### 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.9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 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 Unpublished Work.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Original Issue: March 11, 2014 747-53A2863 1 of 55 6.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 2 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT**

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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 3 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 4 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT**

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.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes Yes Weight and Balance Change

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 5 of 55**Reference Affected**  **Planning Data** 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 Yes Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required
**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 6 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT MANPOWER**  **Elapsed Hours Total Task Hours**  **Airplanes** 54.50 112.50 Group 1, 2 and4 Airplanes - Inspection andPreventive Modification 74.50 152.50 Group 1, 2 and4 Airplanes - Inspection and Repair 29.25 56.25 Group 3 Air-planes - Inspection and Preventive Modification 39.25 76.25 Group 3 Air-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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 7 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 8 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT**

### 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.
**DESCRIPTION CONFIGURATION**  **GROUP** 747 airplanes line number 1 through 206.
- 1 747 airplanes line number 207 through 1419, except 747-200F, 747-400F and 747 Large Cargo Freighter (LCF) airplanes. - 2
747-200F and 747-400F airplanes line number 207 through 1419.
- 3 747 LCF airplanes.

- 4

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 **Group Variable Number** 1 RA001 - RA034

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 9 of 55**Group Variable Number** 1 RA101 - RA115 1 RA161 - RA164 1 RA201 - RA203 1 RA216 - RA217 1 RA245 - RA246 1 RA251 - RA261 2 RA262 - RA266 1 RA301 - RA312 2 RA313 - RA318 1 RA351 - RA360 1 RA369 - RA373 1 RA401 - RA416 2 RA417 - RA418 1 RA501 - RA502 1 RA521 - RA527 2 RA528 1 RA532 - RA540 2 RA541 - RA548 1 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 2 RA725 - RA731 1 RA741 - RA743 2 RA744 - RA745 2 RA749 - RA750 1 RA761 - RA762

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 10 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**1 RA781 - RA782 2 RA783 - RA784 1 RA901 - RA916 1 RB001 - RB005 2 RB006 - RB012 1 RB013 - RB014 2 RB015 - RB016 1 RB041 - RB044 1 RB071 - RB075 1 RB101 - RB102 2 RB411 - RB413 2 RB421 2 RB601 - RB607 2 RB681 - RB697 2 RB711 2 RB721 - RB723 2 RB741 - RB748 1 RD001 - RD002 2 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 11 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**2 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 12 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**2 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 3 RL401 - RL403 3 RL411 - RL436 3 RL451 - RL456 3 RL461 - RL462 3 RL471 - RL481 3 RL491 - RL492

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 13 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**3 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 2 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 14 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**2 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 3 RM851 - RM859 3 RM861 - RM863 3 RM871 - RM899 3 RM901 - RM906 3 RM911 3 RR001 - RR005 3 RR021 - RR025 3 RR031 1 RR201 3 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 15 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**3 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 2 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 16 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**2 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 4 RT631 - RT632 2 RT633 - RT657 2 RT671 - RT673 2 RT681 - RT682 2 RT691 - RT699 2 RT701 - RT704 2 RT711 - RT717 2 RT741 - RT742 4 RT743

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 17 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group**  **Variable Number**2 RT744 - RT757 2 RT776 - RT777 2 RT781 - RT784 2 RT801 - RT803 2 RT811 - RT814 2 RT831 - RT837 2 RT861 - RT864 4 RT876 2 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. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 18 of 55 **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 Zone**  **Model** 121, 122, 211, 212 747-100, 747-200B, 747-200F **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 121, 122, 211, 212 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D, 747SP, 747SR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 19 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group 3:** 
**Affected Maintenance Zones Zone**  **Model** 121, 211 747-200F, 747-400F **Group 4:**
**Affected Maintenance Zones Zone**  **Model** 121, 122, 211, 212 747-400 **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)**  **Action Condition** 

- Within 3,000 flight-cycles or 24 months,whichever occurs first, afterthe original issue date of this service bulletin. Before 12,000total flight-cycles.Do PART 1: MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWERCORNER SKIN DETAILED AND SURFACE HFEC INSPECTION for cracks. All airplanes

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 20 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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) Action**  **Condition**

- Before further flight. OPTION 1: Do PART 2:PREVENTIVE MODIFICATION. CONDITION 1: NO CRACK FOUND 6,000 flight-cycles.

- OPTION 2: Repeat PART 1: MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKINDETAILED AND SURFACE HFEC INSPECTION for cracks.

- Before further flight. Do PART 3: REPAIR. CONDITION 2: ANY 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) Action**  **Condition**

- Within 3,000 flight-cycles or 24 months,whichever occurs first, afterthe original issue date of this service bulletin. Before 12,000total flight-cycles.Do PART 1: MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWERCORNER SKIN DETAILED AND SURFACE HFEC INSPECTION for cracks. All airplanes

- Before further flight. OPTION 1: Do PART 2:PREVENTIVE MODIFICATION CONDITION 1: NO CRACK FOUND 6,000 flight-cycles.

- OPTION 2: Repeat PART 1: MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKINDETAILED AND SURFACE HFEC INSPECTION for cracks.

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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 21 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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)**  **Action Condition** 

- Within 6,000flight-cycles after modification in accordance with PART 2: PREVENTIVE MODIFICATIONor repair in accordance withPART 3: REPAIR. Before 22,000total flight-cycles. Do detailed inspectionsof the modified or repaired area at the left Main Entry Door 1 cutout in accordance with PART 4: POST-MODIFICATIONOR POST-REPAIR DETAILED INSPECTION. (a)Airplanes modified in accordance with PART 2: PREVENTIVE MODIFICATION or repaired in accordance with PART 3: REPAIR.

3,000 flight-cycles.

- Repeat PART 4: POST- MODIFICATION ORPOST-REPAIR DETAILED INSPECTION. CONDITION 3: NO CRACK FOUND

- Before further flight. Contact Boeing for repair 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) Action**  **Condition**

- Within 6,000flight-cycles after modification in accordance with PART 2: PREVENTIVE MODIFICATIONor repair in accordance withPART 3: REPAIR. Before 22,000total flight-cycles. Do detailed inspectionsof the modified or repaired area at the right Main Entry Door 1 cutout in accordance with PART 4: POST-MODIFICATIONOR POST-REPAIR DETAILED INSPECTION. (a)Airplanes modified in accordance with PART 2: PREVENTIVE MODIFICATION or repaired in accordance with PART 3: REPAIR.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 22 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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)**  **Action Condition**  3,000 flight-cycles.

- Repeat PART 4: POST- MODIFICATION ORPOST-REPAIR DETAILED INSPECTION. CONDITION 3: NO CRACK FOUND

- Before further flight. Contact Boeing for repair 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) Action**  **Condition**

- Within 3,000flight-cycles after modification in accordance with PART 2: PREVENTIVE MODIFICATIONor repair in accordance withPART 3: REPAIR. Before 15,000total flight-cycles. Do detailed inspectionsof the modified or repaired area at the left and right Main Entry Door 1 cutouts in accordancewith PART 4: POSTMODIFICATION ORPOST-REPAIR DETAILED INSPECTION. (a)Airplanes modified in accordance with PART 2: PREVENTIVE MODIFICATION or repaired in accordance with PART 3: REPAIR.

1,500 flight-cycles.

- Repeat PART 4: POST- MODIFICATION ORPOST-REPAIR DETAILED INSPECTION. CONDITION 3: NO CRACK FOUND

- Before further flight. Contact Boeing for repair 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 23 of 55 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 24 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group 1-2, 4:**  **Table 1 - Inspection and Preventive Modification Installation on Both Sides Elapsed Hours**  **Task Hours Number of Persons**  **Task** 2.00 8.00 4 Open Access 2.25 2.25 1 Inspect Left Side (Figure 1) 2.25 2.25 1 Inspect Right Side (Figure 2) 23.00 46.00 2 Install Preventive Modification on the Left Side 23.00 46.00 2 Install Preventive Modification on the Right Side 2.00 8.00 4 Close Access 54.50 112.50 TOTAL FOR EACH AIRPLANE **Group 3: Table 2 - Inspection and Preventive Modification Installation on the Left Side**  **Elapsed Hours Task Hours**  **Number of Persons Task**  2.00 4.00 2 Open Access 2.25 2.25 1 Inspect Left Side (Figure 1) 23.00 46.00 2 Install Preventive Modification on the Left Side 2.00 4.00 2 Close Access 29.25 56.25 TOTAL FOR EACH AIRPLANE **Group 1-2, 4: Table 3 - Inspection and Repair Installation on Both Sides** **Elapsed Hours Task Hours**  **Number of Persons Task**  2.00 8.00 4 Open Access 2.25 2.25 1 Inspect Left Side (Figure 1) 2.25 2.25 1 Inspect Right Side (Figure 2) 33.00 66.00 2 Install Repair on the Left Side

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 25 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Group 1-2, 4:**  **Table 3 - Inspection and Repair Installation on Both Sides Elapsed Hours**  **Task Hours Number of Persons**  **Task** 33.00 66.00 2 Install Repair on the Right Side 2.00 8.00 4 Close Access 74.50 152.50 TOTAL FOR EACH AIRPLANE **Group 3: Table 4 - Inspection and Repair Installation on the Left Side** **Elapsed Hours Task Hours**  **Number of Persons Task**  2.00 4.00 2 Open Access 2.25 2.25 1 Inspect Left Side (Figure 1) 33.00 66.00 2 Install Repair on the Left Side 2.00 4.00 2 Close Access 39.25 76.25 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane**  +6768.8 +15.4 Group 1, Group 2 and Group 4 airplanes (except 747SP) - Preventive modification installed on both sides +9845.5 +15.4 747SP airplanes - Preventive modification in- stalled on both sides +3384.4 +7.7 Group 3 airplanes - Preventive modification in- stalled on the left side +26885.9 +61.1 Group 1 airplanes - Repair installed on both sides +27411.5 +62.3 Group 2 and Group 4 airplanes (except 747SP) - Repair installed on both sides +39872.0 +62.3 747SP airplanes - Repair installed on both sides +14328.7 +31.1 Group 3 airplanes - Repair installed on the left side
**I. Electrical Load Data** Not changed (747-400, 747-400F).

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 26 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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:
**ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- - 1 Kit - FWD Lower Corner Preventive and Repair Mod, Main Entry Door #1 675U0004

- A 2

- A 3

- - 4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 27 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT ADCN**  **DCN/REV Sheet**  **Title Drawing No** 

- A PSDL Kit - FWD Lower Corner Preventive and Repair Mod, Main Entry Door #1 675U0004#DL

- A KPL Kit - FWD Lower Corner Preventive Mod, Main Entry Door #1 675U0004-1

- A KPL Kit - FWD Lower Corner Preventive Mod, Main Entry Door #1 675U0004-2

- C KPL Kit - FWD Lower Corner Repair Mod, Main Entry Door #1 675U0004-3

- C KPL Kit - FWD Lower Corner Repair Mod, Main Entry Door #1 675U0004-4

- C KPL Kit - FWD Lower Corner Repair Mod, Main Entry Door #1 675U0004-5

- C KPL Kit - FWD Lower Corner Repair Mod, Main Entry Door #1 675U0004-6
3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number** Reveal Installation - No 1 Main Entry Door 65B10023 Reveal Installation - No 1 Main Entry Door (Rework Dwg) 65B16200 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 28 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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 Ser vice Bulletin (US**  **Dollars) ROLT as of the**  **original issue date of this Ser** **vice Bulletin (Cal endar Days)**  **QTY Date**  **Name Kit Number** 

$3,060 320 1 10/01/2013 Top Kit - Group 1, 2 and 4 015U1930-1 4 11/26/2013 $1,530 320 (a) (a) Top Kit - Group 3 015U1930-2 $1,530 320 1 10/01/2013 Preventive Modification Kit, Left Side 675U0004-1 $1,530 320 1 10/01/2013 Preventive Modification Kit, Right Side 675U0004-2 $7,380 476 1 10/31/2013 Repair Kit, Left Side - Group 1 675U0004-3 $7,380 476 1 10/31/2013 Repair Kit, Right Side - Group 1 675U0004-4 $9,360 476 4 10/31/2013 Repair Kit, Left Side - Group 2, 3 and 4 675U0004-5 $9,360 476 4 10/31/2013 Repair Kit, Right Side - 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 29 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -2**  **-1**

- - Top Kit - Main En- try Door 1 ForwardLower Skin Reinforcement - Group 1, 2 and 4 . - 015U1930-1

- - Top Kit - Main En- try Door 1 ForwardLower Skin Reinforcement - Group 3 - . 015U1930-2

- - KIT - FWD LOWERCORNER PREVENTIVE MOD, MAIN ENTRY DOOR #1 1 1 675U0004-1

- - KIT - FWD LOWERCORNER PREVENTIVE MOD, MAIN ENTRY DOOR #1 . 1 675U0004-2

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 30 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-2 -1**  (b)

- KIT - FWD LOWERCORNER PREVENTIVE MOD, MAIN ENTRY DOOR #1 . - 675U0004-1

(b)

- KIT - FWD LOWERCORNER PREVENTIVE MOD, MAIN ENTRY DOOR #1 - . 675U0004-2

(a)

- RAW STOCK FOR WEDGE 1 1 675U0005-9 (a)

- RAW STOCK FOR WEDGE 1 1 675U0005-10 (a)

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

- CORNER REIN- FORCEMENT . 1 675U0005-13 (a)

- CORNER REIN- FORCEMENT 1

. 675U0005-14 (a)

- FILLER

. 1 675U0005-15 (a)

- FILLER 1

. 675U0005-16

- - BOLT 5 5 BACB30LH3K10

- - BOLT 1 1 BACB30LH3K11

- - BOLT 2 2 BACB30LH3K14

- - BOLT 1 1 BACB30LH3K6

- - BOLT 7 7 BACB30LH3K7

- - BOLT 1 1 BACB30LH3K8

- - BOLT 6 6 BACB30NW6K10X

- - BOLT 2 2 BACB30NW6K12X

- - BOLT 1 1 BACB30NW6K13X

- - BOLT 1 1 BACB30NW6K4Y

- - BOLT 5 5 BACB30NW6K5

- - BOLT 4 4 BACB30NW6K6X

- - BOLT 28 28 BACB30NW6K6Y

- - BOLT 2 2 BACB30NW6K7X

- - BOLT 2 2 BACB30NW6K7Y

- - BOLT 11 11 BACB30NW6K8X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 31 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-2 -1** 

- - BOLT 9 9 BACB30NW6K9X

- - BOLT 2 2 BACB30NW6K9Y

- - BOLT, 2 2 BACB30NW8K7

- - BOLT 3 3 BACB30NX6K10X

- - BOLT 4 4 BACB30NX6K12X

- - BOLT 2 2 BACB30NX6K13X

- - BOLT 1 1 BACB30NX6K14X

- - BOLT 4 4 BACB30NX6K3Y

- - BOLT 49 49 BACB30NX6K6

- - BOLT 17 17 BACB30NX6K6Y

- - BOLT 4 4 BACB30NX6K7X

- - BOLT 1 1 BACB30NX6K7Y

- - BOLT 2 2 BACB30NX6K8X

- - BOLT 5 5 BACB30NX8K10X

- - BOLT 5 5 BACB30NX8K10Y

- - BOLT 3 3 BACB30NX8K9X

- - BOLT 3 3 BACB30NX8K9Y

- - BOLT 3 3 BACB30VF4K6

- - COLLAR 22 22 BACC30AC6

- - COLLAR 8 8 BACC30AC8

- - COLLAR 66 66 BACC30BH6

- - COLLAR 8 8 BACC30BH8

- - COLLAR 44 44 BACC30M6

- - COLLAR 2 2 BACC30M8

- - COLLAR 33 33 BACC30R6

- - FILLER, TAPERED 1 1 BACF3T01E50-31

- - FILLER, TAPERED 1 1 BACF3T08G36-31

- - NUTPLATE, CAPPED 3 3 BACN10JX4S

- - RIVET 6 6 BACR15BA3AD4C

- - RIVET 6 6 BACR15BA3AD6C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 32 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-2 -1** 

- - WASHER, SELF- ALIGN 5 5 BACW10CA104CC

- - WASHER, SELF- ALIGN 5 5 BACW10CA31PV

- - WASHER 16 16 BACW10EG61C

- - WASHER 21 21 BACW10EG62C

- - WASHER 50 50 BACW10EG6C

- - WASHER 8 8 BACW10EG81C

- - WASHER 8 8 BACW10EG82C

- - RIVET 2 2 MS20427M4-4

- - RIVET 2 2 MS20427M4-5 (a) This part is not used in production. (b) There are more parts than are necessary.
**Kit 675U0004 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -6**  **-5 -4**  **-3** (b) KIT - FWD LOWER CORNER REPAIRMOD, MAIN ENTRY DOOR #1 . . . - 675U0004-3

(b) KIT - FWD LOWER CORNER REPAIRMOD, MAIN ENTRY DOOR #1 . . - . 675U0004-4

(b) KIT - FWD LOWER CORNER REPAIRMOD, MAIN ENTRY DOOR #1 . - . . 675U0004-5

(b) KIT - FWD LOWER CORNER REPAIRMOD, MAIN ENTRY DOOR #1 - . . . 675U0004-6

- STGR, S-27AL, STA 434-440 . 1

. 1 65B07657U635

- STGR, S-27AL, STA 440-460 . 1

. 1 65B07657U636

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 33 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-6 -5**  **-4 -3** 

- STGR, S-27AR, STA 434-440 1

. 1

. 65B07657U706

- STGR, S-27AR, STA 440-460 1

. 1

. 65B07657U708 (a) CORNER REIN- FORCEMENT . 1

. 1 675U0005-1 (a) CORNER REIN- FORCEMENT 1

. 1

. 675U0005-2 (a) DOUBLER

. 1

. 1 675U0005-3 (a) DOUBLER 1

. 1

. 675U0005-4 (a) TRIPLER

. 1

. 1 675U0005-5 (a) TRIPLER 1

. 1

. 675U0005-6 (a) STRINGER, S- 27AL, STA 420- 434 . 1

. 1 675U0005-7

(a) STRINGER, S- 27AR, STA 420- 434 1

. 1

. 675U0005-8

(a) RAW STOCK FOR WEDGE 1 1 1 1 675U0005-9 (a) RAW STOCK FOR WEDGE 1 1

. . 675U0005-10 (a) STOP PLATE 1 1 1 1 675U0005-11 (a) RADIUS FILLER 5 5

. . 675U0005-12

- BOLT 6 6

. . BACB30LH3K10

- BOLT 6 6 5 5 BACB30LH3K12

- BOLT 5 5

. . BACB30LH3K13

- BOLT 2 2 2 2 BACB30LH3K16 (BACB30LH3K17 or BACB30LH3K18 optional)

- BOLT 2 2 1 1 BACB30LH3K8

- BOLT 7 7 6 6 BACB30LH3K9

- BOLT 15 15 14 14 BACB30NW6K10X

- BOLT

. . 1 1 BACB30NW6K10Y

- BOLT 11 11 10 10 BACB30NW6K11X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 34 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-6 -5**  **-4 -3** 

- BOLT 9 9 8 8 BACB30NW6K12X

- BOLT 2 2 2 2 BACB30NW6K12Y

- BOLT 5 5 5 5 BACB30NW6K14X

- BOLT 2 2 2 2 BACB30NW6K15X

- BOLT 1 1 1 1 BACB30NW6K16X

- BOLT 88 88 88 88 BACB30NW6K3

- BOLT 1 1 1 1 BACB30NW6K4

- BOLT 82 82 54 54 BACB30NW6K4Y

- BOLT 5 5 5 5 BACB30NW6K5

- BOLT 4 4 4 4 BACB30NW6K5X

- BOLT 30 30 15 15 BACB30NW6K5Y

- BOLT 1 1 1 1 BACB30NW6K6X

- BOLT 8 8 1 1 BACB30NW6K6Y

- BOLT 3 3 2 2 BACB30NW6K7X

- BOLT

. . 1 1 BACB30NW6K7Y

- BOLT 28 28 28 28 BACB30NW6K8

- BOLT 4 4 1 1 BACB30NW6K8X

- BOLT 46 46 46 46 BACB30NW6K8Y

- BOLT 4 4 4 4 BACB30NW6K9X

- BOLT 1 1 1 1 BACB30NW6K9Y

- BOLT 2 2

. . BACB30NW8K11X

- BOLT 2 2 2 2 BACB30NW8K11Y

- BOLT 5 5

. . BACB30NW8K12X

- BOLT 5 5 5 5 BACB30NW8K12Y

- BOLT 1 1 2 2 BACB30NW8K6

- BOLT 2 2 2 2 BACB30NW8K9

- BOLT 3 3 3 3 BACB30NX6K10X

- BOLT 8 8 8 8 BACB30NX6K11X

- BOLT 1 1 1 1 BACB30NX6K13X

- BOLT 4 4 4 4 BACB30NX6K14X

- BOLT 1 1 1 1 BACB30NX6K15X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 35 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-6 -5**  **-4 -3** 

- BOLT 1 1 1 1 BACB30NX6K16X

- BOLT 2 2

. . BACB30NX6K4Y

- BOLT

. . 116 116 BACB30NX6K5

- BOLT 283 283 168 168 BACB30NX6K6

- BOLT 4 4 4 4 BACB30NX6K6Y

- BOLT 15 15 15 15 BACB30NX6K7

- BOLT 68 68 64 64 BACB30NX6K7Y

- BOLT 2 2 2 2 BACB30NX6K8X

- BOLT 24 24 3 3 BACB30NX6K8Y

- BOLT 5 5 5 5 BACB30NX6K9X

- BOLT 2 2 2 2 BACB30NX8K10

- BOLT 1 1 1 1 BACB30NX8K10X

- BOLT

. . 1 1 BACB30NX8K10Y

- BOLT 2 2

. . BACB30NX8K11X

- BOLT 2 2 2 2 BACB30NX8K11Y

- BOLT 24 24 23 23 BACB30NX8K5

- BOLT 12 12 11 11 BACB30NX8K6

- BOLT 1 1 1 1 BACB30NX8K6Y

- BOLT 6 6 9 9 BACB30NX8K8

- BOLT 1 1

. . BACB30NX8K8X

- BOLT 1 1 1 1 BACB30NX8K8Y

- BOLT 20 20 20 20 BACB30NX8K9

- BOLT 4 4

. . BACB30NX8K9X

- BOLT 4 4 5 5 BACB30NX8K9Y

- BOLT 3 3 3 3 BACB30VF3K8

- BOLT 6 6 6 6 BACB30VT8K2

- BOLT 2 2 2 2 BACB30VT8K3

- BOLT 6 6 6 6 BACB30VT8K4

- COLLAR 101 101 71 71 BACC30AC6

- COLLAR 8 8 10 10 BACC30AC8

- COLLAR 327 327 327 327 BACC30BH6

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 36 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-6 -5**  **-4 -3** 

- COLLAR 80 80 73 73 BACC30BH8

- COLLAR 14 14 14 14 BACC30BL8

- COLLAR 188 188 180 180 BACC30M6

- COLLAR 10 10 4 4 BACC30M8

- COLLAR 169 169 123 123 BACC30R6

- COLLAR 7 7 7 7 BACC30R8

- FILLER 29 29 29 29 BACF33C100- 075DF

- FILLER 25 25

. . BACF33C111- 075DF

- FILLER 1 1 1 1 BACF3F008D035NN

- FILLER

. . 1 1 BACF3F008D174NN

- FILLER 1 1 1 1 BACF3F015R031NN

- FILLER 1 1 1 1 BACF3F024T109NN

- FILLER 1 1 1 1 BACF3T01K31-31

- RIVET 22 22 22 22 BACR15BB7D6C

- RIVET 9 9 9 9 BACR15BB7D7C

- RIVET 132 132 149 149 BACR15GF6D6

- RIVET 15 15

. . BACR15GF6D7

- RIVET 11 11 11 11 BACR15GF6D8

- RIVET 1 1 1 1 BACR15GF7D6

- RIVET 6 6 6 6 BACR15GF7D8

- SHIM 1 1 1 1 BACS40R031A058F

- WASHER 10 10 10 10 BACW10CA104CC

- WASHER 10 10 10 10 BACW10CA31PV

- WASHER 28 28 28 28 BACW10EG61C

- WASHER 101 101 72 72 BACW10EG62C

- WASHER 300 300 300 300 BACW10EG6C

- WASHER 8 8 1 1 BACW10EG81C

- WASHER 8 8 10 10 BACW10EG82C

- WASHER 71 71 87 87 BACW10EG8C

- RIVET 2 2 2 2 MS20427M4-4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 37 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT Kit 675U0004**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-6 -5**  **-4 -3** 

- RIVET 2 2

. . MS20427M4-5

- RIVET 1 1 1 1 MS20615-8MP10

- RIVET 1 1 1 1 MS20615-8MP13

- RIVET 1 1 1 1 MS20615-8MP15 (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.
**Notes Name**  **QTY Part Number /**  **Specification** (a) Sealant 1 pintper 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.
**Notes New Part Number**  **Name QTY**  **Existing Part Number**  (a) (c) (b) Threshold - Left MED #1 1 65B10023-( ) or 65B16200-( ) (a) (c) (b) Threshold - Right MED #1 1 65B10023-( ) or 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 38 of 55 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 39 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 40 of 55 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 41 of 55 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 42 of 55 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 43 of 55 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 44 of 55 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 45 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT FIGURE 1: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 46 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT FIGURE 1: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 47 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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**  Do a detailed inspection of the skin at the corner of the door cutout in the area shown for any crack. - - Skin Inspect 1

Do a surface HFEC inspection of theskin 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. - - Skin Inspect 2

**FIGURE 1: LEFT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 48 of 55 **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)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 49 of 55 **BOEING SERVICE BULLETIN 747-53A2863 ALERT**  **ALERT FIGURE 2: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION**  **(SHEET 2 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 50 of 55 **BOEING SERVICE BULLETIN 747-53A2863 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**  Do a detailed inspection of the skin at the corner of the door cutout in the area shown for any crack. - - Skin Inspect 1

Do a surface HFEC inspection of theskin 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. - - Skin Inspect 2

**FIGURE 2: RIGHT MAIN ENTRY DOOR 1 CUTOUT FORWARD LOWER CORNER SKIN INSPECTION (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: March 11, 2014 747-53A2863 51 of 55 **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 52 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.
**More Data Qty**  **Identification Name**  **Task Step**  Do a detailed inspection of the skin anddoublers at the corner of the door cutout in the area shown for any crack. - - Skin and Doublers Inspect 1

**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 53 of 55 **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.
**More Data Qty**  **Identification Name**  **Task Step**  Do a detailed inspection of the skin anddoublers at the corner of the door cutout in the area shown for any crack. - - Skin and Doublers Inspect 1

**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**