Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2863

Original Issue: March 11, 2014

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Skin Crack at the Lower Forward Corner of Main Entry Door 1 -

Inspection, Repair and Modification

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.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2014 Boeing.

Unpublished Work. All Rights Reserved.

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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 28

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 38

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 39

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

FIGURE 1: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

FIGURE 2: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

[Group 1-2, 4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIGURE 3: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 52

FIGURE 4: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 54

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BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

ALERT

Summary Number: 747-53A2863

Original Issue: March 11, 2014

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Skin Crack at the Lower Forward Corner of Main Entry Door 1 -

Inspection, Repair and Modification

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 of the fuselage skin at the lower forward corner of the

cutout for Main Entry Door (MED) 1. Skin cracks that are not found and repaired can become large and could

adversely affect the structural integrity of the airplane.

Operators have told Boeing about cracks at the lower forward corner of the MED 1 cutout on two airplanes. A

1.0 inch long crack in the skin and bearstrap was found on an airplane with 17,605 flight-cycles. A 5.0 inch long

crack was found in the skin, skin doubler and bearstrap on an airplane with 21,759 flight-cycles. In addition, four

cracks between 0.18 and 1.85 inch long were found on Boeing's fatigue test airplane between 40,000 and 52,250

pressure cycles. Analysis indicates that the crack initiates in the skin and can propagate into the bonded doubler

and bearstrap.

Accomplishment of the inspections in this service bulletin and installation of a repair or modification will help

ensure the structural integrity of the lower forward corner of the MED 1 cutout.

Boeing Service Related Problem (SRP) 747-SRP-53-0395 is related to this service bulletin.

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

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes

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Planning Data Affected Reference

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected No Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION (PRR 85901-118RS)

On the left and right side, as applicable, open MED 1 and remove the door lower threshold. Do detailed and

surface High Frequency Eddy Current (HFEC) inspections of the skin at the lower forward corner of the door

cutout for any crack.

If no crack is found, install a preventive modification in accordance with this service bulletin, or close access

and repeat the skin inspections at the time given in this service bulletin.

If any crack is found, install a repair in accordance with this service bulletin.

After installation of the preventive modification or the repair, continue to do inspections in accordance with this

service bulletin.

EFFECTIVITY

All 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F,

747SP, and 747SR Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2009-18-07 and AD 2010-01-01 are related

to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes, inspections or repair procedures

given in this service bulletin.

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ALERT ALERT
MANPOWER

Airplanes Total Task Hours Elapsed Hours

Group 1, 2 and 112.50 54.50

4 Airplanes - Inspection and

Preventive Modification

Group 1, 2 and 152.50 74.50

4 Airplanes - Inspection and

Repair

Group 3 Air- 56.25 29.25

planes - Inspection and Preventive Modification

Group 3 Air- 76.25 39.25

planes - Inspection and Repair

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2863

Original Issue: March 11, 2014

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Skin Crack at the Lower Forward Corner of Main Entry Door 1 -

Inspection, Repair and Modification

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 airplanes shown below. Refer to PRR 85901-118RS for data about

this change.

GROUP CONFIGURATION DESCRIPTION

1 - 747 airplanes line number 1 through 206.

747 airplanes line number 207 through 1419, except 747-200F,

747-400F and 747 Large Cargo Freighter (LCF) airplanes.

2 -

3 - 747-200F and 747-400F airplanes line number 207 through 1419.

4 - 747 LCF airplanes.

Airplane Models:

747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400,

747-400D, 747-400F, 747SP, 747SR

Variable Number Group

RA001 - RA034 1

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Variable Number Group

RA101 - RA115 1

RA161 - RA164 1

RA201 - RA203 1

RA216 - RA217 1

RA245 - RA246 1

RA251 - RA261 1

RA262 - RA266 2

RA301 - RA312 1

RA313 - RA318 2

RA351 - RA360 1

RA369 - RA373 1

RA401 - RA416 1

RA417 - RA418 2

RA501 - RA502 1

RA521 - RA527 1

RA528 2

RA532 - RA540 1

RA541 - RA548 2

RA551 - RA552 1

RA559 - RA561 1

RA581 - RA582 1

RA585 1

RA601 - RA602 1

RA631 - RA635 1

RA651 - RA652 1

RA671 - RA677 1

RA701 - RA702 1

RA721 - RA724 1

RA725 - RA731 2

RA741 - RA743 1

RA744 - RA745 2

RA749 - RA750 2

RA761 - RA762 1

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Variable Number Group

RA781 - RA782 1

RA783 - RA784 2

RA901 - RA916 1

RB001 - RB005 1

RB006 - RB012 2

RB013 - RB014 1

RB015 - RB016 2

RB041 - RB044 1

RB071 - RB075 1

RB101 - RB102 1

RB411 - RB413 2

RB421 2

RB601 - RB607 2

RB681 - RB697 2

RB711 2

RB721 - RB723 2

RB741 - RB748 2

RD001 - RD002 1

RD003 - RD004 2

RD021 - RD022 2

RD041 - RD059 2

RD071 - RD072 2

RD081 - RD083 2

RD091 - RD092 2

RD101 - RD104 2

RD121 - RD127 2

RD131 - RD144 2

RD166 - RD167 2

RD171 - RD172 2

RD181 - RD183 2

RD201 - RD204 2

RD221 - RD227 2

RD231 - RD235 2

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Variable Number Group

RD241 - RD243 2

RD251 - RD262 2

RD271 - RD272 2

RD291 - RD292 2

RD301 - RD302 2

RD311 2

RD351 - RD358 2

RD361 - RD366 2

RD381 - RD383 2

RD411 - RD414 2

RD421 - RD426 2

RD431 - RD435 2

RD441 - RD442 2

RD451 - RD456 2

RD461 2

RD471 - RD475 2

RD513 - RD519 2

RD531 - RD533 2

RD551 2

RD561 2

RD571 2

RD581 - RD583 2

RD591 - RD593 2

RD601 - RD607 2

RD621 - RD623 2

RD641 - RD649 2

RD651 - RD659 2

RD661 2

RD671 2

RD681 - RD682 2

RD691 - RD692 2

RD701 - RD702 2

RD721 - RD722 2

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ALERT ALERT
Variable Number Group

RD741 - RD742 2

RD751 - RD755 2

RD761 2

RD771 - RD775 2

RD781 - RD783 2

RD791 - RD792 2

RE001 2

RF001 - RF006 2

RG001 - RG009 2

RG091 2

RG095 2

RG101 - RG104 2

RG121 - RG126 2

RG141 - RG142 2

RG161 - RG164 2

RG171 - RG174 2

RG191 - RG193 2

RG211 - RG213 2

RG221 - RG222 2

RH101 - RH102 2

RH111 - RH112 2

RH121 - RH122 2

RJ131 - RJ133 2

RJ151 - RJ152 2

RJ301 - RJ303 2

RJ321 - RJ322 2

RJ331 - RJ333 2

RL401 - RL403 3

RL411 - RL436 3

RL451 - RL456 3

RL461 - RL462 3

RL471 - RL481 3

RL491 - RL492 3

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ALERT ALERT
Variable Number Group

RL501 - RL502 3

RL511 - RL516 3

RL521 - RL522 3

RL531 - RL534 3

RL551 3

RL561 - RL568 3

RL571 - RL572 3

RL576 - RL577 3

RL579 3

RL581 - RL586 3

RL651 - RL655 3

RL671 - RL675 3

RL681 - RL684 3

RL751 - RL752 3

RM001 - RM007 2

RM010 - RM013 2

RM021 - RM024 2

RM026 - RM030 2

RM036 - RM045 2

RM051 - RM053 2

RM071 2

RM081 - RM084 2

RM091 2

RM096 - RM097 2

RM116 - RM117 2

RM126 - RM132 2

RM136 - RM147 2

RM156 - RM158 2

RM166 - RM177 2

RM191 - RM192 2

RM231 - RM233 2

RM241 - RM246 2

RM261 - RM264 2

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ALERT ALERT
Variable Number Group

RM316 - RM318 2

RM331 - RM333 2

RM341 2

RM351 - RM355 2

RM366 - RM367 2

RM401 - RM403 2

RM426 2

RM431 2

RM441 - RM443 2

RM445 2

RM801 - RM803 2

RM811 - RM813 2

RM851 - RM859 3

RM861 - RM863 3

RM871 - RM899 3

RM901 - RM906 3

RM911 3

RR001 - RR005 3

RR021 - RR025 3

RR031 3

RR201 1

RR202 - RR206 3

RR221 - RR226 3

RR261 - RR267 3

RR301 - RR310 3

RR331 - RR332 3

RR336 3

RR341 - RR345 3

RR361 - RR362 3

RR421 - RR422 3

RR431 - RR432 3

RR441 - RR442 3

RR451 3

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ALERT ALERT
Variable Number Group

RR501 - RR504 3

RR521 - RR522 3

RR526 3

RR531 3

RR551 - RR556 3

RR561 3

RR566 3

RR701 3

RR721 - RR724 3

RR746 - RR748 3

RR851 - RR856 3

RR861 - RR862 3

RR951 - RR952 3

RS001 - RS002 2

RS201 2

RS211 - RS212 2

RS221 - RS222 2

RS231 - RS241 2

RS251 - RS259 2

RS263 2

RS265 - RS268 2

RS271 - RS276 2

RS291 - RS292 2

RS301 - RS306 2

RS311 - RS320 2

RS331 - RS333 2

RS341 - RS342 2

RS699 2

RS701 - RS703 2

RS711 - RS713 2

RS721 - RS722 2

RS731 - RS732 2

RS741 - RS743 2

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ALERT ALERT
Variable Number Group

RS751 - RS752 2

RS761 - RS762 2

RS771 2

RS781 - RS782 2

RS786 2

RT001 - RT014 2

RT021 - RT022 2

RT031 - RT035 2

RT041 - RT047 2

RT061 2

RT071 - RT075 2

RT101 - RT103 2

RT121 2

RT131 - RT137 2

RT151 - RT152 2

RT161 - RT168 2

RT401 - RT412 2

RT431 - RT447 2

RT451 - RT469 2

RT471 - RT499 2

RT501 - RT535 2

RT551 - RT568 2

RT571 - RT591 2

RT601 - RT630 2

RT631 - RT632 4

RT633 - RT657 2

RT671 - RT673 2

RT681 - RT682 2

RT691 - RT699 2

RT701 - RT704 2

RT711 - RT717 2

RT741 - RT742 2

RT743 4

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ALERT ALERT
Variable Number Group

RT744 - RT757 2

RT776 - RT777 2

RT781 - RT784 2

RT801 - RT803 2

RT811 - RT814 2

RT831 - RT837 2

RT861 - RT864 2

RT876 4

RT877 - RT880 2

RT931 - RT932 2

RT945 - RT949 2

RT951 - RT955 2

RT966 - RT967 2

RU001 - RU006 2

RU016 - RU017 2

RU031 - RU032 2

RU051 - RU052 2

RU059 - RU062 2

RU081 - RU083 2

RU101 - RU102 2

RU121 - RU132 2

RU801 - RU809 2

RU831 - RU841 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions to do inspections of the fuselage skin at the lower forward corner

of the cutout for Main Entry Door (MED) 1. Skin cracks that are not found and repaired can become

large and could adversely affect the structural integrity of the airplane.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
Operators have told Boeing about cracks at the lower forward corner of the MED 1 cutout on two

airplanes. A 1.0 inch long crack in the skin and bearstrap was found on an airplane with 17,605

flight-cycles. A 5.0 inch long crack was found in the skin, skin doubler and bearstrap on an airplane

with 21,759 flight-cycles. In addition, four cracks between 0.18 and 1.85 inch long were found on

Boeing's fatigue test airplane between 40,000 and 52,250 pressure cycles. Analysis indicates that the

crack initiates in the skin and can propagate into the bonded doubler and bearstrap.

Accomplishment of the inspections in this service bulletin and installation of a repair or modification

will help ensure the structural integrity of the lower forward corner of the MED 1 cutout.

Boeing Service Related Problem (SRP) 747-SRP-53-0395 is related to this service bulletin.

D. Description

On the left and right side, as applicable, open MED 1 and remove the door lower threshold. Do detailed

and surface High Frequency Eddy Current (HFEC) inspections of the skin at the lower forward corner

of the door cutout for any crack.

If no crack is found, install a preventive modification in accordance with this service bulletin, or close

access and repeat the skin inspections at the time given in this service bulletin.

If any crack is found, install a repair in accordance with this service bulletin.

After installation of the preventive modification or the repair, continue to do inspections in accordance

with this service bulletin.

NOTE: Detailed inspections of the skin around the main entry door cutouts are included in Boeing

Service Bulletin 747-53A2349, "FUSELAGE - Inspections Based On Fatigue Test Results"

and Boeing Service Bulletin 747-53A2500, "FUSELAGE - Main Frame - Inspections Based

on Fatigue Test Results".

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

747-100, 747-200B, 747-200F 121, 122, 211, 212

Group 2:

Affected Maintenance Zones

Model Zone

747-100, 747-100B, 747-100B 121, 122, 211, 212

SUD, 747-200B, 747-200C,

747-300, 747-400, 747-400D,

747SP, 747SR

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ALERT ALERT
Group 3:

Affected Maintenance Zones

Model Zone

747-200F, 747-400F 121, 211

Group 4:

Affected Maintenance Zones

Model Zone

747-400 121, 122, 211, 212

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2009-18-07 and AD 2010-01-01

are related to this service bulletin.

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.

Table 1: Inspection, Modification and Repair of the Skin at the Forward Lower Corner of the Left Main

Entry Door 1 Cutout

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight-cycles or

24 months,

whichever occurs first, after

the original issue date of this

service bulletin.

Before 12,000

total flight-cycles.

Do PART 1: MAIN ENTRY DOOR 1 CUTOUT

FORWARD LOWER

CORNER SKIN DETAILED AND SURFACE

HFEC INSPECTION for

cracks.

All airplanes

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ALERT ALERT
Table 1: Inspection, Modification and Repair of the Skin at the Forward Lower Corner of the Left Main

Entry Door 1 Cutout

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

OPTION 1: Do PART 2: Before further flight. -

PREVENTIVE MODIFICATION.

CONDITION 1: NO

CRACK FOUND

OPTION 2: Repeat PART - 6,000 flight-cycles.

1: MAIN ENTRY DOOR

1 CUTOUT FORWARD

LOWER CORNER SKIN

DETAILED AND SURFACE HFEC INSPECTION for cracks.

CONDITION 2: ANY Do PART 3: REPAIR. Before further flight. -

CRACK FOUND

Group 1-2, 4:

Table 2: Inspection, Modification and Repair of the Skin at the Forward Lower Corner of the Right Main

Entry Door 1 Cutout

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight-cycles or

24 months,

whichever occurs first, after

the original issue date of this

service bulletin.

Before 12,000

total flight-cycles.

Do PART 1: MAIN ENTRY DOOR 1 CUTOUT

FORWARD LOWER

CORNER SKIN DETAILED AND SURFACE

HFEC INSPECTION for

cracks.

All airplanes

OPTION 1: Do PART 2: Before further flight. -

PREVENTIVE MODIFICATION

CONDITION 1: NO

CRACK FOUND

OPTION 2: Repeat PART - 6,000 flight-cycles.

1: MAIN ENTRY DOOR

1 CUTOUT FORWARD

LOWER CORNER SKIN

DETAILED AND SURFACE HFEC INSPECTION for cracks.

CONDITION 2: ANY Do PART 3: REPAIR. Before further flight. -

CRACK FOUND

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ALERT ALERT
Group 1-3:

Table 3: Post-Modification or Post-Repair Inspection of the Forward Lower Corner of the Left Main Entry

Door 1 Cutout

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 6,000 -

flight-cycles after modification

in accordance

with PART 2:

PREVENTIVE

MODIFICATION

or repair in accordance with

PART 3: REPAIR.

Before 22,000

total flight-cycles.

Do detailed inspections

of the modified or repaired area at the left

Main Entry Door 1 cutout

in accordance with PART

4: POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION.

(a)

Airplanes modified in accordance with PART 2: PREVENTIVE MODIFICATION

or repaired in accordance

with PART 3: REPAIR.

Repeat PART 4: POST- - 3,000 flight-cycles.

MODIFICATION OR

POST-REPAIR DETAILED INSPECTION.

CONDITION 3: NO

CRACK FOUND

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

CONDITION 4: ANY

CRACK FOUND

(a) There are additional mandated inspections in this area per Boeing Service Bulletins 747-53A2349 and

747-53A2500, and Boeing 747 SSID Vol 1 Item F-41B. After modification, only direction 2 can be used

for 747 SSID Vol 1 Item F-41B.

Group 1-2:

Table 4: Post-Modification or Post-Repair Inspection of the Forward Lower Corner of the Right Main

Entry Door 1 Cutout

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 6,000 -

flight-cycles after modification

in accordance

with PART 2:

PREVENTIVE

MODIFICATION

or repair in accordance with

PART 3: REPAIR.

Before 22,000

total flight-cycles.

Do detailed inspections

of the modified or repaired area at the right

Main Entry Door 1 cutout

in accordance with PART

4: POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION.

(a)

Airplanes modified in accordance with PART 2: PREVENTIVE MODIFICATION

or repaired in accordance

with PART 3: REPAIR.

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ALERT ALERT
Group 1-2:

Table 4: Post-Modification or Post-Repair Inspection of the Forward Lower Corner of the Right Main

Entry Door 1 Cutout

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Repeat PART 4: POST- - 3,000 flight-cycles.

MODIFICATION OR

POST-REPAIR DETAILED INSPECTION.

CONDITION 3: NO

CRACK FOUND

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

CONDITION 4: ANY

CRACK FOUND

(a) There are additional mandated inspections in this area per Boeing Service Bulletins 747-53A2349 and

747-53A2500, and Boeing 747 SSID Vol 1 Item F-41B. After modification, only direction 2 can be used

for 747 SSID Vol 1 Item F-41B.

Group 4:

Table 5: Post-Modification or Post-Repair Inspection of the Forward Lower Corner of the Left and Right

Main Entry Door 1 Cutout

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 3,000 -

flight-cycles after modification

in accordance

with PART 2:

PREVENTIVE

MODIFICATION

or repair in accordance with

PART 3: REPAIR.

Before 15,000

total flight-cycles.

Do detailed inspections

of the modified or repaired area at the left and

right Main Entry Door 1

cutouts in accordance

with PART 4: POSTMODIFICATION OR

POST-REPAIR DETAILED INSPECTION.

(a)

Airplanes modified in accordance with PART 2: PREVENTIVE MODIFICATION

or repaired in accordance

with PART 3: REPAIR.

Repeat PART 4: POST- - 1,500 flight-cycles.

MODIFICATION OR

POST-REPAIR DETAILED INSPECTION.

CONDITION 3: NO

CRACK FOUND

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

CONDITION 4: ANY

CRACK FOUND

(a) There are additional mandated inspections in this area per Boeing Service Bulletins 747-53A2349 and

747-53A2500, and Boeing 747 SSID Vol 1 Item F-41B. After modification, only direction 2 can be used

for 747 SSID Vol 1 Item F-41B.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
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.

The Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the accomplishment of

the inspections, repairs and modifications with the corresponding compliance times specified in

Paragraph 1.E., Compliance, of Service Bulletin 747-53A2863, as an AMOC to the inspections and

repairs at the main entry door (MED) 1 forward lower comer required by paragraphs (g)(4) and (j)(4)

of AD 2009-18-07. This AMOC is valid only for areas where inspections, repairs or modifications are

done in accordance with this service bulletin. All other areas of AD 2009-18-07 remain fully applicable

and must be complied with accordingly. When this service bulletin specifies contacting Boeing for repair

instructions, the repair instructions must be approved by the FAA in accordance with paragraph (p) of

AD 2009-18-07. All provisions of AD 2009-18-07 that are not specifically referenced in this paragraph

remain fully applicable and must be complied with accordingly.

In addition, the manager of the FAA Seattle ACO approves the accomplishment of the inspections,

repairs and modifications with the corresponding compliance times specified in Paragraph 1.E.,

Compliance, of Service Bulletin 747-53A2863, as an AMOC to the inspections and repairs at the main

entry door (MED) 1 forward lower comer required by paragraphs (g) and (j) of AD 2010-01-01. This

AMOC is valid only for areas where inspections, repairs or modifications are done in accordance with

this service bulletin. Other areas of MED 1 and all other areas of AD 2010-01-01 remain fully applicable

and must be complied with accordingly. When this SB specifies contacting Boeing for repair instructions,

the repair instructions must be approved by the FAA in accordance with paragraph (m) of AD 2010-01-01.

All provisions of AD 2010-01-01 that are not specifically referenced in this paragraph remain fully

applicable and must be complied with accordingly.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection and modification

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.

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ALERT ALERT
Group 1-2, 4:

Table 1 - Inspection and Preventive Modification Installation on Both Sides

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Inspect Left Side 1 2.25 2.25

(Figure 1)

Inspect Right Side 1 2.25 2.25

(Figure 2)

Install Preventive 2 46.00 23.00

Modification on the

Left Side

Install Preventive 2 46.00 23.00

Modification on the

Right Side

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 112.50 54.50

Group 3:

Table 2 - Inspection and Preventive Modification Installation on the Left Side

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 4.00 2.00

Inspect Left Side 1 2.25 2.25

(Figure 1)

Install Preventive 2 46.00 23.00

Modification on the

Left Side

Close Access 2 4.00 2.00

TOTAL FOR EACH AIRPLANE 56.25 29.25

Group 1-2, 4:

Table 3 - Inspection and Repair Installation on Both Sides

Task Number of Persons Task Hours Elapsed Hours

Open Access 4 8.00 2.00

Inspect Left Side 1 2.25 2.25

(Figure 1)

Inspect Right Side 1 2.25 2.25

(Figure 2)

Install Repair on the 2 66.00 33.00

Left Side

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ALERT ALERT
Group 1-2, 4:

Table 3 - Inspection and Repair Installation on Both Sides

Task Number of Persons Task Hours Elapsed Hours

Install Repair on the 2 66.00 33.00

Right Side

Close Access 4 8.00 2.00

TOTAL FOR EACH AIRPLANE 152.50 74.50

Group 3:

Table 4 - Inspection and Repair Installation on the Left Side

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 4.00 2.00

Inspect Left Side 1 2.25 2.25

(Figure 1)

Install Repair on the 2 66.00 33.00

Left Side

Close Access 2 4.00 2.00

TOTAL FOR EACH AIRPLANE 76.25 39.25

H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

Group 1, Group 2 and Group 4 airplanes (except +15.4 +6768.8

747SP) - Preventive modification installed on

both sides

747SP airplanes - Preventive modification in- +15.4 +9845.5

stalled on both sides

Group 3 airplanes - Preventive modification in- +7.7 +3384.4

stalled on the left side

Group 1 airplanes - Repair installed on both sides +61.1 +26885.9

Group 2 and Group 4 airplanes (except 747SP) +62.3 +27411.5

- Repair installed on both sides

747SP airplanes - Repair installed on both sides +62.3 +39872.0

Group 3 airplanes - Repair installed on the left +31.1 +14328.7

side

I. Electrical Load Data

Not changed (747-400, 747-400F).

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ALERT ALERT
Not applicable (all other affected 747).

J. References

1. Existing Data:

a. Engineering Change Memo PRR 85901-118RS

b. Boeing Service Bulletin 747-53A2349, 747-53A2500

c. Boeing Service Letter 747-SL-00-018

d. Boeing Service Related Problem (SRP) 747-SRP-53-0395

e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2009-18-07, 2010-01-01

f. Service Bulletin Index D6-30300

g. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00

h. 747 Supplemental Structural Inspection Document (SSID) Vol 1Item F-41B

i. 747-100/200/300 Aircraft Maintenance Manual (AMM) 25-21-03, 25-21-04, 25-52-01, 25-52-04,

25-59-01, 25-59-05, 53-11-02

j. 747-100/200/300 Structural Repair Manual (SRM) 51-30-09

k. 747-400 Aircraft Maintenance Manual (AMM) 25-21-01, 25-21-04, 25-52-01, 25-52-04,

25-59-01, 25-59-05, 53-11-02

l. 747-400 Structural Repair Manual (SRM) 51-40-09

m. 747-400F Structural Repair Manual (SRM) 51-40-09

n. 747-400LCF Structural Repair Manual (SRM) 51-40-09

o. 747-400SF Structural Repair Manual (SRM) 51-40-09

p. 747-SP Structural Repair Manual (SRM) 51-30-09

2. Data Supplied with this Service Bulletin:

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

Kit - FWD Lower Corner Preventive and 1 - -

Repair Mod, Main Entry Door #1

675U0004

2 A -

3 A -

4 - -

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
Drawing No Title Sheet DCN/REV ADCN

Kit - FWD Lower Corner Preventive and PSDL A -

Repair Mod, Main Entry Door #1

675U0004#DL

Kit - FWD Lower Corner Preventive Mod, KPL A -

Main Entry Door #1

675U0004-1

Kit - FWD Lower Corner Preventive Mod, KPL A -

Main Entry Door #1

675U0004-2

Kit - FWD Lower Corner Repair Mod, Main KPL C -

Entry Door #1

675U0004-3

Kit - FWD Lower Corner Repair Mod, Main KPL C -

Entry Door #1

675U0004-4

Kit - FWD Lower Corner Repair Mod, Main KPL C -

Entry Door #1

675U0004-5

Kit - FWD Lower Corner Repair Mod, Main KPL C -

Entry Door #1

675U0004-6

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

65B10023 Reveal Installation - No 1 Main Entry Door

65B16200 Reveal Installation - No 1 Main Entry Door (Rework Dwg)

The table above lists applicable drawings used to prepare this service bulletin. The drawings are

not necessary to make the specified changes, and are not supplied with this service bulletin. The

drawings may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability

information.

M. Software Accomplishment Summary

Not affected.

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the original issue

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name Date QTY

Top Kit - Group 1, 2 10/01/2013 1 320 $3,060

and 4

015U1930-1

11/26/2013 4

015U1930-2 Top Kit - Group 3 (a) (a) 320 $1,530

Preventive Modification 10/01/2013 1 320 $1,530

Kit, Left Side

675U0004-1

Preventive Modification 10/01/2013 1 320 $1,530

Kit, Right Side

675U0004-2

Repair Kit, Left Side - 10/31/2013 1 476 $7,380

Group 1

675U0004-3

Repair Kit, Right Side - 10/31/2013 1 476 $7,380

Group 1

675U0004-4

Repair Kit, Left Side - 10/31/2013 4 476 $9,360

Group 2, 3 and 4

675U0004-5

Repair Kit, Right Side - 10/31/2013 4 476 $9,360

Group 2 and 4

675U0004-6

(a) The content of the 015U1930-2 Top Kit is included in the 015U1930-1 Top Kits.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes, inspections or repair

procedures given in this service bulletin.

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ALERT ALERT
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.

1.

2. To make installation easier, some Boeing parts are sent in an 'interim'

configuration. Boeing will identify these interim configurations with a 'U', 'W' or

'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the

'dash' configuration when installed as given in the Accomplishment Instructions

of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS

- SPARES" and Boeing Service Letter 747-SL-00-018 for more information.

3. If grip length shown is not available at Boeing, fasteners supplied in kits may be

one grip length longer than indicated. Also, if any fasteners part numbers listed

are not available or have been superseded, substitute fasteners may be supplied

in kits.

Kit 015U1930

Existing Part Notes

Number

New Part Number QTY Name

-1 -2

Top Kit - Main En- - -

try Door 1 Forward

Lower Skin Reinforcement - Group

1, 2 and 4

015U1930-1 - .

Top Kit - Main En- - -

try Door 1 Forward

Lower Skin Reinforcement - Group

3

015U1930-2 . -

KIT - FWD LOWER - -

CORNER PREVENTIVE MOD, MAIN

ENTRY DOOR #1

675U0004-1 1 1

KIT - FWD LOWER - -

CORNER PREVENTIVE MOD, MAIN

ENTRY DOOR #1

675U0004-2 1 .

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ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-1 -2

KIT - FWD LOWER - (b)

CORNER PREVENTIVE MOD, MAIN

ENTRY DOOR #1

675U0004-1 - .

KIT - FWD LOWER - (b)

CORNER PREVENTIVE MOD, MAIN

ENTRY DOOR #1

675U0004-2 . -

RAW STOCK FOR - (a)

WEDGE

675U0005-9 1 1

RAW STOCK FOR - (a)

WEDGE

675U0005-10 1 1

675U0005-11 1 1 STOP PLATE - (a)

CORNER REIN- - (a)

FORCEMENT

675U0005-13 1 .

CORNER REIN- - (a)

FORCEMENT

675U0005-14 . 1

675U0005-15 1 . FILLER - (a)

675U0005-16 . 1 FILLER - (a)

BACB30LH3K10 5 5 BOLT - -

BACB30LH3K11 1 1 BOLT - -

BACB30LH3K14 2 2 BOLT - -

BACB30LH3K6 1 1 BOLT - -

BACB30LH3K7 7 7 BOLT - -

BACB30LH3K8 1 1 BOLT - -

BACB30NW6K10X 6 6 BOLT - -

BACB30NW6K12X 2 2 BOLT - -

BACB30NW6K13X 1 1 BOLT - -

BACB30NW6K4Y 1 1 BOLT - -

BACB30NW6K5 5 5 BOLT - -

BACB30NW6K6X 4 4 BOLT - -

BACB30NW6K6Y 28 28 BOLT - -

BACB30NW6K7X 2 2 BOLT - -

BACB30NW6K7Y 2 2 BOLT - -

BACB30NW6K8X 11 11 BOLT - -

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ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-1 -2

BACB30NW6K9X 9 9 BOLT - -

BACB30NW6K9Y 2 2 BOLT - -

BACB30NW8K7 2 2 BOLT, - -

BACB30NX6K10X 3 3 BOLT - -

BACB30NX6K12X 4 4 BOLT - -

BACB30NX6K13X 2 2 BOLT - -

BACB30NX6K14X 1 1 BOLT - -

BACB30NX6K3Y 4 4 BOLT - -

BACB30NX6K6 49 49 BOLT - -

BACB30NX6K6Y 17 17 BOLT - -

BACB30NX6K7X 4 4 BOLT - -

BACB30NX6K7Y 1 1 BOLT - -

BACB30NX6K8X 2 2 BOLT - -

BACB30NX8K10X 5 5 BOLT - -

BACB30NX8K10Y 5 5 BOLT - -

BACB30NX8K9X 3 3 BOLT - -

BACB30NX8K9Y 3 3 BOLT - -

BACB30VF4K6 3 3 BOLT - -

BACC30AC6 22 22 COLLAR - -

BACC30AC8 8 8 COLLAR - -

BACC30BH6 66 66 COLLAR - -

BACC30BH8 8 8 COLLAR - -

BACC30M6 44 44 COLLAR - -

BACC30M8 2 2 COLLAR - -

BACC30R6 33 33 COLLAR - -

BACF3T01E50-31 1 1 FILLER, TAPERED - -

BACF3T08G36-31 1 1 FILLER, TAPERED - -

NUTPLATE, - -

CAPPED

BACN10JX4S 3 3

BACR15BA3AD4C 6 6 RIVET - -

BACR15BA3AD6C 6 6 RIVET - -

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ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-1 -2

WASHER, SELF- - -

ALIGN

BACW10CA104CC 5 5

WASHER, SELF- - -

ALIGN

BACW10CA31PV 5 5

BACW10EG61C 16 16 WASHER - -

BACW10EG62C 21 21 WASHER - -

BACW10EG6C 50 50 WASHER - -

BACW10EG81C 8 8 WASHER - -

BACW10EG82C 8 8 WASHER - -

MS20427M4-4 2 2 RIVET - -

MS20427M4-5 2 2 RIVET - -

(a) This part is not used in production.

(b) There are more parts than are necessary.

Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-3 -4 -5 -6

KIT - FWD LOWER (b)

CORNER REPAIR

MOD, MAIN ENTRY DOOR #1

675U0004-3 - . . .

KIT - FWD LOWER (b)

CORNER REPAIR

MOD, MAIN ENTRY DOOR #1

675U0004-4 . - . .

KIT - FWD LOWER (b)

CORNER REPAIR

MOD, MAIN ENTRY DOOR #1

675U0004-5 . . - .

KIT - FWD LOWER (b)

CORNER REPAIR

MOD, MAIN ENTRY DOOR #1

675U0004-6 . . . -

STGR, S-27AL, -

STA 434-440

65B07657U635 1 . 1 .

STGR, S-27AL, -

STA 440-460

65B07657U636 1 . 1 .

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-3 -4 -5 -6

STGR, S-27AR, -

STA 434-440

65B07657U706 . 1 . 1

STGR, S-27AR, -

STA 440-460

65B07657U708 . 1 . 1

CORNER REIN- (a)

FORCEMENT

675U0005-1 1 . 1 .

CORNER REIN- (a)

FORCEMENT

675U0005-2 . 1 . 1

675U0005-3 1 . 1 . DOUBLER (a)

675U0005-4 . 1 . 1 DOUBLER (a)

675U0005-5 1 . 1 . TRIPLER (a)

675U0005-6 . 1 . 1 TRIPLER (a)

STRINGER, S- (a)

27AL, STA 420-

434

675U0005-7 1 . 1 .

STRINGER, S- (a)

27AR, STA 420-

434

675U0005-8 . 1 . 1

RAW STOCK FOR (a)

WEDGE

675U0005-9 1 1 1 1

RAW STOCK FOR (a)

WEDGE

675U0005-10 . . 1 1

675U0005-11 1 1 1 1 STOP PLATE (a)

675U0005-12 . . 5 5 RADIUS FILLER (a)

BACB30LH3K10 . . 6 6 BOLT -

BACB30LH3K12 5 5 6 6 BOLT -

BACB30LH3K13 . . 5 5 BOLT -

BACB30LH3K16 2 2 2 2 BOLT -

(BACB30LH3K17

or BACB30LH3K18

optional)

BACB30LH3K8 1 1 2 2 BOLT -

BACB30LH3K9 6 6 7 7 BOLT -

BACB30NW6K10X 14 14 15 15 BOLT -

BACB30NW6K10Y 1 1 . . BOLT -

BACB30NW6K11X 10 10 11 11 BOLT -

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-3 -4 -5 -6

BACB30NW6K12X 8 8 9 9 BOLT -

BACB30NW6K12Y 2 2 2 2 BOLT -

BACB30NW6K14X 5 5 5 5 BOLT -

BACB30NW6K15X 2 2 2 2 BOLT -

BACB30NW6K16X 1 1 1 1 BOLT -

BACB30NW6K3 88 88 88 88 BOLT -

BACB30NW6K4 1 1 1 1 BOLT -

BACB30NW6K4Y 54 54 82 82 BOLT -

BACB30NW6K5 5 5 5 5 BOLT -

BACB30NW6K5X 4 4 4 4 BOLT -

BACB30NW6K5Y 15 15 30 30 BOLT -

BACB30NW6K6X 1 1 1 1 BOLT -

BACB30NW6K6Y 1 1 8 8 BOLT -

BACB30NW6K7X 2 2 3 3 BOLT -

BACB30NW6K7Y 1 1 . . BOLT -

BACB30NW6K8 28 28 28 28 BOLT -

BACB30NW6K8X 1 1 4 4 BOLT -

BACB30NW6K8Y 46 46 46 46 BOLT -

BACB30NW6K9X 4 4 4 4 BOLT -

BACB30NW6K9Y 1 1 1 1 BOLT -

BACB30NW8K11X . . 2 2 BOLT -

BACB30NW8K11Y 2 2 2 2 BOLT -

BACB30NW8K12X . . 5 5 BOLT -

BACB30NW8K12Y 5 5 5 5 BOLT -

BACB30NW8K6 2 2 1 1 BOLT -

BACB30NW8K9 2 2 2 2 BOLT -

BACB30NX6K10X 3 3 3 3 BOLT -

BACB30NX6K11X 8 8 8 8 BOLT -

BACB30NX6K13X 1 1 1 1 BOLT -

BACB30NX6K14X 4 4 4 4 BOLT -

BACB30NX6K15X 1 1 1 1 BOLT -

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ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-3 -4 -5 -6

BACB30NX6K16X 1 1 1 1 BOLT -

BACB30NX6K4Y . . 2 2 BOLT -

BACB30NX6K5 116 116 . . BOLT -

BACB30NX6K6 168 168 283 283 BOLT -

BACB30NX6K6Y 4 4 4 4 BOLT -

BACB30NX6K7 15 15 15 15 BOLT -

BACB30NX6K7Y 64 64 68 68 BOLT -

BACB30NX6K8X 2 2 2 2 BOLT -

BACB30NX6K8Y 3 3 24 24 BOLT -

BACB30NX6K9X 5 5 5 5 BOLT -

BACB30NX8K10 2 2 2 2 BOLT -

BACB30NX8K10X 1 1 1 1 BOLT -

BACB30NX8K10Y 1 1 . . BOLT -

BACB30NX8K11X . . 2 2 BOLT -

BACB30NX8K11Y 2 2 2 2 BOLT -

BACB30NX8K5 23 23 24 24 BOLT -

BACB30NX8K6 11 11 12 12 BOLT -

BACB30NX8K6Y 1 1 1 1 BOLT -

BACB30NX8K8 9 9 6 6 BOLT -

BACB30NX8K8X . . 1 1 BOLT -

BACB30NX8K8Y 1 1 1 1 BOLT -

BACB30NX8K9 20 20 20 20 BOLT -

BACB30NX8K9X . . 4 4 BOLT -

BACB30NX8K9Y 5 5 4 4 BOLT -

BACB30VF3K8 3 3 3 3 BOLT -

BACB30VT8K2 6 6 6 6 BOLT -

BACB30VT8K3 2 2 2 2 BOLT -

BACB30VT8K4 6 6 6 6 BOLT -

BACC30AC6 71 71 101 101 COLLAR -

BACC30AC8 10 10 8 8 COLLAR -

BACC30BH6 327 327 327 327 COLLAR -

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-3 -4 -5 -6

BACC30BH8 73 73 80 80 COLLAR -

BACC30BL8 14 14 14 14 COLLAR -

BACC30M6 180 180 188 188 COLLAR -

BACC30M8 4 4 10 10 COLLAR -

BACC30R6 123 123 169 169 COLLAR -

BACC30R8 7 7 7 7 COLLAR -

BACF33C100- 29 29 29 29 FILLER -

075DF

BACF33C111- . . 25 25 FILLER -

075DF

BACF3F008D035NN 1 1 1 1 FILLER -

BACF3F008D174NN 1 1 . . FILLER -

BACF3F015R031NN 1 1 1 1 FILLER -

BACF3F024T109NN 1 1 1 1 FILLER -

BACF3T01K31-31 1 1 1 1 FILLER -

BACR15BB7D6C 22 22 22 22 RIVET -

BACR15BB7D7C 9 9 9 9 RIVET -

BACR15GF6D6 149 149 132 132 RIVET -

BACR15GF6D7 . . 15 15 RIVET -

BACR15GF6D8 11 11 11 11 RIVET -

BACR15GF7D6 1 1 1 1 RIVET -

BACR15GF7D8 6 6 6 6 RIVET -

BACS40R031A058F 1 1 1 1 SHIM -

BACW10CA104CC 10 10 10 10 WASHER -

BACW10CA31PV 10 10 10 10 WASHER -

BACW10EG61C 28 28 28 28 WASHER -

BACW10EG62C 72 72 101 101 WASHER -

BACW10EG6C 300 300 300 300 WASHER -

BACW10EG81C 1 1 8 8 WASHER -

BACW10EG82C 10 10 8 8 WASHER -

BACW10EG8C 87 87 71 71 WASHER -

MS20427M4-4 2 2 2 2 RIVET -

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
Kit 675U0004

Existing Part Notes

Number

New Part Number QTY Name

-3 -4 -5 -6

MS20427M4-5 . . 2 2 RIVET -

MS20615-8MP10 1 1 1 1 RIVET -

MS20615-8MP13 1 1 1 1 RIVET -

MS20615-8MP15 1 1 1 1 RIVET -

(a) This part is not used in production.

(b) There are more parts than are necessary.

2. Parts and Materials Supplied by the Operator

The following parts or materials are necessary to do the change in this service bulletin. Parts and

materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine

operator part and material supply to make sure all necessary parts and materials are available.

Part Number / QTY Name Notes

Specification

1 pint Sealant (a)

per affected

door

BMS 5-95

(a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)

for supplier data.

3. Parts Modified and Reidentified

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the

number of parts changed on each airplane.

Existing Part QTY Name New Part Number Notes

Number

Threshold - Left MED (b) (a) (c)

#1

65B10023-( ) or 1

65B16200-( )

Threshold - Right MED (b) (a) (c)

#1

65B10023-( ) or 1

65B16200-( )

(a) Make the change in accordance with this service bulletin.

(b) There is no equivalent Boeing part number for the changed part. Identify on the part that

the change done in accordance with this service bulletin was made.

(c) This part is not used in production.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

The 747-100/200/300 SRM 51-30-09, 747-SP SRM 51-30-09 747-400 SRM 51-40-09, 747-400F SRM

51-40-09, 747-400LCF SRM 51-40-09, and 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.

Engineering, service, and a kit of cold working tools made for this change are available from Fatigue

Technology, Inc. or West Coast Industries, Inc.

• Refer To: FTI Kit Number: FTI-747-53-2863-1

Fatigue Technology, Inc.

P.O. Box C-88388

Seattle, WA 98188 USA

Phone Number (206) 246-2010

Fax (206) 244-9886

• Refer To: WCI Kit Number: WCI-747-53A-2863

West Coast Industries, Inc.

14900 Whitman Avenue North

Seattle, WA 98133-6532 USA

Phone Number (206) 365-7513

Fax (206) 365-7483

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.

Cold working tools are necessary to do the change given in this service bulletin. To get the cold working

tools, refer to Paragraph 2.E., Special Tooling - Price and Availability.

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ALERT ALERT
Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT

BLANK PAGE
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 "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.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
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. Some Boeing parts are supplied in a temporary configuration. Those parts are

identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is

permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-'

(dash) part number. Boeing Drawing 005W0900 contains more data.

13. Shaded areas in Figures are to separate the non-critical and non-authoritative

information from the critical and authoritative information.

14. 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.

15. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

16. The CONDITIONS, ACTIONS and OPTIONS shown apply to each affected side of

the airplane independently.

B. WORK INSTRUCTIONS

1. Do PART 1: MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN DETAILED

AND SURFACE HFEC INSPECTION for cracks.

CONDITION 1: NO CRACK FOUND

a. OPTION 1: Do PART 2: PREVENTIVE MODIFICATION.

b. OPTION 2: Repeat PART 1: MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER

SKIN DETAILED AND SURFACE HFEC INSPECTION for cracks.

CONDITION 2: ANY CRACK FOUND

a. Do PART 3: REPAIR.

2. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
PART 1: MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN DETAILED AND

SURFACE HFEC INSPECTION

1. Open left Main Entry Door 1.

2. Group 1-2, 4:

Open right Main Entry Door 1.

3. Remove and keep the left main entry door scuff plate and threshold. Refer to 747-400 AMM

53-11-02 or 747-100/200/300 AMM 53-11-02 as accepted procedures.

4. Group 1-2, 4:

Remove and keep the right main entry door scuff plate and threshold. Refer to 747-400 AMM

53-11-02 or 747-100/200/300 AMM 53-11-02 as accepted procedures.

5. Do detailed and surface HFEC inspections at left main entry door 1 in accordance with FIGURE

1.

6. Group 1-2, 4:

Do detailed and surface HFEC inspections at right main entry door 1 in accordance with FIGURE

2.

7. If the Preventive Modification or Repair will not be done at this time, install the applicable main

entry door scuff plate and threshold. Refer to 747-400 AMM 53-11-02 or 747-100/200/300 AMM

53-11-02 as accepted procedures.

PART 2: PREVENTIVE MODIFICATION

1. Remove and keep the doorway lining and sidewall insulation for internal access to the forward

lower corner of the MED 1 cutout. Refer to 747-100/200/300 AMM 25-21-03, 747-400 AMM

25-21-01, 747-100/200/300 AMM 25-21-04, 747-400 AMM 25-21-04, 747-100/200/300 AMM

25-59-01, 747-100/200/300 AMM 25-59-05, 747-400 AMM 25-59-01 and 747-400 AMM 25-59-05

as accepted procedures.

2. In the forward lower lobe cargo compartment, remove and keep the ceiling and sidewall lining and

insulation for internal access to the forward lower corner of the MED 1 cutout. Refer to

747-100/200/300 AMM 25-52-01, 747-400 AMM 25-52-01, 747-100/200/300 AMM 25-52-04 and

747-400 AMM 25-52-04 as accepted procedures.

3. On the left side, Install the 675U0004-1 preventive modification in accordance with Sheet PSDL

and Sheet 1 of Drawing 675U0004.

4. Group 1-2, 4:

On the right side, Install the 675U0004-2 preventive modification in accordance with Sheet PSDL

and Sheet 1 of Drawing 675U0004.

5. Install the applicable main entry door scuff plate and threshold. Refer to 747-400 AMM 53-11-02

or 747-100/200/300 AMM 53-11-02 as accepted procedures.

6. Do detailed inspections of the modified area in accordance with PART 4: POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
PART 3: REPAIR

1. Remove and keep the doorway lining and sidewall insulation for internal access to the forward

lower corner of the MED 1 cutout. Refer to 747-100/200/300 AMM 25-21-03, 747-400 AMM

25-21-01, 747-100/200/300 AMM 25-21-04, 747-400 AMM 25-21-04, 747-100/200/300 AMM

25-59-01, 747-100/200/300 AMM 25-59-05, 747-400 AMM 25-59-01 and 747-400 AMM 25-59-05

as accepted procedures.

2. In the forward lower lobe cargo compartment, remove and keep the ceiling and sidewall lining and

insulation for internal access to the forward lower corner of the MED 1 cutout. Refer to

747-100/200/300 AMM 25-52-01, 747-400 AMM 25-52-01, 747-100/200/300 AMM 25-52-04 and

747-400 AMM 25-52-04 as accepted procedures.

3. Group 1:

On the left side, Install the 675U0004-3 repair in accordance with Sheet PSDL, Sheet 2 and Sheet

4 of Drawing 675U0004.

4. Group 2-4:

On the left side, Install the 675U0004-5 repair in accordance with Sheet PSDL, Sheet 3 and Sheet

4 of Drawing 675U0004.

5. Group 1:

On the right side, Install the 675U0004-4 repair in accordance with Sheet PSDL, Sheet 2 and

Sheet 4 of Drawing 675U0004.

6. Group 2, 4:

On the right side, Install the 675U0004-6 repair in accordance with Sheet PSDL, Sheet 3 and

Sheet 4 of Drawing 675U0004.

7. Install the doorway lining and sidewall insulation removed for access to the forward lower corner

of the MED 1 cutout. Refer to 747-100/200/300 AMM 25-21-03, 747-400 AMM 25-21-01,

747-100/200/300 AMM 25-21-04, 747-400 AMM 25-21-04, 747-100/200/300 AMM 25-59-01,

747-100/200/300 AMM 25-59-05, 747-400 AMM 25-59-01 and 747-400 AMM 25-59-05 as accepted

procedures.

8. In the forward lower lobe cargo compartment, install the ceiling and sidewall lining and insulation

removed for access to the forward lower corner of the MED 1 cutout. Refer to 747-100/200/300

AMM 25-52-01, 747-400 AMM 25-52-01, 747-100/200/300 AMM 25-52-04 and 747-400 AMM

25-52-04 as accepted procedures.

9. Install the applicable main entry door scuff plate and threshold. Refer to 747-400 AMM 53-11-02

or 747-100/200/300 AMM 53-11-02 as accepted procedures.

10. Do detailed inspections of the repaired area in accordance with PART 4: POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION.

PART 4: POST-MODIFICATION OR POST-REPAIR DETAILED INSPECTION

1. Do detailed inspections at left main entry door 1 in accordance with FIGURE 3.

2. Group 1-2, 4:

Do detailed inspections at right main entry door 1 in accordance with FIGURE 4.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
CONDITION 3: NO CRACK FOUND

a. Repeat PART 4: POST-MODIFICATION OR POST-REPAIR DETAILED INSPECTION for

any crack.

CONDITION 4: ANY CRACK FOUND

a. Contact Boeing for repair instructions and do the repair.

3. Put the airplane back to a serviceable condition.

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
FIGURE 1: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
FIGURE 1: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

Step Task Name Identification Qty More Data

Do a detailed inspection of the skin at the

corner of the door

cutout in the area

shown for any crack.

1 Inspect Skin - -

Do a surface HFEC

inspection of the

skin around the fasteners in the area

shown for any crack

in accordance with

747 NDT Manual

Part 6, 51-00-00,

Procedure 4 or 23.

2 Inspect Skin - -

FIGURE 1: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
This Figure applies only to: Group 1-2, 4.

FIGURE 2: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
FIGURE 2: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

Step Task Name Identification Qty More Data

Do a detailed inspection of the skin at the

corner of the door

cutout in the area

shown for any crack.

1 Inspect Skin - -

Do a surface HFEC

inspection of the

skin around the fasteners in the area

shown for any crack

in accordance with

747 NDT Manual

Part 6, 51-00-00,

Procedure 4 or 23.

2 Inspect Skin - -

FIGURE 2: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
FIGURE 3: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER POST-MODIFICATION OR

POST-REPAIR DETAILED INSPECTION

(SHEET 1 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: March 11, 2014

747-53A2863

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
The step number shown below agrees with the number shown in the circle symbol in the figure.

Step Task Name Identification Qty More Data

Do a detailed inspection of the skin and

doublers at the corner of the door

cutout in the area

shown for any crack.

1 Inspect Skin and Doublers - -

FIGURE 3: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER POST-MODIFICATION OR

POST-REPAIR DETAILED INSPECTION

(SHEET 2 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: March 11, 2014

747-53A2863

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BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
FIGURE 4: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION

(SHEET 1 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: March 11, 2014

747-53A2863

54 of 55

BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT
The step number shown below agrees with the number shown in the circle symbol in the figure.

Step Task Name Identification Qty More Data

Do a detailed inspection of the skin and

doublers at the corner of the door

cutout in the area

shown for any crack.

1 Inspect Skin and Doublers - -

FIGURE 4: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER POST-MODIFICATION

OR POST-REPAIR DETAILED INSPECTION

(SHEET 2 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: March 11, 2014

747-53A2863

55 of 55

BOEING SERVICE BULLETIN 747-53A2863

ALERT ALERT