Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2839

Original Issue: November 06, 2012

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Skin and Bear Strap Crack at the Aft Upper Corner of the Main

Entry Door 5 Cutout - Inspection, Repair and Modification

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ECCN: 9E991

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Copyright © 2012 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

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This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

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BLANK PAGE
Table of Contents

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

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

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

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

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

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

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

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 30

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 45

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 46

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

FIGURE 1: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE LEFT MAIN

ENTRY DOOR 5 CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

FIGURE 2: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

FIGURE 3: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE RIGHT MAIN

ENTRY DOOR 5 CUTOUT [Group 1-2, 4] . . . . . . . . . . . . . . . . . . . . . . . . . . 59

FIGURE 4: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY

DOOR 5 CUTOUT [Group 1-2, 4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

FIGURE 5: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

FIGURE 6: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE RIGHT MAIN

ENTRY DOOR 5 CUTOUT [Group 1-2, 4] . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF

THE MAIN ENTRY DOOR 5 CUTOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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Commercial 

Airplanes 747

Service Bulletin

ALERT

Summary Number: 747-53A2839

Original Issue: November 06, 2012

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Skin and Bear Strap Crack at the Aft Upper Corner of the Main

Entry Door 5 Cutout - 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 and internal bear strap at the aft

upper corner of the cutout for Main Entry Door (MED) 5. Skin and bear strap cracks that are not found and

repaired can become large and result in in-flight depressurization of the airplane.

An operator has told Boeing that a 3.65 inch long crack was found at the aft upper corner of the right MED 5

cutout on an airplane with 11,047 flight-cycles. The skin (including the bonded doubler and tripler) and bear

strap were found to be cracked. This is the first reported crack to extend up to the door edge frame.

Boeing has received several reports of cracks that did not extend up to the door edge frame on more than thirty

airplanes. The affected airplanes had flown between 10,042 and 31,410 total flight-cycles at the time the cracks

were found.

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

prevent in-flight depressurization of the airplane and ensure the structural integrity of the aft upper corner of the

MED 5 cutout.

Boeing Service Related Problem (SRP) 747-SRP-53-0361 is related to this service bulletin.

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

information.

Planning Data Affected Reference

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

AD Related Yes Paragraph 1.E., Compliance

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

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Planning Data Affected Reference

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

Publications Affected No Paragraph 1.K., Publications Affected

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

Operations Manual and/or FAA Approved Airplane Flight Manual)

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

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

by the Operator

Operator Supplied Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION (PRR 85901-110RS)

Do a detailed inspection for existing repairs at the aft upper corner of the main entry door 5 cutout. If any repair

is found, contact Boeing for instructions.

Measure the edge margin at certain fastener locations around the corner of the door cutout. The threshold of

the subsequent inspection is dependent on the measured edge margin. At the applicable times given in Paragraph

1.E., Compliance, do detailed and High Frequency Eddy Current (HFEC) inspections of the skin and bear strap

for cracks at the aft upper corner of the door cutout. If any crack is found, repair in accordance with this service

bulletin. If no cracks are found, put the airplane back to a serviceable condition and do the inspections again

and install the preventive modification at the applicable times given in Paragraph 1.E., Compliance. As an

alternative to repeat inspections, install a preventive modification in accordance with this service bulletin.

Do post-repair or post-modification detailed and Low Frequency Eddy Current (LFEC) inspections at the times

given in Paragraph 1.E., Compliance, Table 3.

EFFECTIVITY

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

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

COMPLIANCE

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

to this service bulletin.

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 available for airplanes in warranty as of September 2, 1997. Please refer to

Paragraph 2.B., Industry Support Information.

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MANPOWER

Group 1-2, 4:

Airplanes Total Task Hours Elapsed Hours

Inspection for previous repairs and edge 1.00 1.00

margin measurement

Inspection and preventive modification 35.70 23.10

installed on both sides

Post repair/post modification inspection 33.20 16.70

Group 3, 5:

Airplanes Total Task Hours Elapsed Hours

Inspection for previous repairs and edge 0.50 0.50

margin measurement

Inspection and preventive modification 20.85 13.05

installed on the left side

Post repair/post modification inspection 16.70 8.45

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits.

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

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Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2839

Original Issue: November 06, 2012

ATA System: 5331

SUBJECT: FUSELAGE - Skin - Skin and Bear Strap Crack at the Aft Upper Corner of the Main

Entry Door 5 Cutout - 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 PRR85901-110RS for data about

this change.

GROUP CONFIGURATION DESCRIPTION

1 - All 747 airplanes line number 1 through 85.

All 747SR, 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C,

747-300, 747-400 and 747-400D airplanes line number 86 through

1235, except 747 Large Cargo Freighter (LCF) airplanes. Door 5

does not exist on LCF airplanes.

2 -

All 747-200F and 747-400F airplanes line number 86 through 1235.

These airplanes do not have a Door 5 on the right side.

3 -

4 - All 747-400 airplanes line number 1236 through 1419.

All 747-400F airplanes line number 1236 through 1419. These

airplanes do not have a Door 5 on the right side.

5 -

Airplane Models:

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

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

Variable Number Group

RA001 - RA026 1

RA027 - RA034 2

RA101 - RA112 1

RA113 - RA115 2

RA161 - RA162 1

RA163 - RA164 2

RA201 - RA203 1

RA216 - RA217 2

RA245 - RA246 2

RA251 - RA254 1

RA255 - RA266 2

RA301 - RA303 1

RA304 - RA318 2

RA351 - RA359 1

RA360 2

RA369 - RA373 2

RA401 - RA405 1

RA406 - RA418 2

RA501 1

RA502 2

RA521 - RA523 1

RA524 - RA528 2

RA532 - RA548 2

RA551 - RA552 1

RA559 - RA561 2

RA581 1

RA582 2

RA585 2

RA601 - RA602 1

RA631 - RA632 1

RA633 - RA635 2

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Variable Number Group

RA651 - RA652 2

RA671 - RA677 2

RA701 - RA702 2

RA721 - RA731 2

RA741 - RA745 2

RA749 - RA750 2

RA761 - RA762 2

RA781 - RA784 2

RA901 - RA907 1

RA908 - RA916 2

RB001 - RB016 2

RB041 - RB043 1

RB044 2

RB071 - RB075 2

RB101 - RB102 2

RB411 - RB413 2

RB421 2

RB601 - RB607 2

RB681 - RB697 2

RB711 2

RB721 - RB723 2

RB741 - RB748 2

RD001 - 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

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Variable Number Group

RD181 - RD183 2

RD201 - RD204 2

RD221 - RD227 2

RD231 - RD235 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

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Variable Number Group

RD681 - RD682 2

RD691 - RD692 2

RD701 - RD702 2

RD721 - RD722 2

RD741 - RD742 2

RD751 - RD755 2

RD761 2

RD771 - RD775 2

RD781 - RD783 2

RD791 - RD792 2

RE001 2

RF001 - RF006 4

RJ131 - RJ133 2

RJ151 - RJ152 2

RJ301 - RJ303 2

RJ321 - RJ322 2

RJ331 - RJ333 2

RL401 - RL403 5

RL411 - RL436 5

RL451 - RL456 5

RL461 - RL462 5

RL471 - RL481 5

RL491 - RL492 5

RL501 - RL502 5

RL511 - RL516 5

RL521 - RL522 5

RL531 - RL534 5

RL551 5

RL561 - RL568 5

RL571 - RL572 5

RL576 - RL577 5

RL579 5

RL581 - RL586 5

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Variable Number Group

RL651 - RL655 5

RL671 - RL675 5

RL681 - RL684 5

RL751 - RL752 5

RM001 - RM002 2

RM003 - RM007 4

RM010 4

RM011 - RM012 2

RM013 4

RM021 - RM024 2

RM026 - RM027 2

RM028 - RM030 4

RM036 - RM038 2

RM039 - RM045 4

RM051 2

RM052 - RM053 4

RM071 2

RM081 - RM084 2

RM091 2

RM096 - RM097 2

RM116 - RM117 2

RM126 - RM130 2

RM131 - RM132 4

RM136 - RM147 2

RM156 - RM157 2

RM158 4

RM166 - RM176 2

RM177 4

RM191 - RM192 2

RM231 - RM232 2

RM233 4

RM241 - RM244 2

RM245 - RM246 4

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Variable Number Group

RM261 - RM264 2

RM316 2

RM317 - RM318 4

RM331 - RM332 2

RM333 4

RM341 4

RM351 - RM355 4

RM366 - RM367 4

RM401 - RM403 4

RM426 4

RM431 4

RM441 - RM443 4

RM445 4

RM801 2

RM802 - RM803 4

RM811 - RM813 2

RM851 - RM852 3

RM853 - RM859 5

RM861 3

RM862 - RM863 5

RM871 3

RM872 - RM880 5

RM881 - RM885 3

RM886 - RM890 5

RM891 - RM899 3

RM901 - RM906 5

RM911 5

RR001 - RR005 3

RR021 - RR025 3

RR031 3

RR201 - RR206 3

RR221 - RR226 3

RR261 - RR267 3

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Variable Number Group

RR301 - RR310 3

RR331 - RR332 3

RR336 3

RR341 - RR345 3

RR361 - RR362 3

RR421 - RR422 3

RR431 - RR432 3

RR441 - RR442 3

RR451 3

RR501 - RR504 3

RR521 - RR522 3

RR526 3

RR531 3

RR551 - RR556 3

RR561 3

RR566 3

RR701 3

RR721 - RR724 3

RR746 - RR748 3

RR851 - RR856 3

RR861 - RR862 3

RR951 - RR952 3

RS001 - RS002 2

RS201 2

RS211 - RS212 2

RS221 - RS222 2

RS231 - RS241 2

RS251 - RS259 2

RS263 2

RS265 - RS268 2

RS271 - RS276 2

RS291 - RS292 2

RS301 - RS306 2

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Variable Number Group

RS311 - RS320 2

RS331 - RS333 2

RS341 - RS342 2

RS699 2

RS701 - RS703 2

RS711 - RS713 2

RS721 - RS722 2

RS731 - RS732 2

RS741 - RS743 2

RS751 - RS752 2

RS761 - RS762 2

RS771 2

RS781 - RS782 2

RS786 2

RT001 - RT014 2

RT021 - RT022 2

RT031 - RT035 2

RT041 - RT047 2

RT061 2

RT071 - RT075 2

RT101 - RT103 2

RT121 2

RT131 - RT137 2

RT151 - RT152 2

RT161 - RT168 2

RT401 - RT412 2

RT431 - RT447 2

RT451 - RT469 2

RT471 - RT499 2

RT501 - RT535 2

RT551 - RT568 2

RT571 - RT591 2

RT601 - RT630 2

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Variable Number Group

RT633 - RT657 2

RT671 - RT673 2

RT681 - RT682 2

RT691 - RT699 2

RT701 - RT704 2

RT711 - RT717 2

RT741 - RT742 2

RT744 - RT757 2

RT776 - RT777 2

RT781 - RT784 2

RT801 - RT803 2

RT811 - RT814 2

RT831 - RT837 2

RT861 - RT864 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

2. Spares Affected

None.

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B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions to do inspections of the fuselage skin and internal bear strap at

the aft upper corner of the cutout for Main Entry Door (MED) 5. Skin and bear strap cracks that are not

found and repaired can become large and result in in-flight depressurization of the airplane.

An operator has told Boeing that a 3.65 inch long crack was found at the aft upper corner of the right

MED 5 cutout on an airplane with 11,047 flight-cycles. The skin (including the bonded doubler and

tripler) and bear strap were found to be cracked. This is the first reported crack to extend up to the door

edge frame.

Boeing has received several reports of cracks that did not extend up to the door edge frame on more

than thirty airplanes. The affected airplanes had flown between 10,042 and 31,410 total flight-cycles

at the time the cracks were found.

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

will help prevent in-flight depressurization of the airplane and ensure the structural integrity of the aft

upper corner of the MED 5 cutout.

Boeing Service Related Problem (SRP) 747-SRP-53-0361 is related to this service bulletin.

D. Description

Do a detailed inspection for existing repairs at the aft upper corner of the main entry door 5 cutout. If

any repair is found, contact Boeing for instructions.

Measure the edge margin at certain fastener locations around the corner of the door cutout. The

threshold of the subsequent inspection is dependent on the measured edge margin. At the applicable

times given in Paragraph 1.E., Compliance, do detailed and High Frequency Eddy Current (HFEC)

inspections of the skin and bear strap for cracks at the aft upper corner of the door cutout. If any crack

is found, repair in accordance with this service bulletin. If no cracks are found, put the airplane back

to a serviceable condition and do the inspections again and install the preventive modification at the

applicable times given in Paragraph 1.E., Compliance. As an alternative to repeat inspections, install

a preventive modification in accordance with this service bulletin.

Do post-repair or post-modification detailed and Low Frequency Eddy Current (LFEC) inspections at

the times given in Paragraph 1.E., Compliance, Table 3.

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

Group 1:

Affected Maintenance Zones

Model Zone

747-100 271, 272

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Group 2:

Affected Maintenance Zones

Model Zone

747-100, 747-100B, 747-100B 271, 272

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

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

747SR

Group 3:

Affected Maintenance Zones

Model Zone

747-200F, 747-400F 271

Group 4:

Affected Maintenance Zones

Model Zone

747-400 271, 272

Group 5:

Affected Maintenance Zones

Model Zone

747-400F 271

E. Compliance

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

are related to this service bulletin.

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.

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ALERT ALERT
Table 1: Inspection at the aft upper corner of the cutout for left Main Entry Door 5

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 1,500 -

flight-cycles after the original

issue date on

this service bulletin.

Before 10,000

total flight-cycles.

Do a detailed inspection

to determine if a repair

exists at the aft upper

corner of the cutout for

left Main Entry Door 5 in

accordance with Paragraph 3.B., Work Instructions, PART 1.

All airplanes.

AND

Measure the edge margin

at certain fastener locations at the aft upper corner of the cutout for left

Main Entry Door 5 in accordance with Paragraph

3.B., Work Instructions,

PART 1.

Contact Boeing with de- Before further flight. -

tails of the installed repair. Do inspections or

change the repair in accordance with the Boeing

instructions.

Any door cutout where a

repair is found.

Do detailed, open-hole Before further flight. -

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 3.

If no repair is found, and if

the measured edge margin

at any affected fastener location is less than 0.70

inch.

Within 1,500 -

flight-cycles after the original

issue date on

this service bulletin.

Before 18,000

total flight-cycles.

Do detailed, open-hole

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 3.

If no repair is found, and if

the measured edge margin

at all affected fastener locations is 0.70 inch or

greater.

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ALERT ALERT
Table 1: Inspection at the aft upper corner of the cutout for left Main Entry Door 5

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Install a preventive modi- Before further flight. -

fication in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

No crack found, and the

measured edge margin at

any affected fastener location is less than 0.70 inch.

OR

Within 3,000 flight-cycles of the 3,000 flight-cycles

previous inspection done in accordance with Paragraph 3.B., Work

Instructions, PART 3.

Do detailed, open-hole

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 3.

AND

Within 6,000 -

flight-cycles after the original

issue date on

this service bulletin.

Before 20,000

total flight-cycles.

Install a preventive modification in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

Install a preventive modi- Before further flight. -

fication in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

No crack found, and the

measured edge margin at

all affected fastener locations is 0.70 inch or

greater.

OR

Within 3,000 flight-cycles of the 3,000 flight-cycles

previous inspection done in accordance with Paragraph 3.B., Work

Instructions, PART 3.

Do detailed, open-hole

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 3.

AND

Within 1,500 -

flight-cycles after the original

issue date on

this service bulletin.

Before 35,000

total flight-cycles.

Install a preventive modification in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

Install a repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

PART 5.

All cracks found are less

than 3.0 inch long.

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ALERT ALERT
Table 1: Inspection at the aft upper corner of the cutout for left Main Entry Door 5

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Install a repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

PART 6.

Any crack found to be

equal to or greater than 3.0

inch long.

Group 1-2, 4:

Table 2: Inspection at the aft upper corner of the cutout for right Main Entry Door 5

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 1,500 -

flight-cycles after the original

issue date on

this service bulletin.

Before 10,000

total flight-cycles.

Do a detailed inspection

to determine if a repair

exists at the aft upper

corner of the cutout for

right Main Entry Door 5 in

accordance with Paragraph 3.B., Work Instructions, PART 2.

All airplanes.

AND

Measure the edge margin

at certain fastener locations at the aft upper corner of the cutout for right

Main Entry Door 5 in accordance with Paragraph

3.B., Work Instructions,

PART 2.

Contact Boeing with de- Before further flight. -

tails of the installed repair. Do inspections or

change the repair in accordance with the Boeing

instructions.

Any door cutout where a

repair is found.

Do detailed, open-hole Before further flight. -

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 4.

If no repair is found, and if

the measured edge margin

at any affected fastener location is less than 0.70

inch.

Within 1,500 -

flight-cycles after the original

issue date on

this service bulletin.

Before 18,000

total flight-cycles.

Do detailed, open-hole

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 4.

If no repair is found, and if

the measured edge margin

at all affected fastener locations is 0.70 inch or

greater.

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ALERT ALERT
Group 1-2, 4:

Table 2: Inspection at the aft upper corner of the cutout for right Main Entry Door 5

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Install a preventive modi- Before further flight. -

fication in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

No crack found, and the

measured edge margin at

any affected fastener location is less than 0.70 inch.

OR

Within 3,000 flight-cycles of the 3,000 flight-cycles

previous inspection done in accordance with Paragraph 3.B., Work

Instructions, PART 4.

Do detailed, open-hole

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 4.

AND

Within 6,000 -

flight-cycles after the original

issue date on

this service bulletin.

Before 20,000

total flight-cycles.

Install a preventive modification in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

Install a preventive modi- Before further flight. -

fication in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

No crack found, and the

measured edge margin at

all affected fastener locations is 0.70 inch or

greater.

OR

Within 3,000 flight-cycles of the 3,000 flight-cycles

previous inspection done in accordance with Paragraph 3.B., Work

Instructions, PART 4.

Do detailed, open-hole

HFEC and surface HFEC

inspections for cracks in

accordance with Paragraph 3.B., Work Instructions, PART 4.

AND

Within 1,500 -

flight-cycles after the original

issue date on

this service bulletin.

Before 35,000

total flight-cycles.

Install a preventive modification in accordance

with Paragraph 3.B.,

Work Instructions, PART

5.

Install a repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

PART 5.

All cracks found are less

than 3.0 inch long.

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ALERT ALERT
Group 1-2, 4:

Table 2: Inspection at the aft upper corner of the cutout for right Main Entry Door 5

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Install a repair in accor- Before further flight. -

dance with Paragraph

3.B., Work Instructions,

PART 6.

Any crack found to be

equal to or greater than 3.0

inch long.

Table 3: Post-Repair/Post-Modification Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 15,000 flight-cycles after -

the repair or the modification was

installed.

Do post-repair/post-modification detailed and

LFEC inspections for

cracks in accordance with

Paragraph 3.B., Work Instructions, PART 7.

Any Main Entry Door 5 aft

upper corner modified or

repaired in accordance with

Paragraph 3.B., Work Instructions, PART 5 or

PART 6.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Cracks found during postrepair/post-modification inspections in accordance

with Paragraph 3.B., Work

Instructions, PART 7.

Within 3,000 flight-cycles of the 3,000 flight-cycles

previous inspection done in accordance with Paragraph 3.B., Work

Instructions, PART 7.

Do post-repair/post-modification detailed and

LFEC inspections for

cracks in accordance with

Paragraph 3.B., Work Instructions, PART 7.

No crack found during

post-repair/post-modification inspections in accordance with Paragraph 3.B.,

Work Instructions, PART 7.

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.

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ALERT ALERT
The manager of the FAA Seattle Aircraft Certification Office (ACO) approves the inspections, repairs

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

of Service Bulletin 747-53A3839, as an AMOC to the inspections and repairs at the main entry door 5

aft upper corner 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 MED 5 and MED 1 through 4 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 Aircraft Certificate Office (ACO) approves the inspections,

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

Compliance, of Service Bulletin 747-53A2839, as an AMOC to the inspections and repairs at the main

entry door 5 aft upper corner required by paragraphs (g)(1) 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 SB.

Other areas of MED 5 and all other areas per SB 747-53A2500 Revision 1 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 repair 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.

Group 1-2, 4:

Table 1 - Left and Right Main Entry Door 5 Cutout Upper Aft Corner Inspection for Existing

Repairs and Edge Margin Measurement

Task Number of Persons Task Hours Elapsed Hours

Inspect left side for 1 0.25 0.25

existing repair - FIGURE 1

Inspect right side for 1 0.25 0.25

existing repair - FIGURE 3

Measure left side 1 0.25 0.25

edge margin - FIGURE 2

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ALERT ALERT
Group 1-2, 4:

Table 1 - Left and Right Main Entry Door 5 Cutout Upper Aft Corner Inspection for Existing

Repairs and Edge Margin Measurement

Task Number of Persons Task Hours Elapsed Hours

Measure right side 1 0.25 0.25

edge margin - FIGURE 4

TOTAL FOR EACH AIRPLANE 1.00 1.00

Group 3, 5:

Table 2 - Left Main Entry Door 5 Cutout Upper Aft Corner Inspection for Existing Repairs

and Edge Margin Measurement

Task Number of Persons Task Hours Elapsed Hours

Inspect left side for 1 0.25 0.25

existing repair - FIGURE 1

Measure left side 1 0.25 0.25

edge margin - FIGURE 2

TOTAL FOR EACH AIRPLANE 0.50 0.50

Group 1-2, 4:

Table 3 - Inspection and Repair or Preventive Modification

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 3.00 1.50

Inspect left side - 1 5.25 5.25

FIGURE 5

Inspect right side - 1 5.25 5.25

FIGURE 6

Left side repair or 2 9.60 4.80

preventive modification (Paragraph 3.B.,

Work Instructions,

PART 5)

Right side repair or 2 9.60 4.80

preventive modification (Paragraph 3.B.,

Work Instructions,

PART 5)

Close Access 2 3.00 1.50

TOTAL FOR EACH AIRPLANE 35.70 23.10

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Group 3, 5:

Table 4 - Inspection and Repair or Preventive modification

Task Number of Persons Task Hours Elapsed Hours

Open Access 2 3.00 1.50

Inspect left side - 1 5.25 5.25

FIGURE 5

Left side repair or 2 9.60 4.80

preventive modification (Paragraph 3.B.,

Work Instructions,

PART 5)

Close Access 2 3.00 1.50

TOTAL FOR EACH AIRPLANE 20.85 13.05

Group 1-2, 4:

Table 5 - Post-Repair/Post-Modification Inspection

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.10 0.10

Inspect left and right 2 33.00 16.50

side - FIGURE 7

Close Access 1 0.10 0.10

TOTAL FOR EACH AIRPLANE 33.20 16.70

Group 3, 5:

Table 6 - Post-Repair/Post-Modification Inspection

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.10 0.10

Inspect left side only 2 16.50 8.25

- FIGURE 7

Close Access 1 0.10 0.10

TOTAL FOR EACH AIRPLANE 16.70 8.45

NOTE: Additional time may be required for repairs if cracks are found.

H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

Group 1 +58.2 +132935.5

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ALERT ALERT
Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

Group 2 +58.2 +132935.5

Group 3 +29.1 +66467.7

Group 4 +58.2 +132935.5

Group 5 +28.8 +65709.7

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Engineering Change Memo PRR 85901-110RS

b. Boeing Service Related Problem (SRP) 747-SRP-53-0361

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

d. Service Bulletin Index D6-30300

e. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Part 6, 53-30-00

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

g. 747-400 Aircraft Maintenance Manual (AMM) 25-21-01, 52-11-00

2. Data supplied with this Service Bulletin

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

Kit - Aft Upper Corner Repair, Main Entry 1 - -

Door #5

675U0001

2 - -

3 - -

4 - -

5 - -

6 - -

7 - -

8 - -

DL - -

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BOEING SERVICE BULLETIN 747-53A2839

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

Drawing Number Title

65B04157 Skin Panel Instl - STA 2181.1 to STA 2360 S-12 thru S-19

65B04850 Strap Installation - No. 5 Entry Door

65B04856 Reveal Instl - Upper & Lower No. 5 Main Entry Door

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:

Publication Chapter-Section

747 Aircraft Maintenance Manual

747 Corrosion Prevention Manual

747 Fault Reporting Manual

747 Fault Isolation Manual

747 Structural Repair Manual

747 Illustrated Parts Catalog 53-12

747 Weight and Balance Manual

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.

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

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

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

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

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

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

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

2. Fax to (206) 662-7145

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

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

Unit Price as of the original issue date of this Service Bulletin (US Dollars)ROLT as of the original

issue date of this Service

Bulletin (Calendar Days)

Kit Number Name

Top Kit - Door 5 Cutout Aft (a) $16,336

Upper Corner Small Repair

- Group 1

015U1914-1

Top Kit - Door 5 Cutout Aft (a) $17,426

Upper Corner Small Repair

- Group 2

015U1914-2

Top Kit - Door 5 Cutout Aft (a) $8,713

Upper Corner Small Repair

- Group 3

015U1914-3

Top Kit - Door 5 Cutout Aft (a) $16,362

Upper Corner Small Repair

- Group 4

015U1914-4

Top Kit - Door 5 Cutout Aft (a) $7,731

Upper Corner Small Repair

- Group 5

015U1914-5

Top Kit - Door 5 Cutout Aft (a) $16,016

Upper Corner Large Repair

- Group 1

015U1914-11

Top Kit - Door 5 Cutout Aft (a) $17,130

Upper Corner Large Repair

- Group 2

015U1914-12

Top Kit - Door 5 Cutout Aft (a) $8,565

Upper Corner Large Repair

- Group 3

015U1914-13

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

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

Unit Price as of the original issue date of this Service Bulletin (US Dollars)ROLT as of the original

issue date of this Service

Bulletin (Calendar Days)

Kit Number Name

Top Kit - Door 5 Cutout Aft (a) $15,890

Upper Corner Large Repair

- Group 4

015U1914-14

Top Kit - Door 5 Cutout Aft (a) $7,654

Upper Corner Large Repair

- Group 5

015U1914-15

(a) Refer to the Boeing PART page on myboeingfleet.com or contact first responder at fr@boeing.com for

Reorder Lead Time (ROLT) information.

B. Industry Support Information

Boeing warranty remedies are available for 747 airplanes in warranty as of September 2, 1997. For

task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Commercial Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be

supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service

bulletin number and reference the airplane variable numbers in your purchase order.

Boeing warranty remedies are not available for the inspection or repair procedures given in this service

bulletin.

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. 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. Boeing Document D-590 and Boeing Drawing 65B88700 are used to

determine the part numbers used as substitutes.

Kit 015U1914

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5

Top Kit - Door 5

Cutout Aft Upper

Corner Small Repair - Group 1

015U1914-1 - . . . .

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ALERT ALERT
Kit 015U1914

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5

Top Kit - Door 5

Cutout Aft Upper

Corner Small Repair - Group 2

015U1914-2 . - . . .

Top Kit - Door 5

Cutout Aft Upper

Corner Small Repair - Group 3

015U1914-3 . . - . .

Top Kit - Door 5

Cutout Aft Upper

Corner Small Repair - Group 4

015U1914-4 . . . - .

Top Kit - Door 5

Cutout Aft Upper

Corner Small Repair - Group 5

015U1914-5 . . . . -

675U0001-1 1 . . . . KIT

675U0001-2 1 . . . . KIT

675U0001-3 . 1 1 . . KIT

675U0001-4 . 1 . . . KIT

675U0001-5 . . . 1 . KIT

675U0001-6 . . . 1 . KIT

675U0001-7 . . . . 1 KIT

Kit 015U1914

Existing Part Notes

Number

New Part Number QTY Name

-11 -12 -13 -14 -15

Top Kit - Door 5

Cutout Aft Upper

Corner Large Repair - Group 1

015U1914-11 - . . . .

Top Kit - Door 5

Cutout Aft Upper

Corner Large Repair - Group 2

015U1914-12 . - . . .

Top Kit - Door 5

Cutout Aft Upper

Corner Large Repair - Group 3

015U1914-13 . . - . .

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Kit 015U1914

Existing Part Notes

Number

New Part Number QTY Name

-11 -12 -13 -14 -15

Top Kit - Door 5

Cutout Aft Upper

Corner Large Repair - Group 4

015U1914-14 . . . - .

Top Kit - Door 5

Cutout Aft Upper

Corner Large Repair - Group 5

015U1914-15 . . . . -

675U0001-10 1 . . . . KIT

675U0001-11 . 1 1 . . KIT

675U0001-12 . 1 . . . KIT

675U0001-13 . . . 1 . KIT

675U0001-14 . . . 1 . KIT

675U0001-15 . . . . 1 KIT

675U0001-9 1 . . . . KIT

Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4

675U0001-1 - . . . KIT

675U0001-2 . - . . KIT

675U0001-3 . . - . KIT

675U0001-4 . . . - KIT

UPR AFT DEPRESSOR65B04856-25 1 . 1 .

UPR AFT DEPRESSOR

65B04856-26 . 1 . 1

UPR AFT DEPRESSOR65B04856-27 1 . 1 .

UPR AFT DEPRESSOR65B04856-28 . 1 . 1

65B04856-31 1 1 1 1 SHIM

675U0002-1 1 . 1 . DOUBLER

675U0002-13 1 . 1 . FILLER

675U0002-14 . 1 . 1 FILLER

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Copyright © Unpublished Work - See page 1 for details.

Original Issue: November 06, 2012

747-53A2839

34 of 76

BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4

675U0002-2 . 1 . 1 DOUBLER

675U0002-3 1 . 1 . TRIPLER

675U0002-4 . 1 . 1 TRIPLER

675U0002-5 1 . 1 . QUADRUPLER

675U0002-6 . 1 . 1 QUADRUPLER

BACB30MY5K3 1 1 1 1 BOLT

BACB30MY5K8 1 1 1 1 BOLT

BACB30MY8K7 2 2 2 2 BOLT

BACB30NW6K10X 11 11 17 17 BOLT

BACB30NW6K10Y . . 8 8 BOLT

BACB30NW6K11X 13 13 15 15 BOLT

BACB30NW6K12X 41 41 41 41 BOLT

BACB30NW6K13X 1 1 1 1 BOLT

BACB30NW6K14X 1 1 1 1 BOLT

BACB30NW6K5X 3 3 2 2 BOLT

BACB30NW6K5Y 1 1 2 2 BOLT

BACB30NW6K6X 2 2 4 4 BOLT

BACB30NW6K7X 11 11 30 30 BOLT

BACB30NW6K8 5 5 5 5 BOLT

BACB30NW6K8X 20 20 1 1 BOLT

BACB30NW6K8Y . . 18 18 BOLT

BACB30NW6K9X 12 12 14 14 BOLT

BACB30NW8K10Y . . 2 2 BOLT

BACB30NW8K11X 3 3 3 3 BOLT

BACB30NW8K12X 18 18 20 20 BOLT

BACB30NW8K13X 4 4 6 6 BOLT

BACB30NW8K14X 2 2 2 2 BOLT

BACB30NW8K15X 6 6 7 7 BOLT

BACB30NW8K16X 8 8 8 8 BOLT

BACB30NW8K17X 7 7 7 7 BOLT

BACB30NW8K3 22 22 22 22 BOLT

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4

BACB30NW8K4 74 74 74 74 BOLT

BACB30NW8K5 9 9 9 9 BOLT

BACB30NW8K6 42 42 36 36 BOLT

BACB30NW8K6Y . . 6 6 BOLT

BACB30NW8K7 24 24 7 7 BOLT

BACB30NW8K8 2 2 . . BOLT

BACB30NW8K8X 4 4 4 4 BOLT

BACB30NW8K8Y . . 2 2 BOLT

BACB30NW8K9 75 75 3 3 BOLT

BACB30NW8K9X 4 4 8 8 BOLT

BACB30NW8K9Y . . 66 66 BOLT

BACC30M5 2 2 2 2 COLLAR

BACC30M6 130 130 120 120 COLLAR

BACC30M8 317 317 247 247 COLLAR

BACC30R6 1 1 33 33 COLLAR

BACC30R8 . . 77 77 COLLAR

BACF3F011M030NF 1 1 1 1 FILLER

BACF3F011M042NF 1 1 1 1 FILLER

BACF3F023M024NF 1 1 1 1 FILLER

BACF3F023M036NF 1 1 1 1 FILLER

BACF3F065X069NN 1 1 1 1 FILLER

BACR15BB5D5C 2 2 2 2 RIVET

BACR15BB5D7C 1 1 1 1 RIVET

BACR15BB5D9C 1 1 1 1 RIVET

BACR15BB8D12C 2 2 2 2 RIVET

BACR15GF6D9 1 1 1 1 RIVET

BACS40R010E010F 1 1 1 1 SHIM

BACS40R065E069F 1 1 1 1 SHIM

WASHER, SELFALIGNBACW10CA104CC 21 21 30 30

WASHER, SELFALIGNBACW10CA31PV 21 21 30 30

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4

WASHER, SELFALIGNINGBACW10CA41PV 12 12 15 15

BACW10CA5CC 12 12 15 15 WASHER

MS20615-6MP13 7 7 7 7 RIVET

MS20615-6MP18 4 4 4 4 RIVET

MS20615-8MP14 1 1 1 1 RIVET

MS20615-8MP15 1 1 1 1 RIVET

Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7

675U0001-5 - . . KIT

675U0001-6 . - . KIT

675U0001-7 . . - KIT

UPR AFT DEPRESSOR65B04856-25 1 . 1

UPR AFT DEPRESSOR65B04856-26 . 1 .

UPR AFT DEPRESSOR65B04856-27 1 . 1

UPR AFT DEPRESSOR65B04856-28 . 1 .

65B04856-31 1 1 1 SHIM

675U0002-1 1 . 1 DOUBLER

675U0002-13 1 . . FILLER

675U0002-14 . 1 . FILLER

675U0002-2 . 1 . DOUBLER

675U0002-3 1 . 1 TRIPLER

675U0002-4 . 1 . TRIPLER

675U0002-5 1 . 1 QUADRUPLER

675U0002-6 . 1 . QUADRUPLER

BACB30MY5K3 1 1 . BOLT

BACB30MY5K8 1 1 . BOLT

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7

BACB30MY8K7 2 2 . BOLT

BACB30NW6K10X 9 9 14 BOLT

BACB30NW6K10Y 8 8 . BOLT

BACB30NW6K11X 12 12 12 BOLT

BACB30NW6K12X 27 27 38 BOLT

BACB30NW6K15X 4 4 . BOLT

BACB30NW6K5X 4 4 4 BOLT

BACB30NW6K5Y 1 1 2 BOLT

BACB30NW6K6X 6 6 4 BOLT

BACB30NW6K6Y 2 2 1 BOLT

BACB30NW6K7X 9 9 9 BOLT

BACB30NW6K8 5 5 5 BOLT

BACB30NW6K8Y 18 18 17 BOLT

BACB30NW6K9X 11 11 11 BOLT

BACB30NW8K10Y 2 2 . BOLT

BACB30NW8K11X 3 3 3 BOLT

BACB30NW8K12X 20 20 20 BOLT

BACB30NW8K13X 4 4 4 BOLT

BACB30NW8K14X 2 2 2 BOLT

BACB30NW8K15X 7 7 7 BOLT

BACB30NW8K16X 8 8 8 BOLT

BACB30NW8K17X 7 7 7 BOLT

BACB30NW8K3 22 22 22 BOLT

BACB30NW8K4 74 74 79 BOLT

BACB30NW8K5 9 9 9 BOLT

BACB30NW8K6 36 36 37 BOLT

BACB30NW8K6Y 6 6 8 BOLT

BACB30NW8K7 24 24 21 BOLT

BACB30NW8K8X 4 4 4 BOLT

BACB30NW8K8Y 2 2 3 BOLT

BACB30NW8K9 3 3 3 BOLT

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7

BACB30NW8K9X 4 4 4 BOLT

BACB30NW8K9Y 68 68 68 BOLT

BACC30M5 2 2 . COLLAR

BACC30M6 106 106 103 COLLAR

BACC30M8 240 240 240 COLLAR

BACC30R6 32 32 20 COLLAR

BACC30R8 79 79 80 COLLAR

BACF3F011M030NF 1 1 . FILLER

BACF3F011M042NF 1 1 . FILLER

BACF3F023M024NF 1 1 . FILLER

BACF3F023M036NF 1 1 . FILLER

BACF3F065X069NN 1 1 1 FILLER

BACR15BB5D5C 2 2 . RIVET

BACR15BB5D7C 1 1 . RIVET

BACR15BB5D9C 1 1 . RIVET

BACR15BB8D12C 2 2 2 RIVET

BACR15GF6D9 1 1 1 RIVET

BACS40R010E010F 1 1 1 SHIM

BACS40R065E069F 1 1 1 SHIM

WASHER, SELFALIGNBACW10CA104CC 13 13 13

WASHER, SELFALIGNBACW10CA31PV 13 13 13

WASHER, SELFALIGNINGBACW10CA41PV 15 15 15

BACW10CA5CC 15 15 15 WASHER

MS20615-6MP13 7 7 7 RIVET

MS20615-6MP18 4 4 4 RIVET

MS20615-8MP14 1 1 1 RIVET

MS20615-8MP15 1 1 1 RIVET

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Copyright © Unpublished Work - See page 1 for details.

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-9 -10 -11 -12

675U0001-10 . - . . KIT

675U0001-11 . . - . KIT

675U0001-12 . . . - KIT

675U0001-9 - . . . KIT

UPR AFT DEPRESSOR65B04856-25 1 . 1 .

UPR AFT DEPRESSOR65B04856-26 . 1 . 1

UPR AFT DEPRESSOR65B04856-27 1 . 1 .

UPR AFT DEPRESSOR65B04856-28 . 1 . 1

65B04856-31 1 1 1 1 SHIM

675U0002-10 . 1 . 1 TRIPLER

675U0002-11 1 . 1 . QUADRUPLER

675U0002-12 . 1 . 1 QUADRUPLER

675U0002-13 1 . 1 . FILLER

675U0002-14 . 1 . 1 FILLER

675U0002-7 1 . 1 . DOUBLER

675U0002-8 . 1 . 1 DOUBLER

675U0002-9 1 . 1 . TRIPLER

BACB30MY5K3 1 1 1 1 BOLT

BACB30MY5K8 1 1 1 1 BOLT

BACB30MY8K7 2 2 2 2 BOLT

BACB30NW6K10X 13 13 19 19 BOLT

BACB30NW6K10Y . . 8 8 BOLT

BACB30NW6K11X 14 14 16 16 BOLT

BACB30NW6K12X 48 48 48 48 BOLT

BACB30NW6K13X 1 1 1 1 BOLT

BACB30NW6K14X 1 1 1 1 BOLT

BACB30NW6K4Y . . 4 4 BOLT

BACB30NW6K5X 3 3 3 3 BOLT

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-9 -10 -11 -12

BACB30NW6K5Y 7 7 8 8 BOLT

BACB30NW6K6X 2 2 8 8 BOLT

BACB30NW6K6Y . . 4 4 BOLT

BACB30NW6K7X 13 13 13 13 BOLT

BACB30NW6K7Y . . 1 1 BOLT

BACB30NW6K8 4 4 4 4 BOLT

BACB30NW6K8X 19 19 . . BOLT

BACB30NW6K8Y . . 18 18 BOLT

BACB30NW6K9X 14 14 16 16 BOLT

BACB30NW8K10Y . . 2 2 BOLT

BACB30NW8K11X 3 3 3 3 BOLT

BACB30NW8K12X 18 18 20 20 BOLT

BACB30NW8K13X 4 4 6 6 BOLT

BACB30NW8K14X 2 2 2 2 BOLT

BACB30NW8K15X 6 6 7 7 BOLT

BACB30NW8K16X 8 8 8 8 BOLT

BACB30NW8K17X 7 7 7 7 BOLT

BACB30NW8K3 22 22 22 22 BOLT

BACB30NW8K4 83 83 84 84 BOLT

BACB30NW8K5 21 21 21 21 BOLT

BACB30NW8K6 94 94 90 90 BOLT

BACB30NW8K6X 2 2 . . BOLT

BACB30NW8K6Y . . 6 6 BOLT

BACB30NW8K7 24 24 24 24 BOLT

BACB30NW8K8 2 2 . . BOLT

BACB30NW8K8X 4 4 4 4 BOLT

BACB30NW8K8Y . . 2 2 BOLT

BACB30NW8K9 74 74 3 3 BOLT

BACB30NW8K9X 4 4 4 4 BOLT

BACB30NW8K9Y . . 70 70 BOLT

BACC30M5 2 2 2 2 COLLAR

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Copyright © Unpublished Work - See page 1 for details.

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-9 -10 -11 -12

BACC30M6 142 142 139 139 COLLAR

BACC30M8 392 392 319 319 COLLAR

BACC30R6 7 7 48 48 COLLAR

BACC30R8 . . 81 81 COLLAR

BACF3F023M024NF 1 1 1 1 FILLER

BACF3F023M036NF 1 1 1 1 FILLER

BACF3F069X078NN 1 1 1 1 FILLER

BACR15BB5D5C 2 2 2 2 RIVET

BACR15BB5D7C 1 1 1 1 RIVET

BACR15BB5D9C 1 1 1 1 RIVET

BACR15BB8D12C 2 2 2 2 RIVET

BACR15GF6D9 1 1 1 1 RIVET

BACS40R010E010F 1 1 1 1 SHIM

BACS40R069E078F 1 1 1 1 SHIM

WASHER, SELFALIGN

BACW10CA104CC 24 24 33 33

WASHER, SELFALIGNBACW10CA31PV 24 24 33 33

WASHER, SELFALIGNINGBACW10CA41PV 12 12 15 15

BACW10CA5CC 12 12 15 15 WASHER

MS20615-6MP13 7 7 7 7 RIVET

MS20615-6MP18 4 4 4 4 RIVET

MS20615-8MP14 1 1 1 1 RIVET

MS20615-8MP15 1 1 1 1 RIVET

Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-13 -14 -15

675U0001-13 - . . KIT

675U0001-14 . - . KIT

675U0001-15 . . - KIT

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-13 -14 -15

UPR AFT DEPRESSOR65B04856-25 1 . 1

UPR AFT DEPRESSOR65B04856-26 . 1 .

UPR AFT DEPRESSOR65B04856-27 1 . 1

UPR AFT DEPRESSOR65B04856-28 . 1 .

65B04856-31 1 1 1 SHIM

675U0002-10 . 1 . TRIPLER

675U0002-11 1 . 1 QUADRUPLER

675U0002-12 . 1 . QUADRUPLER

675U0002-13 1 . . FILLER

675U0002-14 . 1 . FILLER

675U0002-7 1 . 1 DOUBLER

675U0002-8 . 1 . DOUBLER

675U0002-9 1 . 1 TRIPLER

BACB30MY5K3 1 1 . BOLT

BACB30MY5K8 1 1 . BOLT

BACB30MY8K7 2 2 . BOLT

BACB30NW6K10X 9 9 13 BOLT

BACB30NW6K10Y 8 8 . BOLT

BACB30NW6K11X 12 12 13 BOLT

BACB30NW6K12X 44 44 44 BOLT

BACB30NW6K15X 4 4 . BOLT

BACB30NW6K4Y 4 4 . BOLT

BACB30NW6K5X 4 4 4 BOLT

BACB30NW6K5Y 7 7 7 BOLT

BACB30NW6K6X 5 5 3 BOLT

BACB30NW6K6Y 6 6 . BOLT

BACB30NW6K7X 14 14 14 BOLT

BACB30NW6K7Y 1 1 . BOLT

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Copyright © Unpublished Work - See page 1 for details.

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-13 -14 -15

BACB30NW6K8 4 4 4 BOLT

BACB30NW6K8X 3 3 3 BOLT

BACB30NW6K8Y 18 18 18 BOLT

BACB30NW6K9X 11 11 11 BOLT

BACB30NW8K10Y 2 2 . BOLT

BACB30NW8K11X 3 3 3 BOLT

BACB30NW8K12X 20 20 20 BOLT

BACB30NW8K13X 4 4 4 BOLT

BACB30NW8K14X 2 2 2 BOLT

BACB30NW8K15X 7 7 7 BOLT

BACB30NW8K16X 8 8 8 BOLT

BACB30NW8K17X 7 7 7 BOLT

BACB30NW8K3 22 22 22 BOLT

BACB30NW8K4 81 81 85 BOLT

BACB30NW8K5 21 21 21 BOLT

BACB30NW8K6 90 90 93 BOLT

BACB30NW8K6Y 6 6 8 BOLT

BACB30NW8K7 24 24 21 BOLT

BACB30NW8K8X 4 4 4 BOLT

BACB30NW8K8Y 2 2 3 BOLT

BACB30NW8K9 3 3 3 BOLT

BACB30NW8K9X 4 4 4 BOLT

BACB30NW8K9Y 68 68 66 BOLT

BACC30M5 2 2 . COLLAR

BACC30M6 119 119 116 COLLAR

BACC30M8 318 318 316 COLLAR

BACC30R6 44 44 28 COLLAR

BACC30R8 79 79 79 COLLAR

BACF3F023M024NF 1 1 . FILLER

BACF3F023M036NF 1 1 . FILLER

BACF3F069X078NN 1 1 1 FILLER

BOEING PROPRIETARY -

Copyright © Unpublished Work - See page 1 for details.

Original Issue: November 06, 2012

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
Kit 675U0001

Existing Part Notes

Number

New Part Number QTY Name

-13 -14 -15

BACR15BB5D5C 2 2 . RIVET

BACR15BB5D7C 1 1 . RIVET

BACR15BB5D9C 1 1 . RIVET

BACR15BB8D12C 2 2 2 RIVET

BACR15GF6D9 1 1 1 RIVET

BACS40R010E010F 1 1 1 SHIM

BACS40R069E078F 1 1 1 SHIM

WASHER, SELFALIGNBACW10CA104CC 13 13 13

WASHER, SELFALIGNBACW10CA31PV 13 13 13

WASHER, SELFALIGNINGBACW10CA41PV 15 15 15

BACW10CA5CC 15 15 15 WASHER

MS20615-6MP13 7 7 7 RIVET, SOLID

MS20615-6MP18 4 4 4 RIVET, SOLID

MS20615-8MP14 1 1 1 RIVET, SOLID

MS20615-8MP15 1 1 1 RIVET, SOLID

2. Parts and Materials Supplied by the Operator

Part Number / QTY Name Notes

Specification

4 to 10 necessary, depending on airplane group and

seal depressor configuration, for each open-hole

HFEC inspection done in

accordance with FIGURE 5

and/or FIGURE 6. (b)

BACR15CE6D8 4 - 10 Rivet

BMS 5-95 1 pint Sealant (a)

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

for supplier data.

(b) Optional: BACR15GF6D8, BACR15GF61D8 or BACR15GF7D8.

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
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.

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BOEING SERVICE BULLETIN 747-53A2839

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

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque limits to tighten nuts and bolts are in SRM Chapter 51

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

6. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

7. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

8. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

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BOEING SERVICE BULLETIN 747-53A2839

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. Edge Margin is defined as the distance from the centerline of a fastener hole (or

fastener) to the nearest part edge.

B. WORK INSTRUCTIONS

PART 1 - Left Main Entry Door 5 Inspection for Existing Repair and Edge Margin Measurement

1. Get external access to the aft upper corner of the cutout for left Main Entry Door 5.

2. Do a detailed inspection of the aft upper corner of the cutout for left Main Entry Door 5 for the

existence of a repair in accordance with FIGURE 1.

3. Measure the edge margin at certain fastener locations in accordance with FIGURE 2.

4. If a repair is found at the aft upper corner of the cutout for left Main Entry Door 5, contact Boeing

with details of the repair, including the fastener edge margins measured in accordance with FIGURE

2. Do inspections or change the repair, as described by Boeing.

5. If no repair is found, do an inspection in accordance with PART 3 at the applicable time given in

Paragraph 1.E., Compliance, Table 1.

Group 1-2, 4:

PART 2 - Right Main Entry Door 5 Inspection for Existing Repair and Edge Margin Measurement

1. Get external access to the aft upper corner of the cutout for right Main Entry Door 5.

2. Do a detailed inspection of the aft upper corner of the cutout for right Main Entry Door 5 for the

existence of a repair in accordance with FIGURE 3.

3. Measure the edge margin at certain fastener locations in accordance with FIGURE 4.

4. If a repair is found at the aft upper corner of the cutout for right Main Entry Door 5, contact Boeing

with details of the repair, including the fastener edge margins measured in accordance with FIGURE

4. Do inspections or change the repair, as described by Boeing.

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5. If no repair is found, do an inspection in accordance with PART 4 at the applicable time given in

Paragraph 1.E., Compliance, Table 2.

PART 3 - Left Main Entry Door 5 Detailed and HFEC Inspections

1. Open left Main Entry Door 5. Refer to 747-400 AMM 52-11-00 as an accepted procedure.

2. Remove and keep the doorway lining and sidewall insulation above MED 5. Refer to 747-400 AMM

25-21-01 or 747-100/200/300 AMM 25-21-03 and 747-100/200/300 AMM 25-21-04 as accepted

procedures.

3. Do inspections of the aft upper corner of the cutout for left Main Entry Door 5 in accordance with

FIGURE 5.

4. If no crack is found, install equipment removed for access and put the airplane back to a serviceable

condition. Do the inspections in PART 3 again and install the preventive modification in accordance

with PART 5 at the applicable times given in Paragraph 1.E., Compliance, Table 1.

NOTE: As an alternative, install a preventive modification in accordance with PART 5

5. If all cracks found are less than 3.0 inches long, install a repair in accordance with PART 5.

6. If any crack found that is 3.0 inches long or longer, install a repair in accordance with PART 6.

Group 1-2, 4:

PART 4 - Right Main Entry Door 5 Detailed and HFEC Inspections

1. Open right Main Entry Door 5. Refer to 747-400 AMM 52-11-00 as an accepted procedure.

2. Remove and keep the doorway lining and sidewall insulation above MED 5. Refer to 747-400 AMM

25-21-01 or 747-100/200/300 AMM 25-21-03 and 747-100/200/300 AMM 25-21-04 as accepted

procedures.

3. Do inspections of the aft upper corner of the cutout for right Main Entry Door 5 in accordance with

FIGURE 6.

4. If no crack is found, install equipment removed for access and put the airplane back to a serviceable

condition. Do the inspections in PART 4 again and install the preventive modification in accordance

with PART 5 at the applicable times given in Paragraph 1.E., Compliance, Table 2.

NOTE: As an alternative, install a preventive modification in accordance with PART 5.

5. If all cracks found are less than 3.0 inches long, install a repair in accordance with PART 5.

6. If any crack found that is 3.0 inches long or longer, install a repair in accordance with PART 6.

PART 5 - Preventive Modification/Small Repair (Repair for Cracks Less Than 3.0 Inches Long,

or if No Cracks are Found)

1. Open the affected Main Entry Door 5. Refer to 747-400 AMM 52-11-00 as an accepted procedure.

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2. Remove and keep the doorway lining and sidewall insulation above MED 5. Refer to 747-400 AMM

25-21-01 or 747-100/200/300 AMM 25-21-03 and 747-100/200/300 AMM 25-21-04 as accepted

procedures.

3. Do the steps that follow. For each affected airplane group, do the work in accordance with the

Boeing drawings shown in the table that follows:

Group Left Side Right Side

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 1

(675U0001-2 Installation)

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 1

(675U0001-1 Installation)

1

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 2

(675U0001-4 Installation)

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 2

(675U0001-3 Installation)

2

Boeing Drawing 675U0001, Sheet DL and -

Boeing Drawing 675U0001, Sheet 2

(675U0001-3 Installation)

3

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 3

(675U0001-6 Installation)

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 3

(675U0001-5 Installation)

4

Boeing Drawing 675U0001, Sheet DL and -

Boeing Drawing 675U0001, Sheet 4

(675U0001-7 Installation)

5

a. Remove and keep the gutter from above the door cutout.

b. Remove and discard seal depressors at the aft upper corner of the door cutout.

c. Trim the skin and bear strap at the aft upper corner of the door cutout. The table that follows

gives the location of the detailed trim dimensions on each affected drawing sheet. If a different

trim profile than shown in the drawing is necessary, contact Boeing.

NOTE: It is not necessary to trim the skin and bear strap if no cracks were found during the

inspections done in accordance with PART 3 or PART 4, and if the edge margin

measured in PART 1 or PART 2 at all affected fastener holes is 3.50D or greater

(where D is the fastener hole diameter).

Group Drawing Trim Detail Location

1 Drawing 675U0001, Sheet 1 View 1D13 in Zone B28

2, 3 Drawing 675U0001, Sheet 2 View 1D13 in Zone E27

4 Drawing 675U0001, Sheet 3 View 2D13 in Zone B27

5 Drawing 675U0001, Sheet 4 View 1D13 in Zone B28

d. Install seal depressors and a doubler, tripler and a quadrupler, and reinstall the gutter in

accordance with the applicable Boeing drawings.

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4. Install the sidewall insulation and doorway lining above MED 5. Refer to 747-400 AMM 25-21-01

or 747-100/200/300 AMM 25-21-03 and 747-100/200/300 AMM 25-21-04 as accepted procedures.

5. Put the airplane back in a serviceable condition. Do the post-repair/post-modification inspection

in PART 7 at the time given in Paragraph 1.E., Compliance, Table 3.

PART 6 - Large Repair (Repair for Cracks 3.0 Inches Long or Longer)

1. Open the affected Main Entry Door 5. Refer to 747-400 AMM 52-11-00 as an accepted procedure.

2. Remove and keep the doorway lining and sidewall insulation above MED 5. Refer to 747-400 AMM

25-21-01 or 747-100/200/300 AMM 25-21-03 and 747-100/200/300 AMM 25-21-04 as accepted

procedures.

3. Do the steps that follow. For each affected airplane group, do the work in accordance with the

Boeing drawings shown in the table that follows:

Group Left Side Right Side

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 5

(675U0001-10 Installation)

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 5

(675U0001-9 Installation)

1

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 6

(675U0001-12 Installation)

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 6

(675U0001-11 Installation)

2

Boeing Drawing 675U0001, Sheet DL and -

Boeing Drawing 675U0001, Sheet 6

(675U0001-11 Installation)

3

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 7

(675U0001-14 Installation)

Boeing Drawing 675U0001, Sheet DL and

Boeing Drawing 675U0001, Sheet 7

(675U0001-13 Installation)

4

Boeing Drawing 675U0001, Sheet DL and -

Boeing Drawing 675U0001, Sheet 8

(675U0001-15 Installation)

5

a. Remove and keep the gutter from above the door cutout.

b. Remove and discard seal depressors at the aft upper corner of the door cutout.

c. Trim the skin and bear strap at the aft upper corner of the door cutout. The table that follows

gives the location of the detailed trim dimensions on each affected drawing sheet. If a different

trim profile than shown in the drawing is necessary, contact Boeing.

Group Drawing Trim Detail Location

1 Drawing 675U0001, Sheet 5 View 1D14 in Zone B28

2, 3 Drawing 675U0001, Sheet 6 View 1D13 in Zone E27

4 Drawing 675U0001, Sheet 7 View 3D13 in Zone B27

5 Drawing 675U0001, Sheet 8 View 1D14 in Zone B28

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ALERT ALERT
d. Install seal depressors and a doubler, tripler and a quadrupler, and reinstall the gutter in

accordance with the applicable Boeing drawings.

4. Install the sidewall insulation and doorway lining above MED 5. Refer to 747-400 AMM 25-21-01

or 747-100/200/300 AMM 25-21-03 and 747-100/200/300 AMM 25-21-04 as accepted procedures.

5. Put the airplane back in a serviceable condition. Do the post-repair/post-modification inspection

in PART 7 at the time given in Paragraph 1.E., Compliance, Table 3.

PART 7 - Post-Repair/Post-Modification Inspection

1. Open left Main Entry Door 5. Refer to 747-400 AMM 52-11-00 as an accepted procedure.

2. Group 1-2, 4:

Open right Main Entry Door 5. Refer to 747-400 AMM 52-11-00 as an accepted procedure.

3. Remove and keep the doorway lining and sidewall insulation above the affected MED 5. Refer to

747-400 AMM 25-21-01 or 747-100/200/300 AMM 25-21-03 and 747-100/200/300 AMM 25-21-04

as accepted procedures.

4. Do inspections in accordance with FIGURE 7.

5. If any crack is found, contact Boeing for repair instructions and do the repair.

6. If no crack is found, install equipment removed for access and put the airplane back in a serviceable

condition. Do the inspection in PART 7 again at the time given in Paragraph 1.E., Compliance,

Table 3.

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ALERT ALERT
FIGURE 1: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE LEFT MAIN

ENTRY DOOR 5 CUTOUT

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 1: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE LEFT MAIN

ENTRY DOOR 5 CUTOUT

(SHEET 2 OF 3)

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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.

Step Task Name Identification Qty More Data

Do a detailed Inspection at the aft upper

corner of the door 5

cutout, for any repair

installed in the area

shown. (a)

1 Inspect Fuselage Skin - -

(a) A repair may consist of external doublers, freeze plugs, blendouts, or oversize fasteners. Any rivet with

a manufactured head diameter greater than 0.298 inch should be considered an oversize fastener for the

purposes of this inspection.

FIGURE 1: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE LEFT MAIN

ENTRY DOOR 5 CUTOUT

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 2: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 2: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 2 OF 3)

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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.

Step Task Name Identification Qty More Data

1 Measure Fastener Edge Margin - - (a)

Record Fastener Edge Margin - - (a)

(a) At each of the four fastener locations (as shown in Detail A) or five fastener locations (as shown in Detail

B), depending on the existing configuration, common to the seal depressor in the area shown.

FIGURE 2: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 3 OF 3)

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

FIGURE 3: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE RIGHT MAIN

ENTRY DOOR 5 CUTOUT

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
FIGURE 3: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE RIGHT MAIN

ENTRY DOOR 5 CUTOUT

(SHEET 2 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

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747-53A2839

60 of 76

BOEING SERVICE BULLETIN 747-53A2839

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.

Step Task Name Identification Qty More Data

Do a detailed Inspection at the aft upper

corner of the door 5

cutout, for any repair

installed in the area

shown. (a)

1 Inspect Fuselage Skin - -

(a) A repair may consist of external doublers, freeze plugs, blendouts, or oversize fasteners. Any rivet with

a manufactured head diameter greater than 0.298 inch should be considered an oversize fastener for the

purposes of this inspection.

FIGURE 3: INSPECTION FOR EXISTING REPAIRS AT THE AFT UPPER CORNER OF THE RIGHT MAIN

ENTRY DOOR 5 CUTOUT

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2839

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

FIGURE 4: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
FIGURE 4: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 2 OF 3)

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63 of 76

BOEING SERVICE BULLETIN 747-53A2839

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.

Step Task Name Identification Qty More Data

1 Measure Fastener Edge Margin - - (a)

Record Fastener Edge Margin - - (a)

(a) At each of the four fastener locations (as shown in Detail A) or five fastener locations (as shown in Detail

B), depending on the existing configuration, common to the seal depressor in the area shown.

FIGURE 4: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
FIGURE 5: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 1 OF 3)

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ALERT ALERT
FIGURE 5: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53A2839

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.

NOTE: For the purposes of these inspections, "Fuselage Skin Assembly" is defined as the skin, the bonded

doubler and the bonded tripler.

Step Task Name Identification Qty More Data

1 Inspect Door Corner Structure - - (a)

Four or five locations

at each door cutout,

depending on seal

depressor configuration.

2 Remove Rivet - -

Fuselage Skin Assem- - - (b)

bly and Bear Strap

Inspect

Four or five locations

at each door cutout,

depending on existing seal depressor

configuration. (c)

Install (New) Rivet BACR15CE6D8 -

Fuselage Skin Assem- - - (d)

bly

3 Inspect

Inspect Bear Strap - - (d)

(a) Do internal and external detailed inspections for cracks in the area shown.

(b) Do open-hole High Frequency Eddy Current (HFEC) inspections of all layers of the fuselage skin assembly

for cracks, in accordance with 747 NDT Part 6, 51-00-00, Figure 1, 11 or 16.

(c) Install rivets only if no crack indications were found during the open-hole HFEC inspection. Optional:

BACR15GF6D8, BACR15GF61D8 (for 13/64 inch diameter rivet holes) or BACR15GF7D8 (for 7/32 inch

diameter rivet holes).

(d) Do surface HFEC inspections along the edge of all layers of the fuselage skin assembly and of the bear

strap in the area shown for cracks, in accordance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.

FIGURE 5: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53A2839

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

FIGURE 6: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
FIGURE 6: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 2 OF 3)

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Copyright © Unpublished Work - See page 1 for details.

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69 of 76

BOEING SERVICE BULLETIN 747-53A2839

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.

NOTE: For the purposes of these inspections, "Fuselage Skin Assembly" is defined as the skin, the bonded

doubler and the bonded tripler.

Step Task Name Identification Qty More Data

1 Inspect Door Corner Structure - - (a)

Four or five locations

at each door cutout,

depending on seal

depressor configuration.

2 Remove Rivet - -

Fuselage Skin Assem- - - (b)

bly and Bear Strap

Inspect

Four or five locations

at each door cutout,

depending on seal

depressor configuration. (c)

Install (New) Rivet BACR15CE6D8 -

Fuselage Skin Assem- - - (d)

bly

3 Inspect

Inspect Bear Strap - - (d)

(a) Do internal and external detailed inspections for cracks in the area shown.

(b) Do open-hole High Frequency Eddy Current (HFEC) inspections of all layers of the fuselage skin assembly

for cracks, in accordance with 747 NDT Part 6, 51-00-00, Figure 1, 11 or 16.

(c) Install rivets only if no crack indications were found during the open-hole HFEC inspection. Optional:

BACR15GF6D8, BACR15GF61D8 (for 13/64 inch diameter rivet holes) or BACR15GF7D8 (for 7/32 inch

diameter rivet holes).

(d) Do surface HFEC inspections along the edge of all layers of the fuselage skin assembly and of the bear

strap in the area shown for cracks, in accordance with 747 NDT Part 6, 51-00-00, Figure 4 or 23.

FIGURE 6: INSPECTION FOR SKIN CRACKS AT THE AFT UPPER CORNER OF THE RIGHT MAIN ENTRY

DOOR 5 CUTOUT

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF THE

MAIN ENTRY DOOR 5 CUTOUT

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT
FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF THE

MAIN ENTRY DOOR 5 CUTOUT

(SHEET 2 OF 6)

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ALERT ALERT
FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF THE

MAIN ENTRY DOOR 5 CUTOUT

(SHEET 3 OF 6)

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ALERT ALERT
FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF THE

MAIN ENTRY DOOR 5 CUTOUT

(SHEET 4 OF 6)

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ALERT ALERT
FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF THE

MAIN ENTRY DOOR 5 CUTOUT

(SHEET 5 OF 6)

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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.

Step Task Name Identification Qty More Data

Repaired or Modified - - (a)

Area

1 Inspect

2 Inspect Fuselage Skin - - (b)

(a) Do internal and external detailed inspections for cracks in the area shown.

(b) Do an external Low Frequency Eddy Current (LFEC) inspections around the edge of the doubler in the

shaded area shown for cracks, in accordance with 747 NDT Part 6, 53-30-00, Figure 5. It is not necessary

to do these inspections in areas covered by the rain gutter or tapered fillers under the rain gutter.

FIGURE 7: POST-REPAIR/POST-MODIFICATION INSPECTIONS AT THE AFT UPPER CORNER OF THE

MAIN ENTRY DOOR 5 CUTOUT

(SHEET 6 OF 6)

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BOEING SERVICE BULLETIN 747-53A2839

ALERT ALERT