### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Number: 747-53A2880**  Original Issue: December 03, 2014 ATA System: 5311 **SUBJECT:** FUSELAGE - Nose Section - Nose Cargo Door Portal C-3 Frame Upper Closure Fitting Inspection 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 Unpublished Work.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Issue: December 03, 2014 747-53A2880 1 of 38 4.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 2 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 15 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 18 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 18 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 2: OVERSIZE FASTENER REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FIGURE 3: INSURANCE OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 1: C-3 FRAME UPPER CLOSURE FITTING INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . 36 APPENDIX B: PART DEMAND INTENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 3 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 4 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Summary**  **Number: 747-53A2880** Original Issue: December 03, 2014 ATA System: 5311 **SUBJECT:** FUSELAGE - Nose Section - Nose Cargo Door Portal C-3 Frame Upper Closure Fitting Inspection 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 instruction to inspect the upper closure fitting and connected structure at the nose cargo door portal C-3 frame for cracks. Cracks in the upper closure fitting that are not found and repaired can grow with continued use of the airplane and cause a sudden decompression and loss of structural integrity. Boeing issued service bulletin 747-53A2495 in 2003 to give inspections for cracks in the C-3 frame upper closure fittings of 747-200F and 747-200C airplanes. Service bulletin 747-53A2495 was issued in response to crack reports which are described in that service bulletin. The upper closure fittings installed in the airplanes affected by this service bulletin were shot peened during production to increase fatigue resistance; however, subsequent analysis has shown that the increase in fatigue resistance may not be sufficient to ensure that upper closure fitting cracks will be found soon enough with existing inspections per the 747-400 MPD. While there have been no upper closure fitting cracks found on the airplanes affected by this service bulletin, the potential for cracks to initiate and grow in the upper closure fitting makes the inspections given in this service bulletin necessary. It is necessary to do these inspections to make sure that cracks in the upper closure fitting will be found and repaired before they can affect flight safety. Boeing Service Related Problem (SRP) 747-SRP-53-0460 is related to this service bulletin. The table below 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 No Weight and Balance Change

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 5 of 38**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** A Detailed inspection and a Surface High Frequency Eddy Current (HFEC) inspection for cracks in the upper closure fitting and connected structure at the nose cargo door portal C-3 frame are to be accomplished. If any crack is found with these inspections, a repair is to be done in accordance with this service bulletin. The repair alternatives given in this service bulletin are an oversize fastener repair, a time limited repair, and a part replacement repair. Repeat inspections are to be done within a compliance time that can be extended by zero-timing specified fastener holes common to the upper closure fitting. **EFFECTIVITY** All 747-400F 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. Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection and repair procedures given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 6 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 7 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 8 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 747 Service Bulletin **ALERT Number: 747-53A2880**  Original Issue: December 03, 2014 ATA System: 5311 **SUBJECT:** FUSELAGE - Nose Section - Nose Cargo Door Portal C-3 Frame Upper Closure Fitting Inspection 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 applicable to 747-400F airplanes in one group. The Variable Numbers and Group Information for the applicable airplanes is given below.
**DESCRIPTION CONFIGURATION**  **GROUP** All 747-400F Airplanes

- 1

Airplane Models: 747-400F **Group Variable Number**  1 RL401 - RL403 1 RL411 - RL436 1 RL451 - RL456 1 RL461 - RL462 1 RL471 - RL481 1 RL491 - RL492

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 9 of 38**Group Variable Number**  1 RL501 - RL502 1 RL511 - RL516 1 RL521 - RL522 1 RL531 - RL534 1 RL551 1 RL561 - RL568 1 RL571 - RL572 1 RL576 - RL577 1 RL579 1 RL581 - RL586 1 RL651 - RL655 1 RL671 - RL675 1 RL681 - RL684 1 RL751 - RL752 1 RM851 - RM859 1 RM861 - RM863 1 RM871 - RM899 1 RM901 - RM906 1 RM911 1 RR701 1 RR721 - RR724 1 RR746 - RR748 1 RR851 - RR856 1 RR861 - RR862 1 RR951 - RR952 2. Spares Affected None. **B. Concurrent Requirements** None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 10 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT C. Reason**  This service bulletin gives instruction to inspect the upper closure fitting and connected structure at the nose cargo door portal C-3 frame for cracks. Cracks in the upper closure fitting that are not found and repaired can grow with continued use of the airplane and cause a sudden decompression and loss of structural integrity. Boeing issued service bulletin 747-53A2495 in 2003 to give inspections for cracks in the C-3 frame upper closure fittings of 747-200F and 747-200C airplanes. Service bulletin 747-53A2495 was issued in response to crack reports which are described in that service bulletin. The upper closure fittings installed in the airplanes affected by this service bulletin were shot peened during production to increase fatigue resistance; however, subsequent analysis has shown that the increase in fatigue resistance may not be sufficient to ensure that upper closure fitting cracks will be found soon enough with existing inspections per the 747-400 MPD. While there have been no upper closure fitting cracks found on the airplanes affected by this service bulletin, the potential for cracks to initiate and grow in the upper closure fitting makes the inspections given in this service bulletin necessary. It is necessary to do these inspections to make sure that cracks in the upper closure fitting will be found and repaired before they can affect flight safety. Boeing Service Related Problem (SRP) 747-SRP-53-0460 is related to this service bulletin. **D. Description** A Detailed inspection and a Surface High Frequency Eddy Current (HFEC) inspection for cracks in the upper closure fitting and connected structure at the nose cargo door portal C-3 frame are to be accomplished. If any crack is found with these inspections, a repair is to be done in accordance with this service bulletin. The repair alternatives given in this service bulletin are an oversize fastener repair, a time limited repair, and a part replacement repair. Repeat inspections are to be done within a compliance time that can be extended by zero-timing specified fastener holes common to the upper closure fitting. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 221, 222 747-400F **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. A logic diagram showing compliance tasks and compliance times is included as an aid in Appendix A. Do the required actions on both sides of the airplane 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 11 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT Table 1: C-3 Frame Upper Closure Fitting Inspection and Repair**  **Repeat Interval (Not to Exceed)**  **Compliance Time Action**  **Condition**

- Before 28,000 total flight cycles, or 2,000 flight cyclesafter the original issue date of this service bulletin, whichever occurs later.Do PART 1: INSPECTION FOR CRACKS INUPPER CLOSURE FITTING AND CONNECTED STRUCTURE. (g) All airplanes.

3,000 flight cycles. Within 3,000 flight cycles after doing the inspection. OPTION 1: Repeat PART 1. (g) CONDITION 1: NO CRACK FOUND

- Before further flight. OPTION 2: Do PART 3: INSURANCE OVERSIZE. (b) (e) (f) 3,000 flight cycles. Within 20,000 flight cycles after doing PART 3. Repeat PART 1. (g) CONDITION 1.1: NO CRACK FOUND AND PART 3 ACCOMPLISHED

- Before further flight. Do a repair in accordancewith applicable repair instruction given in this service bulletin. (a) (b) CONDITION 2: ANY CRACK FOUND

- Before further flight. Do PART 8: SPECIAL INSTRUCTION REPAIR. (d)CONDITION 2.1: REMAINING CRACK IN STRAP (c) 3,000 flight cycles. Within 3,000 flight cycles after doing PART 2 or PART 6. Repeat PART 1. (g) CONDITION 2.2: ONLY PART 2 AND/OR PART 6 ACCOMPLISHED 3,000 flight cycles. Within 20,000 flight cycles after doing PART 2 or PART 6 and doing PART 3. Repeat PART 1. (g) CONDITION 2.3: PART 2AND/OR PART 6 ACCOMPLISHED PLUS PART 3 ACCOMPLISHED

- Within 10,000 flight cycles after doing PART 4. Do PART 5: REPLACEUPPER CLOSURE FITTING. CONDITION 2.4: PART 4 ACCOMPLISHED 3,000 flight cycles. Within 20,000 flight cycles after doing PART 5. Repeat PART 1. (g) CONDITION 2.5: PART 5 ACCOMPLISHED

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 12 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT Table 1: C-3 Frame Upper Closure Fitting Inspection and Repair**  **Repeat Interval (Not to Exceed)**  **Compliance Time Action**  **Condition** (a) Instruction is given in this service bulletin for the following repairs: – PART 2: OVERSIZE FASTENER REPAIR – PART 3: INSURANCE OVERSIZE – PART 4: TIME LIMITED REPAIR – PART 5: REPLACE UPPER CLOSURE FITTING – PART 6: REPLACE DOUBLER – PART 8: SPECIAL INSTRUCTION REPAIR (applicable if a crack found in the strap cannot be repaired in accordance with PART 2)(b) PART 2 and PART 3 can be accomplished only if limits specified for maximum hole diameter and minimum edge margin can be maintained.The minimum edge margin that applies at the strap can be reduced by fabricating and installing a new doubler in accordance with PART 7: FABRICATE / REPLACE DOUBLER. Thus, accomplishment of PART 2 or PART 3 can include accomplishment of PART 7 also. (c) CONDITION 2.1 applies if a crack is found in the strap and the crack cannot be removed in accordance with PART 2. (d) After a repair is accomplished in accordance with PART 8: SPECIAL INSTRUCTION REPAIR, the post-repair inspections are specified in the repair instructions. (e) PART 3 includes an Open Hole HFEC inspection for cracks. If any crack is found with this inspection, CONDITION 1 is no longer applicable and CONDITION 2: ANY CRACK FOUND becomes applicable. If this occurs, it may not be possible to complete a repair with existing parts due to hole size and/or edge margin limits. (f) Successful accomplishment of PART 3 extends the compliance time for the next inspection; however, a need to access the same area to accomplish other inspections including those given in service bulletins 747-53A2500 and 747-53A2753 could make the extension of the compliance time less advantageous. (g) PART 1 includes instruction to do a Detailed inspection for cracks in the upper closure fitting and connected strap and doubler, and a Surface HFEC inspection for cracks in the upper closure fitting. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 13 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT G. Manpower**  The table below shows an estimate of the task hours necessary to do the inspection given in this service bulletin for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace • Time to schedule the work • Time to inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools. **Elapsed Hours Task Hours**  **Number of Persons Task**  2.0 4.0 2 Open Access 1.0 1.0 1 Inspect (FIGURE 1) 2.0 4.0 2 Close Access 5.0 9.0 TOTAL FOR EACH AIRPLANE
**NOTE:** More time will be necessary for repairs if cracks are found. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Boeing Service Bulletin 747-53A2495, 747-53A2500, 747-53A2753 b. Boeing Service Related Problem (SRP) 747-SRP-53-0460 c. Service Bulletin Index D6-30300 d. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-01 e. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Procedures 1, 4, 11, 16, 23 f. 747-400 Aircraft Maintenance Manual (AMM) 25-11-01, 25-15-00 g. 747-400 Maintenance Planning Data (MPD) h. 747-400F Structural Repair Manual (SRM) 51-10-02, 51-20-07, 51-40

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 14 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**2. Data Supplied with this Service Bulletin: a. Drawings:
**ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- A 1 Time Limited Repair C-3 Upper Closure Fitting Freighter Nose Door 691U0144

- A 2

- A 3

- - 4 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  Frame Installation - Closure, Upper 65B12887 Beam Instl - Body Cab WL 331.5 65B12886 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. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. **M. Software Accomplishment Summary** Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 15 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 16 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the parts 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 parts 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)**  **Name Part Number** 

$136.00 199 Doubler 65B12886-503 $21,465.00 199 Fitting - Closure Frame, Upper (left side) 65B12888-17 $21,465.00 199 Fitting - Closure Frame, Upper, (right side) 65B12888-18 Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. **B. Industry Support Information** Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin. **C. Parts Necessary for Each Airplane** 1. Kits/Parts To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **NOTE:** A part shown below could be necessary to do a change given in this service bulletin. The parts will be needed only as noted in the table.
**Notes Name**  **QTY Part Number /**  **Specification** (a) Doubler

- 65B12886-503 (b) Fitting - Closure Frame, Upper (left side) 1 65B12888-17

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 17 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT Notes**  **Name QTY**  **Part Number / Specification**  (b) Fitting - Closure Frame, Upper, (right side) 1 65B12888-18 (a) The identified doubler will be needed only if a decision is made to accomplish Paragraph 3.B., Work Instructions, PART 6: REPLACE DOUBLER on either side of the airplane. (b) The identified fitting will be needed only if a decision is made to accomplish Paragraph 3.B., Work Instructions, PART 5: REPLACE UPPER CLOSURE FITTING. 2. Parts and Materials Supplied by the Operator The following parts could be necessary to do a change given 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** (b) (c) Bolts/Collars (a) (a) (a) A fastener listed in FIGURE 2 will be needed if a crack is found and repaired in accordance with Paragraph 3.B., Work Instructions, PART 2: OVERSIZE FASTENER REPAIR. Fasteners identified in FIGURE 3 will be needed if Paragraph 3.B., Work Instructions, PART 3: INSURANCE OVERSIZE is accomplished. (b) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (c) Refer to 747 Structural Repair Manual Chapter 51 for alternate fasteners.
3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 18 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values: — Values for structural fasteners are given in 747 Structural Repair Manual, Chapter 51. — Non-standard torque values for maintenance tasks are included in the applicable installation step.
4. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 6. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 19 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**8. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 9. Refer to Appendix A for a logic diagram. The Logic diagram is provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 10. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 11. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 12. If shading is used, shaded areas in Figures are to separate the non-critical and non-authoritative information from the critical and authoritative information. 13. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 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 side of the airplane independently. 17. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC must be done to comply with the AD. Alternative procedures for steps not identified with RC can be used if the RC steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. 18. Edge margin (EM) is the distance from the center of the fastener hole to the edge of the part. The specified minimum value is given as a constant times the hole diameter D **B. WORK INSTRUCTIONS** 1. Remove flight deck sidewall lining and insulation to get access to the C-3 Frame Upper Closure Fitting where the C-3 frame intersects the body frame at STA 287. Refer to 747-400 AMM 25-15-00 as an accepted procedure for removal of the sidewall lining and insulation. To get easier access to the inspection area, remove the pilot and copilot seats. Refer to 747-400 AMM 25-11-01 as an accepted procedure for removal of the seats.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 20 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**2. RC - Do PART 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE. 3. RC - Do one of the OPTIONS given below that applies for the CONDITION found with the PART 1 inspection. a. If CONDITION 1: NO CRACK FOUND applies: (1) OPTION 1: Do steps 4-6 below. **CAUTION:** IF OPTION 2 BELOW IS CHOSEN, REMOVE THE FASTENERS CAREFULLY TO AVOID DAMAGING THE FASTENER HOLES WHEN ACCOMPLISHING PART 3: INSURANCE OVERSIZE. (2) OPTION 2: Do PART 3: INSURANCE OVERSIZE and then do steps 4-6 below. **NOTE:** – Accomplishment of PART 3 is possible only if the insurance oversize can be done within specified hole size and edge margin limits. Sufficient edge margins should be verified before the fasteners are removed. – PART 3 includes an Open Hole HFEC inspection. If any crack is found with this inspection, CONDITION 1 is no longer applicable and CONDITION 2: ANY CRACK FOUND becomes applicable. If this occurs, it may not be possible to complete a repair with existing parts due to hole size and/or edge margin limits. – Successful accomplishment of PART 3 extends the compliance time for the next inspection as shown in Paragraph 1.E., Compliance; however, a need to access the same area to accomplish other inspections including those given in service bulletins 747-53A2500 and 747-53A2753 could make the extension of the compliance time less advantageous. b. If CONDITION 2: ANY CRACK FOUND applies: Accomplish a repair that removes the crack or replaces the cracked part in accordance with one or more of the repairs listed in the table below and then do steps 4-6 below. **NOTE:** Accomplishment of PART 2 is possible only if the crack indication can be eliminated within specified hole size and edge margin limits. – – Accomplishment of PART 3 is possible only if the insurance oversize can be done within specified hole size and edge margin limits. Accomplishment of PART 3 affects the compliance time for the repeat inspection. – If accomplishment of PART 2 or PART 3 is prevented by a short edge margin condition at the strap, a new doubler with increased edge margin can be fabricated and installed in accordance with PART 7: FABRICATE / REPLACE DOUBLER. Accomplishment of PART 7 will reduce the minimum edge margin permitted for the strap; thus, accomplishment of PART 7 could allow for a PART 2, PART 3 repair that would otherwise be prevented.

**Description Applicable Instruction**  OVERSIZE FASTENER REPAIR PART 2 (a) OVERSIZE FASTENER REPAIR + INSURANCE OVERSIZE PART 2 plus PART 3 (a)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 21 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT Description**  **Applicable Instruction** TIME LIMITED REPAIR PART 4 REPLACE UPPER CLOSURE FITTING PART 5 REPLACE DOUBLER PART 6 REPLACE DOUBLER + INSURANCE OVERSIZE PART 6 plus PART 3 (a) (a) PART 2 and PART 3 are applicable only if limits specified for maximum hole diameter and minimum edge margin can be maintained. The minimum edge margin that applies at the strap can be reduced by fabricating and installing a new doubler in accordance with PART 7: FABRICATE / REPLACE DOUBLER. Thus, accomplishment of PART 2 or PART 3 can include accomplishment of PART 7 also.
c. CONDITION 2.1: REMAINING CRACK IN STRAP If a crack is found in the strap that cannot be repaired in accordance with PART 2, do PART 8: SPECIAL INSTRUCTION REPAIR. 4. Install removed flight deck sidewall lining and insulation. Refer to 747-400 AMM 25-15-00 as an accepted procedure for installation of the sidewall lining and insulation. If removed, reinstall the pilot and copilot seats. Refer to 747-400 AMM 25-11-01 as an accepted procedure for installation of the seats. 5. Put the airplane back to a serviceable condition. 6. RC - Repeat PART 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE in accordance with Paragraph 1.E., Compliance. Use the compliance data in Paragraph 1.E., Compliance that applies for the applicable post-change CONDITION identified in the table below. **Description Condition After Change**  ONLY PART 2 AND/OR PART 6 ACCOMPLISHED CONDITION 2.2: PART 2 AND/OR PART 6 ACCOMPLISHED PLUS PART 3 ACCOMPLISHED CONDITION 2.3:
PART 4 ACCOMPLISHED CONDITION 2.4: PART 5 ACCOMPLISHED CONDITION 2.5: PART 8 ACCOMPLISHED CONDITION 2.1.1:
**PART 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE**  1. Do a Detailed inspection and a Surface High Frequency Eddy Current (HFEC) inspection for cracks in the upper closure fitting and connected structure at the nose cargo door portal C-3 frame in accordance with FIGURE 1. Do these inspections on both sides of the airplane.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 22 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT PART 2: OVERSIZE FASTENER REPAIR**  1. Oversize the fastener hole to remove material containing the crack and inspect to confirm that no detectable crack remains in the upper closure fitting or the connected strap and doubler in accordance with FIGURE 2. 2. Install a new fastener at the oversized hole in accordance with FIGURE 2. **PART 3: INSURANCE OVERSIZE** 1. Do an Open Hole HFEC inspection at two fastener holes common to the upper closure fitting in accordance with FIGURE 3 to confirm there is no detectable crack in the upper closure fitting or the connected strap and doubler at these locations. 2. Oversize the two inspected fastener holes common to the upper closure fitting and strap and doubler in accordance with FIGURE 3 to remove material that could contain an undetected crack. 3. Install new fasteners at the oversized holes in accordance with FIGURE 3. **PART 4: TIME LIMITED REPAIR** 1. Do a time limited repair in accordance with drawing 691U0144 except where drawing 691U0144 specifies sections of the 747-100/200/300 Structural Repair Manual (SRM), the equivalent section of the 747-400 SRM is to be used as shown in the table below. **NOTE:** After accomplishment of PART 4: TIME LIMITED REPAIR, PART 5: REPLACE UPPER CLOSURE FITTING must be accomplished within the time given in Paragraph 1.E., Compliance. – – Drawing 691U0144 shows a stop drill repair (or a freeze plug repair for a small crack) and new CRES doublers which must be installed if a stop drill or freeze plug repair is done.
**747-400F SRM Section 747-100/200/300 SRM Section**  747-400F SRM 51-10-02 51-10-01 747-400F SRM 51-20-07 51-10-08 747-400F SRM 51-40 51-30
**PART 5: REPLACE UPPER CLOSURE FITTING** 1. Remove the damaged upper closure fitting and install a new upper closure fitting. Install fitting 65B12888-17 as a left side replacement. Install fitting 65B12888-18 as a right side replacement. If the minimum edge margin at the strap fastener holes common to the upper closure fitting is 1.0D or more but less than 1.7D, fabricate and install a replacement doubler along with the new upper closure fitting in accordance with PART 7: FABRICATE / REPLACE DOUBLER. The edge margin at fastener holes in the new upper closure fitting is to be 1.7D or more. The edge margin at fastener holes in the new doubler is to be 2.0D or more.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 23 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT NOTE:**  If there is a freeze plug installed in the strap, the edge margin calculation at the location of the freeze plug is to be based on the diameter of the hole that holds the freeze plug, not the fastener hole size. If CONDITION 2.4: PART 4 ACCOMPLISHED is applicable and the minimum edge margin at the strap fastener holes common to the upper closure fitting is 1.7D or more, install a new 65B12886-503 doubler along with the new upper closure fitting. The minimum permitted edge margin at fastener holes in the new upper closure fitting and the new doubler is 1.7D. For PART 5 the maximum permitted hole size for fasteners common to the new upper closure fitting, new doubler and strap are as follows:
**Maximum Hole Di ameter**  **Fastener Location**
The maximum diameter specified in FIGURE 2. Bottom two fasteners common to the upper closure fitting / doubler / strap.

0.281 inch. Fasteners common to the upper closure fitting / doubler / strap other than the bottom two fasteners. Contact Boeing if additional instruction is needed to install a new upper closure fitting. If the new fitting cannot be installed within the edge margin and fastener hole size limits given above, contact Boeing to get special instruction and install the new fitting in accordance with the special instruction from Boeing. **PART 6: REPLACE DOUBLER** 1. Remove the damaged doubler and install a new 65B12886-503 doubler. The limits for fastener hole size and edge margin given in this service bulletin apply for the installation of the new doubler. **PART 7: FABRICATE / REPLACE DOUBLER** 1. Fabricate a new replacement doubler that is sized to give 2.0D or more edge margin at all fastener locations. Make the doubler 0.090 inch thick from 7075-T6 Clad sheet per QQ-A-250/13. **NOTE:** Accomplishment of PART 7 could allow for a PART 2 or PART 3 repair that would otherwise be prevented by a short edge margin condition at the strap. If PART 7 is accomplished, the minimum edge margin permitted for the strap changes from 1.7D to 1.0D. 2. Apply Chemical conversion coating to the surfaces of the doubler. Refer to SOPM 20-43-03 as an accepted procedure. 3. Apply one layer of BMS 10-11, Type 1 primer. Refer to SOPM 20-41-02 as an accepted procedure. 4. Remove the existing doubler and install the replacement doubler with 2.0D or more edge margin at all the fastener holes common to the doubler.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 24 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT PART 8: SPECIAL INSTRUCTION REPAIR**  1. If a crack is found in the strap and the crack cannot be repaired in accordance with PART 2: OVERSIZE FASTENER REPAIR, contact Boeing to get special repair and post-repair inspection instruction and do the repair and post-repair inspections.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 25 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 26 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Upper Closure Fitting / Strap / Doubler Inspect 1 (b)

- - Upper Closure Fitting Inspect 2 (a) Do a Detailed inspection for cracks. Inspect all visible parts of the upper closure fitting, strap and doubler in the area shown.

**FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 27 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** (b) Do a Surface HFEC inspection of the upper closure fitting for cracks in accordance with 747 NDT Manual Part 6, 51-00-00, Procedure 4 or 23. Inspect the surface of the upper closure fitting around the heads of the two fasteners shown in Detail C of this figure.

**FIGURE 1: INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 28 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT FIGURE 2: OVERSIZE FASTENER REPAIR**  **(SHEET 1 OF 4)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 29 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one side of the airplane.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Fastener Hole Drill / Ream 1 (b)

- - Upper Closure Fitting / Strap / Doubler Inspect 2 (c)

- - Fastener Install (New) 3 (a) The fastener hole is to be oversized to remove material containing the crack. There are two limitations for this step as follows: 1. The oversized hole must not exceed the maximum diameter for the accomplishment of PART 2: OVERSIZE FASTENER REPAIR given in the table below. Note that accomplishment of PART3: INSURANCE OVERSIZE will be possible only if the oversize is kept within the limit for accomplishment of PART 3 given in the table below. 2. The edge margin for the upper closure fitting, strap and doubler is not to be less than the value specified in the table below. (b) Do an Open Hole HFEC inspection for cracks in the upper closure fitting, strap and doubler in accordance with 747 NDT Manual Part 6, 51-00-00, Figures 1, 11, or 16. If the hole size is less than the maximum permitted size and a crack is indicated with this inspection, repeat steps 1 and 2 as necessary/permitted. (c) Install the fastener identified in the fastener table below that is applicable for the final hole size. This step is not applicable if an additional oversize will be made to accomplish PART 3: INSURANCE OVERSIZE.
**Maximum Hole Diame ter that Permits Ac**  **complishment of PART 3: INSURANCE**  **OVERSIZE Maximum Hole Diame** **ter for Accomplish ment of PART 2:** **OVERSIZE FASTEN ER REPAIR**  **Initial Hole Size**

0.219 0.281 3/16

**FIGURE 2: OVERSIZE FASTENER REPAIR (SHEET 2 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 30 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT Maximum Hole Diame** **ter that Permits Ac complishment of**  **PART 3: INSURANCE OVERSIZE** **Maximum Hole Diame ter for Accomplish**  **ment of PART 2: OVERSIZE FASTEN**  **ER REPAIR Initial Hole Size** 

0.281 0.344 1/4 **Minimum Edge Margin (a) Part**  1.7D Upper Closure Fitting 1.7D Doubler 1.7D if the doubler edge margin is not 2.0D or more at all fastener holes common to the strap and doubler. Strap 1.0D if the doubler edge margin is 2.0D or more at all fastener holes common to the strap and doubler. (b) (a) Edge margin is the distance from the center of the fastener hole to the edge of the part. The specified minimum value is given as a constant times the final hole diameter D. (b) PART 7: FABRICATE / REPLACE DOUBLER gives instruction to fabricate and install a replacement doubler that has 2.0D or more edge margin at all fastener holes common to the strap and doubler. The code shown below agrees with the letter shown in the upper left corner of the fastener symbols in the figure. The applicable fastener is the fastener that applies for the diameter of the fastener hole.
**More Data Hole Dia**  **Qty Identification**  **Name Code** 

- 0.200 - 0.203
- BACB30NX6K6X Bolt A

- - - BACC30BH6 Collar

- 0.216 - 0.219
- BACB30NX6K6Y Bolt

- - - BACC30AC6 Collar

- 0.247 - 0.250
- BACB30NX8K6 Bolt

- - - BACC30BH8 Collar

- 0.263 - 0.266
- BACB30NX8K6X Bolt

- - - BACC30BH8 Collar

- 0.278 - 0.281
- BACB30NX8K6Y Bolt

- - BACC30AC8 Collar

**FIGURE 2: OVERSIZE FASTENER REPAIR (SHEET 3 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 31 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT More Data**  **Hole Dia Qty**  **Identification Name**  **Code** 0.263 - 0.266
- BACB30NX8K6X Bolt B

- - BACC30BH8 Collar 0.278 - 0.281
- BACB30NX8K6Y Bolt

- - BACC30AC8 Collar

- 0.309 - 0.313
- BACB30NX10K6 Bolt

- - BACC30BH10 Collar

- 0.325 - 0.328
- BACB30NX10K6X Bolt

- - - BACC30BH10 Collar

- 0.341 - 0.344
- BACB30NX10K6Y Bolt

- - - BACC30AC10 Collar

**FIGURE 2: OVERSIZE FASTENER REPAIR (SHEET 4 OF 4)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 32 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT FIGURE 3: INSURANCE OVERSIZE**  **(SHEET 1 OF 3)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 33 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NOTE:** If the work given in this figure is accomplished after a crack is removed in accordance with FIGURE 2, the work given in step 1 and step 2 of this figure will already have been accomplished in accordance with FIGURE 2 . The Open Hole HFEC inspection with no crack indication accomplished in accordance with FIGURE 2 is a satisfactory inspection for step 2 of this figure.
**More Data Qty**  **Identification Name**  **Task Step** 

- 2
- Fasteners Remove 1 (a) (b)

- - Upper Closure Fitting / Strap / Doubler Inspect 2 (c)

- - Fastener Hole Drill / Ream 3 (d) 2
- Fasteners Install (New) 4 (a) Do an Open Hole HFEC inspection for cracks in the upper closure fitting, strap and doubler in accordance with 747 NDT Manual Part 6, 51-00-00, Figures 1, 11, or 16. (b) If any crack is found with the inspection given in this step, the remainder of the work given in this figure is not applicable.(c) The diameter of the fastener hole that contains no detectable crack is to be increased by 1/16 inch to remove material that could contain an undetected crack. The hole size is not to exceed the maximum size given in the table below and the edge margin is not to be less than the minimum value given in the table below. The hole diameter is to be within the limits given in the fastener table for the fastener to be installed. (d) Install the fastener identified in the fastener table below that is applicable for the final hole size.
**Maximum Hole Diameter Initial Hole Size**  0.281 3/16 0.344 1/4 **Minimum Edge Margin (a) Part**  1.7D Upper Closure Fitting

**FIGURE 3: INSURANCE OVERSIZE (SHEET 2 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 34 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT Minimum Edge Margin (a)**  **Part** 1.7D Doubler 1.7D if the doubler edge margin is not 2.0D or more at all fastener holes common to the strap and doubler. Strap 1.0D if the doubler edge margin is 2.0D or more at all fastener holes common to the strap and doubler. (b) (a) Edge margin is the distance from the center of the fastener hole to the edge of the part. The specified minimum value is given as a constant times the final hole diameter D. (b) PART 7: FABRICATE / REPLACE DOUBLER gives instruction to fabricate and install a replacement doubler that has 2.0D or more edge margin at all fastener holes common to the strap and doubler.
**More Data Hole Dia**  **Qty Identification**  **Name Code** 

- 0.247 - 0.250
- BACB30NX8K6 Bolt C

- - - BACC30BH8 Collar

- 0.263 - 0.266
- BACB30NX8K6X Bolt

- - - BACC30BH8 Collar

- 0.278 - 0.281
- BACB30NX8K6Y Bolt

- - BACC30AC8 Collar

- 0.309 - 0.313
- BACB30NX10K6 Bolt D

- - BACC30BH10 Collar

- 0.325 - 0.328
- BACB30NX10K6X Bolt

- - - BACC30BH10 Collar

- 0.341 - 0.344
- BACB30NX10K6Y Bolt

- - - BACC30AC10 Collar

**FIGURE 3: INSURANCE OVERSIZE (SHEET 3 OF 3)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 35 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**A description for each PART and CONDITION included in the logic diagram is given in the tables below. The actions associated with each PART are to be done in accordance with Paragraph 3. Accomplishment Instructions.

**APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 1: C-3 FRAME UPPER CLOSURE FITTING INSPECTION AND REPAIR**  **(SHEET 1 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 36 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT Description**  **Part** INSPECTION FOR CRACKS IN UPPER CLOSURE FITTING AND CONNECTED STRUCTURE PART 1: OVERSIZE FASTENER REPAIR (a) (c) PART 2: INSURANCE OVERSIZE (b) (c) PART 3: TIME LIMITED REPAIR PART 4: REPLACE UPPER CLOSURE FITTING PART 5: REPLACE DOUBLER (c) PART 6: FABRICATE / REPLACE DOUBLER (c) PART 7: SPECIAL INSTRUCTION REPAIR (d) PART 8: (a) Accomplishment of PART 2 is possible only if the crack indication can be eliminated within specified hole size and edge margin limits. (b) Accomplishment of PART 3 is possible only if the insurance oversize can be done within specified hole size and edge margin limits. (c) If accomplishment of PART 2 or PART 3 is prevented by a short edge margin condition at the strap, a new doubler with increased edge margin can be fabricated and installed in accordance with PART 7 to reduce the minimum edge margin permitted for the strap. Accomplishment of PART 7 with PART 2 or PART 3 allows the PART 2 or PART 3 repair to be done with edge margin = 1.0D (versus 1.7D) at the strap.(d) Special instruction will be provided by Boeing to repair a crack in the strap that cannot be repaired in accordance with PART 2. Special instruction will also be provided for post-repair inspections that will apply after the special repair is accomplished. **Description Condition**  NO CRACK FOUND CONDITION 1: NO CRACK FOUND AND PART 3 ACCOMPLISHED CONDITION 1.1 ANY CRACK FOUND CONDITION 2: REMAINING CRACK IN STRAP (a) CONDITION 2.1 PART 8 ACCOMPLISHED CONDITION 2.1.1 ONLY PART 2 AND/OR PART 6 ACCOMPLISHED CONDITION 2.2 PART 2 AND/OR PART 6 ACCOMPLISHED PLUS PART 3 ACCOMPLISHED CONDITION 2.3 PART 4 ACCOMPLISHED CONDITION 2.4 PART 5 ACCOMPLISHED CONDITION 2.5 (a) CONDITION 2.1 applies if a crack found in the strap cannot be repaired in accordance with PART 2.

**APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 1: C-3 FRAME UPPER CLOSURE FITTING INSPECTION AND REPAIR**  **(SHEET 2 OF 2)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 37 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT APPENDIX B: PART DEMAND INTENT**  **(SHEET 1 OF 1)** Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 03, 2014 747-53A2880 38 of 38 **BOEING SERVICE BULLETIN 747-53A2880 ALERT**  **ALERT**