. Within 10,000flight cycles after conversion to SF or BCF configuration.Do PART 1: TENSION TIE DETAILED INSPECTION for cracks.-ORDo PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. All airplanes.

(a)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 16 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group 1, Configuration 2; Group 2:**  **Table 1: Tension Tie Inspection, Repair, and Replacement Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever**  **Occurs Later) Action**  **Condition** 2,000 flight cyclesif PART 1 inspection was previously done. - - OPTION 1: Do/Repeat PART 1:TENSION TIE DETAILED INSPECTION for cracks. CONDITION 1: NO TENSION TIE CRACK FOUND. OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. -OR5,000 flight cyclesif PART 2 inspection was previously done.OPTION 3: Do PART 5: TENSION TIE REPLACEMENT. (a)

- Before further flight. Do PART 3: FRAME DETAILED INSPECTION for cracks. CONDITION 2: TENSION TIE CRACK FOUND.

- Before further flight. ACTION 1: Contact Boeing forrepair instructions and do the repair. CONDITION 3: FRAME CRACK FOUND.

- Before further flight. ACTION 2: Do PART 4: TEN- SION TIE REPAIR.

- Before further flight. Do PART 4: TENSION TIE RE- PAIR. CONDITION 4: NO FRAME CRACK FOUND. 2,000 flight cyclesif PART 1 inspection was previously done. - - OPTION 1: Do/Repeat PART 1:TENSION TIE DETAILED INSPECTION for cracks. CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED. OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. -OR5,000 flight cyclesif PART 2 inspection was previously done.OPTION 3: Do PART 5: TENSION TIE REPLACEMENT. (a)

- Within 2,000flight cycles after the Original Issue date ofthis service bulletin. Within 22,000flight cycles after conversion to SF or BCF configuration.Do PART 5: TENSION TIE REPLACEMENT. (a) (b) All airplanes.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 17 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group 1, Configuration 2; Group 2:**  **Table 1: Tension Tie Inspection, Repair, and Replacement Repeat Interval**  **(Not to Exceed) Compliance Time (Whichever**  **Occurs Later) Action**  **Condition**

- Before further flight. Contact Boeing for repair instruc- tions and do the repair. Frame crack isfound during accomplishment ofPART 5: TENSION TIE REPLACEMENT.

- See Compliance Table 2. Do Post-Replacement Tension Tie Inspection and Repair actions in accordance with Compliance Table 2.Tension Tie replacement hasbeen done in accordance with Paragraph 3.B., Work Instructions, PART 5 of this service bulletin. (a) Accomplishment of PART 5: TENSION TIE REPLACEMENT is terminating action for the initial and repetitive inspections specified in this table. However, post-replacement inspections are required as specified in "Table 2: Post-Replacement Tension Tie Inspection and Repair". (b) Due to the after-modification requirements, and the possibility that it will be necessary to replace the tension ties again, Boeing does not recommend tension tie replacement prior to 13,000 total flight-cycles. **Group 1, Configuration 2; Group 2: Table 2: Post-Replacement Tension Tie Inspection and Repair**  **Repeat Interval (Not to Exceed)**  **Compliance Time Action**  **Condition**

- Within 10,000 flight cycles after the tension ties werereplaced in accordance with Paragraph 3.B., Work Instructions,PART5 of this service bulletin.Do PART 1: TENSION TIE DETAILED INSPECTION for cracks.-ORDo PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. Tension Tie replacementhas been done in accordance with Paragraph 3.B., Work Instructions, PART 5 of this service bulletin.

2,000 flight cycles if PART1 inspection was previously done. - OPTION 1: Do/Repeat PART 1:TENSION TIE DETAILED INSPECTION for cracks.CONDITION 1: NO TENSION TIE CRACK FOUND. -OR5,000 flight cycles if PART2 inspection was previously done. OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED andHIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 18 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group 1, Configuration 2; Group 2:**  **Table 2: Post-Replacement Tension Tie Inspection and Repair Repeat Interval (Not to**  **Exceed) Compliance Time**  **Action Condition** 

- Before further flight. Do PART 3: FRAME DETAILED INSPECTION for cracks. CONDITION 2: TENSION TIE CRACK FOUND.

- Before further flight.ACTION 1: Contact Boeing for repair instructions and do the repair. CONDITION 3: FRAME CRACK FOUND.

- Before further flight. ACTION 2: Do PART 4: TENSION TIE REPAIR.

- Before further flight.Do PART 4: TENSION TIE REPAIR. CONDITION 4: NO FRAME CRACK FOUND. 2,000 flight cycles if PART1 inspection was previously done. - OPTION 1: Do/Repeat PART 1:TENSION TIE DETAILED INSPECTION for cracks. CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED. -OR5,000 flight cycles if PART2 inspection was previously done. OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED andHIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle ACO approves the accomplishment of the inspection, repair, and replacement procedures with corresponding compliance times specified in Tables 1 and 2 under Paragraph 1.E., "Compliance" of Service Bulletin 747-53A2866, Original Issue, as an AMOC to the inspection requirements of paragraphs (h) and (i) of AD 2004-07-22 R1, for the inspection of Structural Significant Item (SSI) F-19A, F-19B, F-19D, F-20A, F-20C, and F-20E of the Supplemental Structural Inspection Document (SSID) D6-35022, Revision G, dated December 2000, and Revision TR-08-001, dated June 2006. This AMOC only applies to the areas where tension ties were inspected or replaced in accordance with this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph, including the initial inspection threshold per paragraph (i) of AD 2004-07-22 R1, remain fully applicable and must be complied with accordingly.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 19 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT G. Manpower**  The table below shows an estimate of the task hours necessary to do the inspection and replacement actions 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 inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **INSPECTION and POST-REPLACEMENT INSPECTION Elapsed Hours**  **Task Hours Number of Persons**  **Task** 3.75 15.00 4 Open Access 4.00 16.00 4 FIGURE 1: Tension Tie De- tailed Inspection (a) 33.50 134.00 4 FIGURE 2: Tension Tie De- tailed and High Frequency Eddy Current Inspection (a) 3.00 6.00 2 FIGURE 3: Frame Detailed Inspection (b) 3.75 15.00 4 Restoration 11.50 46.00 TOTAL FOR EACH AIRPLANE (a) The Total for Each Airplane is based on FIGURE 1 inspection. FIGURE 2 inspection is optional to FIGURE 1 inspection. FIGURE 2 estimates are not included in the total. (b) If required. Not included in total. Estimate is for inspection of one frame. Multiply the estimate by the number of frames that need to be inspected.
**REPLACEMENT Elapsed Hours**  **Task Hours Number of Persons**  **Task** 3.75 15.00 4 Open Access 84.00 336.00 4 PART 5 - TENSION TIE RE- PLACEMENT (a) 3.75 15.00 4 Restoration 91.50 366.00 TOTAL FOR EACH AIRPLANE(a) Does not include time for repairs if frames are found cracked during tension tie replacement. If frames are found cracked, more time will be necessary.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 20 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT H. Weight and Balance Changes**  None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Boeing Service Bulletin 747-53A2507, 747-53A2559 b. Boeing Service Letter 747-SL-51-048, 747-SL-53-088 c. Boeing Service Related Problem (SRP) 747-SRP-53-0435 d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1 e. Service Bulletin Index D6-30300 f. Standard Overhaul Practices Manual (SOPM) 20-41-05, 20-43-03, 20-50-01 g. 747 Fleet Team Digest (FTD) 53-13006 h. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00 i. 747-100/200/300 Aircraft Maintenance Manual (AMM) 24-22-00, 25-59-01, 25-59-05 j. 747-100/200/300 Structural Repair Manual (SRM) 51-30-09, 51-50-01 k. 747-400 Aircraft Maintenance Manual (AMM) 24-22-00, 25-59-01, 25-59-05 l. 747-400SF Structural Repair Manual (SRM) 51-40-09, 51-50-02, 53-20-30, 53-40-30 2. Data Supplied with this Service Bulletin: a. Drawings:
**ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- B 1 TENSION TIE INSTL - STA 880 - STA 1220, MOD 657U7304

- D 2

- D 3

- C 4

- C 5

- C 6

- K PL

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 21 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT ADCN**  **DCN/REV Sheet**  **Title Drawing No** 

- A PSDL TENSION TIE INSTL - STA 880 - STA 1220, MOD 657U7304#DL

- C 1 TENSION TIE DETAILS, STA 880 -STA 1220, MOD 657U7314

- C 2

- C 3

- C 4

- C 5

- B 6

- - 7

- - 8

- - 9

- G PL

- - PSDL TENSION TIE DETAILS, STA 880 -STA 1220, MOD 657U7314#DL

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 22 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT ADCN**  **DCN/REV Sheet**  **Title Drawing No** 

- - 11 TENSION TIE REWORK INSTL STA 880 THRU STA 1220 MOD 814B9001

- A 12

- A 13

- A 14

- - 15

- - 16

- - 17

- - 18

- - 19

- - 20

- A 21

- - 22

- - 23

- B 24

- A 25

- B 26

- - 27

- - 28

- - 29

- - 30

- - 31

- B 32

- - 33

- - 34

- - 35

- - 36

- B 37

- - 38

- - 39

- - 40

- A 41

- - 42

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 23 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT ADCN**  **DCN/REV Sheet**  **Title Drawing No** 

- F PSDL TENSION TIE REWORK INSTL STA 880 THRU STA 1220 MOD 814B9001#DL
3. Installation Drawings Used in the Preparation of this Service Bulletin: None. **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. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. **M. Software Accomplishment Summary** Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 24 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin does not show the Boeing price and supply data. **B. Industry Support Information** Boeing warranty remedies are not available for the inspection or modification procedures given in this service bulletin. **C. Parts Necessary for Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Speci-**  **fication** (a) (b) (c) Chemical Conversion Coating as required Alodine (b) (c) Primer as required BMS 10-11, Type I (b) (c) Corrosion Inhibiting Compound as required BMS 3-23, Type II (b) (c) Sealant as required BMS 5-95 (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) This material could be necessary for tension tie repairs. More parts will be necessary if tension tie replacement is required. If necessary, contact Boeing for the engineering drawing information to determine the required parts if tension tie replacement will be accomplished.
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 25 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT E. Special Tooling - Price and Availability**  The 747 Structural Repair Manual Subject 747-100/200/300 SRM 51-30-09 or 747-400SF SRM 51-40-09 gives data about cold working tools and sleeves necessary to do the work given in this service bulletin. These tools are available from industry sources. **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. **NOTE:** Special tools are not necessary to do the change in this service bulletin. However, standard cold working tools are necessary for cold working of the holes at the ends of the tension ties if the tension ties are replaced in accordance with this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 26 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values: — Values for structural fasteners are given in 747 Structural Repair Manual, Chapter 51. — Values for airframe maintenance tasks are included in Chapter 20 of 747 Airplane Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step.
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. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 27 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**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 "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 8. 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. 9. 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. 10. 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. 11. 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. 12. If shading is used, shaded areas in Figures are to separate the non-critical and non-authoritative information from the critical and authoritative information. 13. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number. 14. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 15. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC must be done to comply with the AD. Alternative procedures for steps not identified with RC can be used if the RC steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. 16. For 747-100/200/300 airplanes that have been modified by Boeing to Special Freighter (SF) configuration, the 747-100/200/300 SRM does not include repairs for tension ties from STA 880 to STA 1100 that were installed during conversion. It is acceptable to use 747-400SF SRM 53-20-30 or 747-400SF SRM 53-40-30, as applicable, for repair of STA 880 - STA 1100 tension ties on 747-100/200/300 airplanes.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 28 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**17. Refer to APPENDIX A for Logic Diagram 1 related to the tension tie initial inspection, repair, and replacement requirements. Refer to APPENDIX B for Logic Diagram 2 related to the post-replacement inspection and repair requirements. Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 18. Replacement of tension tie channels with original SF or BCF modification parts in accordance with Paragraph 3.B., Work Instructions, PART 5 on airplanes RS762 and RT456 would cancel the effect of the modification performed by Service Bulletin 747-53A2610. Therefore, PART 5 instructions include a requirement to concurrently incorporate Service Bulletin 747-53A2610 modification on any aft tension tie channels being installed as replacements. **B. WORK INSTRUCTIONS Group 1, Configuration 1:**  No action is required for airplanes that have not been converted by Boeing to Special Freighter (SF) or Boeing Converted Freighter (BCF) configuration. **Group 1, Configuration 2; Group 2: Tension Tie Inspection, Repair, and Replacement**  1. Do PART 1: TENSION TIE DETAILED INSPECTION for cracks, or Do PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. **CONDITION 1: NO TENSION TIE CRACK FOUND** a. Do one of the following: (1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks. (2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. (3) OPTION 3: Do PART 5: TENSION TIE REPLACEMENT. **CONDITION 2: TENSION TIE CRACK FOUND** a. Do PART 3: FRAME DETAILED INSPECTION for cracks. **CONDITION 3: FRAME CRACK FOUND** (1) ACTION 1: Contact Boeing for repair instructions and do the repair. (2) ACTION 2: Do PART 4: TENSION TIE REPAIR. **CONDITION 4: NO FRAME CRACK FOUND** (1) Do PART 4: TENSION TIE REPAIR.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 29 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED**  a. Do one of the following: (1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks. (2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. (3) OPTION 3: Do PART 5: TENSION TIE REPLACEMENT. 2. Do PART 5: TENSION TIE REPLACEMENT. **Group 1, Configuration 2; Group 2: Post-Replacement Tension Tie Inspection and Repair**  1. Do PART 1: TENSION TIE DETAILED INSPECTION for cracks, or Do PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. **CONDITION 1: NO TENSION TIE CRACK FOUND** a. Do one of the following: (1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks. (2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks. **CONDITION 2: TENSION TIE CRACK FOUND** a. Do PART 3: FRAME DETAILED INSPECTION for cracks. **CONDITION 3: FRAME CRACK FOUND** (1) ACTION 1: Contact Boeing for repair instructions and do the repair. (2) ACTION 2: Do PART 4: TENSION TIE REPAIR. **CONDITION 4: NO FRAME CRACK FOUND** (1) Do PART 4: TENSION TIE REPAIR. **CONDITION 5: TENSION TIE CRACK HAS BEEN REPAIRED** a. Do one of the following: (1) OPTION 1: Do/Repeat PART 1: TENSION TIE DETAILED INSPECTION for cracks. (2) OPTION 2: Do/Repeat PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT INSPECTION for cracks.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 30 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group 1, Configuration 2; Group 2:**  **PART 1: TENSION TIE DETAILED INSPECTION** 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 accepted procedures. 2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation. 3. RC - At each tension tie station from 880 to 1100, do a detailed inspection for cracks in the tension tie structure in accordance with FIGURE 1. 4. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure. 5. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure. 6. 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. 7. Return the airplane to a serviceable condition. **Group 1, Configuration 2; Group 2: PART 2: TENSION TIE DETAILED and HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION**  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 accepted procedures. 2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation. 3. RC - At each tension tie station from 880 to 1100, do detailed and HFEC inspections for cracks in the tension tie structure in accordance with FIGURE 2. 4. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure. 5. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure. 6. 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. 7. Return the airplane to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 31 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT Group 1, Configuration 2; Group 2:**  **PART 3: FRAME DETAILED INSPECTION** 1. At any station where a crack was found in a tension tie, remove the main deck cargo compartment lining panels and insulation as necessary to get access to the frame structure between stringer 3 to stringer 12 on both sides of the airplane. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation. 2. RC - At any station where a crack was found in a tension tie, do a detailed inspection of the frame structure between stringer 3 and stringer 12 in accordance with FIGURE 3 **Group 1, Configuration 2; Group 2: PART 4: TENSION TIE REPAIR**  **CAUTION:** MAKE SURE THAT THE AIRPLANE IS SUPPORTED IN THE JIGGED POSITION BEFORE YOU DISASSEMBLE TWO ADJACENT FRAMES OR TENSION TIES. IF YOU DO NOT, YOU WILL CAUSE DAMAGE TO THE STRUCTURE. 1. Put the airplane in a jigged position. Refer to 747-100/200/300 SRM 51-50-01 or 747-400SF SRM 51-50-02 as an accepted procedure. It is not necessary to put the airplane into a jigged position if the airplane has the following conditions: a. Only one tension tie or frame is disassembled. b. There is a minimum of one tension tie and frame attached between those that are disassembled. 2. RC - Repair any cracked tension tie in accordance with 747-400SF SRM 53-20-30 or 747-400SF SRM 53-40-30 as applicable. 3. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure. 4. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 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. **Group 1, Configuration 2; Group 2: PART 5: TENSION TIE REPLACEMENT**  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 accepted procedures. 2. At stations 880 to 1100, remove the main deck cargo compartment lining panels and insulation as necessary to get access to the tension tie structure. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure for lining panels. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure for insulation.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 32 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT CAUTION:**  MAKE SURE THAT THE AIRPLANE IS SUPPORTED IN THE JIGGED POSITION BEFORE YOU DISASSEMBLE TWO ADJACENT FRAMES OR TENSION TIES. IF YOU DO NOT, YOU WILL CAUSE DAMAGE TO THE STRUCTURE. 3. Put the airplane in a jigged position. Refer to 747-100/200/300 SRM 51-50-01 or 747-400SF SRM 51-50-02 as an accepted procedure. It is not necessary to put the airplane into a jigged position if the airplane has the following conditions: a. Only one tension tie or frame is disassembled. b. There is a minimum of one tension tie and frame attached between those that are disassembled. 4. RC - At each station location from STA 880 to STA 1100, remove and discard the existing tension tie channels. Also, remove and discard the existing steel plates, straps and fillers at the outboard ends of the tension ties where the tension ties attach to the frames. 5. RC - After each tension tie is removed, do open hole HFEC inspection for cracks at all hole locations where fasteners where removed from adjacent frame structure to remove the tension tie. Do the inspection in accordance with 747 NDT Manual Part 6, 51-00-00, Procedure 1, 11, or 16. If any crack is found, contact Boeing for repair instructions and do the repair. 6. RC - At each station location from STA 880 to STA 1100, temporarily install new tension tie channels, steel plates, straps, and fillers which are the same as the original SF or BCF modification parts that were removed. Install the new parts in accordance with the applicable SF or BCF modification drawings specified in Paragraph 1.J.2., Data Supplied with this Service Bulletin, except oversize any existing open fastener holes 1/32 inch. Maintain 2D minimum edge margin. Continue with the following steps to install new tension ties. 7. RC - For airplanes that are included in the effectivity of Service Bulletin 747-53A2610, incorporate the Service Bulletin 747-53A2610 modification on the new tension ties, concurrently with installation of the new tension ties. 8. RC - At each station location from STA 880 to STA 1100, cold work the entire stack-up at all fastener holes where the tension tie attaches to the frame. Also, cold work the entire stack-up at all fastener holes that are common to the steel plates/straps, plus three fastener pairs inboard of the ends of the steel plates. Do the cold working at both ends of the tension tie (both sides of the airplane). Use the "high interference" cold work process in accordance with 747-100/200/300 SRM 51-30-09 or 747-400SF SRM 51-40-09, as applicable. 9. RC - After cold working, at each station location from STA 880 to STA 1100, permanently install new tension tie channels, steel plates, straps, and fillers which are the same as the original SF or BCF modification parts that were removed. Install the new structure in accordance with the applicable SF or BCF modification drawings specified in Paragraph 1.J.2., Data Supplied with this Service Bulletin, except install oversize fasteners at existing open fastener holes. 10. RC - Apply BMS 3-23, Type II, or equivalent, Corrosion Inhibiting Compound to the modified areas. Refer to SOPM 20-41-05 as an accepted procedure. 11. Re-install any insulation that was removed for access. Refer to 747-100/200/300 AMM 25-59-05 or 747-400 AMM 25-59-05 as an accepted procedure.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 33 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**12. Re-install any lining panels that were removed for access. Refer to 747-100/200/300 AMM 25-59-01 or 747-400 AMM 25-59-01 as an accepted procedure. 13. 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. 14. Return the airplane to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 34 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT This Figure applies only to: Group 1, Configuration 2; Group 2.** 

**FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100) (SHEET 1 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 35 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100)**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 36 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- 657U7314-( ) Forward and Aft Ten- sion Tie Channels Inspect 1 (a) Do a detailed inspection for cracks in the forward and aft tension tie channels in the inspection area shown. Station 880 is shown. Other stations are similar. Do the inspection at all stations from Station 880 to Station 1100. Inspect Qty 2 tension tie channels (one forward and one aft) at each station location. Total quantity of tension tie channels to be inspected = 24.

**FIGURE 1: TENSION TIE DETAILED INSPECTION (STA 880 - STA 1100) (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 37 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT This Figure applies only to: Group 1, Configuration 2; Group 2.** 

**FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA 880 - STA 1100)**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 38 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA**  **880 - STA 1100) (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 39 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**More Data Qty**  **Identification Name**  **Task Step**  (a) (c)

- 657U7314-( ) Forward and Aft Ten- sion Tie Channels Inspect 1 (b) (c)

- 657U7314-( ) Forward and Aft Ten- sion Tie Channels Inspect 2 (a) Do a detailed inspection for cracks in the forward and aft tension tie channels in the inspection area shown. (b) Do surface HFEC inspection for cracks around fasteners in the tension tie channels. Inspect from both sides of the tension tie in order to inspect both the forward and aft channels. It is not necessary to do theinspection where the tension tie channels are covered by straps, fittings, or other structure. Do the inspection in accordance with 747 NDT Manual Part 6, 51-00-00, Procedure 4 or 23. (c) Station 880 is shown. Other stations are similar. Do the inspection at all stations from Station 880 to Station 1100. Inspect Qty 2 tension tie channels (one forward and one aft) at each station location. Total quantity of tension tie channels to be inspected = 24.

**FIGURE 2: TENSION TIE DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION (STA 880 - STA 1100)**  **(SHEET 3 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 40 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT This Figure applies only to: Group 1, Configuration 2; Group 2.** 

**FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100) (SHEET 1 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 41 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100)**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 42 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**More Data Qty**  **Identification Name**  **Task Step**  (a) (c)

- - Frame - Left Side Inspect 1 (b) (c)

- - Frame - Right Side Inspect 2 (a) Do a detailed inspection for cracks in the left side of the frame between stringer 3L and stringer 12L as shown. Inspect the frame at each station location from STA 880 to STA 1100. Total quantity of frames to be inspected = 12. (b) Do a detailed inspection for cracks in the right side of the frame between stringer 3R and stringer 12R as shown. Inspect the frame at each station location from STA 880 to STA 1100. Total quantity of frames to be inspected = 12. (c) Station 880 is shown. Other stations are similar. Do the inspection at all stations where a crack was found in a tension tie.

**FIGURE 3: FRAME DETAILED INSPECTION (TYPICAL FOR STA 880 - STA 1100) (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 43 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT This Appendix applies only to: Group 1, Configuration 2; Group 2.** 

**APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 44 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**Do PART 5 - TENSION TIE REPLACEMENT before the compliance time for replacement specified in Paragraph 1.E., Compliance, Table 1. After replacement, do inspections as specified in Paragraph 1.E., Compliance, Table 2, and refer to LOGIC DIAGRAM 2. FLAG NOTE 1:

**APPENDIX A: LOGIC DIAGRAM 1 - TENSION TIE INSPECTION, REPAIR, AND REPLACEMENT (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 45 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT This Appendix applies only to: Group 1, Configuration 2; Group 2.** 

**APPENDIX B: LOGIC DIAGRAM 2 - POST-REPLACEMENT TENSION TIE INSPECTION AND REPAIR (SHEET 1 OF 1)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 04, 2013 747-53A2866 46 of 46 **BOEING SERVICE BULLETIN 747-53A2866 ALERT**  **ALERT**