### 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 Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. 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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 1 of 76 4.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 2 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 3 of 76 **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. . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 4 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 5 of 76**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 Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required
**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 6 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT MANPOWER** **Group 1-2, 4: Elapsed Hours**  **Total Task Hours Airplanes**  1.00 1.00 Inspection for previous repairs and edge margin measurement 23.10 35.70 Inspection and preventive modification installed on both sides 16.70 33.20 Post repair/post modification inspection **Group 3, 5: Elapsed Hours**  **Total Task Hours Airplanes**  0.50 0.50 Inspection for previous repairs and edge margin measurement 13.05 20.85 Inspection and preventive modification installed on the left side 8.45 16.70 Post repair/post modification inspection Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Boeing Supplied Kits. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 7 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 8 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**

### 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.
**DESCRIPTION CONFIGURATION**  **GROUP** All 747 airplanes line number 1 through 85.

- 1 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
All 747-400 airplanes line number 1236 through 1419.

- 4 All 747-400F airplanes line number 1236 through 1419. These airplanes do not have a Door 5 on the right side. - 5

Airplane Models:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 9 of 76747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR **Group Variable Number** 1 RA001 - RA026 2 RA027 - RA034 1 RA101 - RA112 2 RA113 - RA115 1 RA161 - RA162 2 RA163 - RA164 1 RA201 - RA203 2 RA216 - RA217 2 RA245 - RA246 1 RA251 - RA254 2 RA255 - RA266 1 RA301 - RA303 2 RA304 - RA318 1 RA351 - RA359 2 RA360 2 RA369 - RA373 1 RA401 - RA405 2 RA406 - RA418 1 RA501 2 RA502 1 RA521 - RA523 2 RA524 - RA528 2 RA532 - RA548 1 RA551 - RA552 2 RA559 - RA561 1 RA581 2 RA582 2 RA585 1 RA601 - RA602 1 RA631 - RA632 2 RA633 - RA635

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 10 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**2 RA651 - RA652 2 RA671 - RA677 2 RA701 - RA702 2 RA721 - RA731 2 RA741 - RA745 2 RA749 - RA750 2 RA761 - RA762 2 RA781 - RA784 1 RA901 - RA907 2 RA908 - RA916 2 RB001 - RB016 1 RB041 - RB043 2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 11 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 12 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**2 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 4 RF001 - RF006 2 RJ131 - RJ133 2 RJ151 - RJ152 2 RJ301 - RJ303 2 RJ321 - RJ322 2 RJ331 - RJ333 5 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 13 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**5 RL651 - RL655 5 RL671 - RL675 5 RL681 - RL684 5 RL751 - RL752 2 RM001 - RM002 4 RM003 - RM0074 RM010 2 RM011 - RM012 4 RM013 2 RM021 - RM024 2 RM026 - RM0274 RM028 - RM030 2 RM036 - RM038 4 RM039 - RM045 2 RM051 4 RM052 - RM053 2 RM071 2 RM081 - RM084 2 RM091 2 RM096 - RM097 2 RM116 - RM117 2 RM126 - RM130 4 RM131 - RM132 2 RM136 - RM147 2 RM156 - RM1574 RM158 2 RM166 - RM176 4 RM177 2 RM191 - RM192 2 RM231 - RM232 4 RM233 2 RM241 - RM2444 RM245 - RM246

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 14 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**2 RM261 - RM264 2 RM316 4 RM317 - RM318 2 RM331 - RM332 4 RM333 4 RM341 4 RM351 - RM355 4 RM366 - RM3674 RM401 - RM403 4 RM426 4 RM431 4 RM441 - RM443 4 RM445 2 RM801 4 RM802 - RM803 2 RM811 - RM813 3 RM851 - RM852 5 RM853 - RM859 3 RM861 5 RM862 - RM863 3 RM871 5 RM872 - RM880 3 RM881 - RM885 5 RM886 - RM890 3 RM891 - RM899 5 RM901 - RM906 5 RM911 3 RR001 - RR005 3 RR021 - RR025 3 RR031 3 RR201 - RR206 3 RR221 - RR226 3 RR261 - RR267

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 15 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**3 RR301 - RR310 3 RR331 - RR332 3 RR336 3 RR341 - RR345 3 RR361 - RR362 3 RR421 - RR422 3 RR431 - RR432 3 RR441 - RR442 3 RR451 3 RR501 - RR504 3 RR521 - RR522 3 RR526 3 RR531 3 RR551 - RR556 3 RR561 3 RR566 3 RR701 3 RR721 - RR724 3 RR746 - RR748 3 RR851 - RR856 3 RR861 - RR862 3 RR951 - RR952 2 RS001 - RS002 2 RS201 2 RS211 - RS212 2 RS221 - RS222 2 RS231 - RS241 2 RS251 - RS259 2 RS263 2 RS265 - RS268 2 RS271 - RS276 2 RS291 - RS292 2 RS301 - RS306

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 16 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**2 RS311 - RS320 2 RS331 - RS333 2 RS341 - RS342 2 RS699 2 RS701 - RS703 2 RS711 - RS713 2 RS721 - RS722 2 RS731 - RS732 2 RS741 - RS743 2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 17 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group**  **Variable Number**2 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. Spares Affected None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 18 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT 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 Zone**  **Model** 271, 272 747-100

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 19 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group 2:** 
**Affected Maintenance Zones Zone**  **Model** 271, 272 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D, 747SR **Group 3:**
**Affected Maintenance Zones Zone**  **Model** 271 747-200F, 747-400F **Group 4:**
**Affected Maintenance Zones Zone**  **Model** 271, 272 747-400 **Group 5:**
**Affected Maintenance Zones Zone**  **Model** 271 747-400F **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 20 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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)**  **Action Condition** 

- Within 1,500flight-cycles after the original issue date onthis service bulletin. Before 10,000total 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 inaccordance with Paragraph 3.B., Work Instructions, PART 1. All airplanes.

AND Measure the edge marginat certain fastener locations at the aft upper corner of the cutout for leftMain Entry Door 5 in accordance with Paragraph 3.B., Work Instructions, PART 1.

- Before further flight. Contact Boeing with de-tails of the installed repair. Do inspections orchange the repair in accordance with the Boeing instructions. Any door cutout where a repair is found.

- Before further flight. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 3. If no repair is found, and if the measured edge marginat any affected fastener location is less than 0.70 inch.

- Within 1,500flight-cycles after the original issue date onthis service bulletin. Before 18,000total flight-cycles. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 3. If no repair is found, and if the measured edge marginat all affected fastener locations is 0.70 inch or greater.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 21 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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)**  **Action Condition** 

- Before further flight. Install a preventive modi- fication in accordance with Paragraph 3.B., Work Instructions, PART 5. No crack found, and the measured edge margin atany affected fastener location is less than 0.70 inch.OR 3,000 flight-cycles Within 3,000 flight-cycles of theprevious inspection done in accordance with Paragraph 3.B., Work Instructions, PART 3. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 3. AND

- Within 6,000flight-cycles after the original issue date onthis service bulletin. Before 20,000total flight-cycles.Install a preventive modification in accordance with Paragraph 3.B., Work Instructions, PART 5.

- Before further flight. Install a preventive modi- fication in accordance with Paragraph 3.B., Work Instructions, PART 5. No crack found, and the measured edge margin atall affected fastener locations is 0.70 inch or greater. OR 3,000 flight-cycles Within 3,000 flight-cycles of theprevious inspection done in accordance with Paragraph 3.B., Work Instructions, PART 3. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 3. AND

- Within 1,500flight-cycles after the original issue date onthis service bulletin. Before 35,000total flight-cycles.Install a preventive modification in accordance with Paragraph 3.B., Work Instructions, PART 5.

- Before further flight. Install a repair in accor- dance with Paragraph 3.B., Work Instructions, PART 5. All cracks found are less than 3.0 inch long.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 22 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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)**  **Action Condition** 

- Before further flight. Install a repair in accor- 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)**  **Action Condition** 

- Within 1,500flight-cycles after the original issue date onthis service bulletin. Before 10,000total 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 inaccordance with Paragraph 3.B., Work Instructions, PART 2. All airplanes.

AND Measure the edge marginat certain fastener locations at the aft upper corner of the cutout for rightMain Entry Door 5 in accordance with Paragraph 3.B., Work Instructions, PART 2.

- Before further flight. Contact Boeing with de-tails of the installed repair. Do inspections orchange the repair in accordance with the Boeing instructions. Any door cutout where a repair is found.

- Before further flight. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 4. If no repair is found, and if the measured edge marginat any affected fastener location is less than 0.70 inch.

- Within 1,500flight-cycles after the original issue date onthis service bulletin. Before 18,000total flight-cycles. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 4. If no repair is found, and if the measured edge marginat all affected fastener locations is 0.70 inch or greater.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 23 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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) Action**  **Condition**

- Before further flight. Install a preventive modi- fication in accordance with Paragraph 3.B., Work Instructions, PART 5. No crack found, and the measured edge margin atany affected fastener location is less than 0.70 inch.OR 3,000 flight-cycles Within 3,000 flight-cycles of theprevious inspection done in accordance with Paragraph 3.B., Work Instructions, PART 4. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 4. AND

- Within 6,000flight-cycles after the original issue date onthis service bulletin. Before 20,000total flight-cycles.Install a preventive modification in accordance with Paragraph 3.B., Work Instructions, PART 5.

- Before further flight. Install a preventive modi- fication in accordance with Paragraph 3.B., Work Instructions, PART 5. No crack found, and the measured edge margin atall affected fastener locations is 0.70 inch or greater. OR 3,000 flight-cycles Within 3,000 flight-cycles of theprevious inspection done in accordance with Paragraph 3.B., Work Instructions, PART 4. Do detailed, open-hole HFEC and surface HFEC inspections for cracks inaccordance with Paragraph 3.B., Work Instructions, PART 4. AND

- Within 1,500flight-cycles after the original issue date onthis service bulletin. Before 35,000total flight-cycles.Install a preventive modification in accordance with Paragraph 3.B., Work Instructions, PART 5.

- Before further flight. Install a repair in accor- dance with Paragraph 3.B., Work Instructions, PART 5. All cracks found are less than 3.0 inch long.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 24 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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) Action**  **Condition**

- Before further flight. Install a repair in accor- 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) Action**  **Condition**

- 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 withParagraph 3.B., Work Instructions, PART 7. Any Main Entry Door 5 aft upper corner modified or repaired in accordance withParagraph 3.B., Work Instructions, PART 5 or PART 6.

- Before further flight. Contact Boeing for repair instructions and do the repair.Cracks found during postrepair/post-modification inspections in accordance with Paragraph 3.B., Work Instructions, PART 7. 3,000 flight-cycles Within 3,000 flight-cycles of theprevious 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 withParagraph 3.B., Work Instructions, PART 7. No crack found duringpost-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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 25 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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 Elapsed Hours**  **Task Hours Number of Persons**  **Task** 0.25 0.25 1 Inspect left side forexisting repair - FIGURE 1 0.25 0.25 1 Inspect right side forexisting repair - FIGURE 3 0.25 0.25 1 Measure left sideedge margin - FIGURE 2

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 26 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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**  **Elapsed Hours Task Hours**  **Number of Persons Task**  0.25 0.25 1 Measure right sideedge margin - FIGURE 4 1.00 1.00 TOTAL FOR EACH AIRPLANE **Group 3, 5: Table 2 - Left Main Entry Door 5 Cutout Upper Aft Corner Inspection for Existing Repairs**  **and Edge Margin Measurement Elapsed Hours**  **Task Hours Number of Persons**  **Task** 0.25 0.25 1 Inspect left side forexisting repair - FIGURE 1 0.25 0.25 1 Measure left sideedge margin - FIGURE 2 0.50 0.50 TOTAL FOR EACH AIRPLANE **Group 1-2, 4: Table 3 - Inspection and Repair or Preventive Modification** **Elapsed Hours Task Hours**  **Number of Persons Task**  1.50 3.00 2 Open Access 5.25 5.25 1 Inspect left side - FIGURE 5 5.25 5.25 1 Inspect right side - FIGURE 6 4.80 9.60 2 Left side repair orpreventive modification (Paragraph 3.B., Work Instructions, PART 5) 4.80 9.60 2 Right side repair orpreventive modification (Paragraph 3.B., Work Instructions, PART 5) 1.50 3.00 2 Close Access 23.10 35.70 TOTAL FOR EACH AIRPLANE

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 27 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Group 3, 5:**  **Table 4 - Inspection and Repair or Preventive modification Elapsed Hours**  **Task Hours Number of Persons**  **Task** 1.50 3.00 2 Open Access 5.25 5.25 1 Inspect left side - FIGURE 5 4.80 9.60 2 Left side repair orpreventive modification (Paragraph 3.B., Work Instructions, PART 5) 1.50 3.00 2 Close Access 13.05 20.85 TOTAL FOR EACH AIRPLANE **Group 1-2, 4: Table 5 - Post-Repair/Post-Modification Inspection**  **Elapsed Hours Task Hours**  **Number of Persons Task**  0.10 0.10 1 Open Access 16.50 33.00 2 Inspect left and right side - FIGURE 7 0.10 0.10 1 Close Access 16.70 33.20 TOTAL FOR EACH AIRPLANE **Group 3, 5: Table 6 - Post-Repair/Post-Modification Inspection**  **Elapsed Hours Task Hours**  **Number of Persons Task**  0.10 0.10 1 Open Access 8.25 16.50 2 Inspect left side only - FIGURE 7 0.10 0.10 1 Close Access 8.45 16.70 TOTAL FOR EACH AIRPLANE
**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**  **(Pounds) Airplane**  +132935.5 +58.2 Group 1

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 28 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane**  +132935.5 +58.2 Group 2 +66467.7 +29.1 Group 3 +132935.5 +58.2 Group 4 +65709.7 +28.8 Group 5
**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:
**ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- - 1 Kit - Aft Upper Corner Repair, Main Entry Door #5 675U0001

- - 2

- - 3

- - 4

- - 5

- - 6

- - 7

- - 8

- - DL

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 29 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**3. Installation Drawings Used in the Preparation of this Service Bulletin
**Title Drawing Number** Skin Panel Instl - STA 2181.1 to STA 2360 S-12 thru S-19 65B04157 Strap Installation - No. 5 Entry Door 65B04850 Reveal Instl - Upper & Lower No. 5 Main Entry Door 65B04856 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: **Chapter-Section Publication**  747 Aircraft Maintenance Manual 747 Corrosion Prevention Manual 747 Fault Reporting Manual 747 Fault Isolation Manual 747 Structural Repair Manual 53-12 747 Illustrated Parts Catalog 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 30 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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 origi nal issue date of this Ser**  **vice Bulletin (US Dollars) ROLT as of the original**  **issue date of this Service Bulletin (Calendar Days)**  **Name Kit Number** 

$16,336 (a) Top Kit - Door 5 Cutout Aft Upper Corner Small Repair - Group 1 015U1914-1

$17,426 (a) Top Kit - Door 5 Cutout Aft Upper Corner Small Repair - Group 2 015U1914-2

$8,713 (a) Top Kit - Door 5 Cutout Aft Upper Corner Small Repair - Group 3 015U1914-3

$16,362 (a) Top Kit - Door 5 Cutout Aft Upper Corner Small Repair - Group 4 015U1914-4

$7,731 (a) Top Kit - Door 5 Cutout Aft Upper Corner Small Repair - Group 5 015U1914-5

$16,016 (a) Top Kit - Door 5 Cutout Aft Upper Corner Large Repair - Group 1 015U1914-11

$17,130 (a) Top Kit - Door 5 Cutout Aft Upper Corner Large Repair - Group 2 015U1914-12

$8,565 (a) Top Kit - Door 5 Cutout Aft Upper Corner Large Repair - Group 3 015U1914-13

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 31 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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 origi** **nal issue date of this Ser vice Bulletin (US Dollars)**  **ROLT as of the original issue date of this Service**  **Bulletin (Calendar Days) Name**  **Kit Number**

$15,890 (a) Top Kit - Door 5 Cutout Aft Upper Corner Large Repair - Group 4 015U1914-14

$7,654 (a) Top Kit - Door 5 Cutout Aft 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 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -5**  **-4 -3**  **-2 -1**  Top Kit - Door 5 Cutout Aft UpperCorner Small Repair - Group 1 . . . . - 015U1914-1

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 32 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 015U1914**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-5 -4**  **-3 -2**  **-1** Top Kit - Door 5 Cutout Aft UpperCorner Small Repair - Group 2 . . . - . 015U1914-2

Top Kit - Door 5 Cutout Aft UpperCorner Small Repair - Group 3 . . - . . 015U1914-3

Top Kit - Door 5 Cutout Aft UpperCorner Small Repair - Group 4 . - . . . 015U1914-4

Top Kit - Door 5 Cutout Aft UpperCorner Small Repair - Group 5 - . . . . 015U1914-5

KIT

. . . . 1 675U0001-1 KIT

. . . . 1 675U0001-2 KIT

. . 1 1

. 675U0001-3 KIT

. . . 1

. 675U0001-4 KIT

. 1

. . . 675U0001-5 KIT

. 1

. . . 675U0001-6 KIT 1

. . . . 675U0001-7
**Kit 015U1914 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -15**  **-14 -13**  **-12 -11**  Top Kit - Door 5 Cutout Aft UpperCorner Large Repair - Group 1 . . . . - 015U1914-11

Top Kit - Door 5 Cutout Aft UpperCorner Large Repair - Group 2 . . . - . 015U1914-12

Top Kit - Door 5 Cutout Aft UpperCorner Large Repair - Group 3 . . - . . 015U1914-13

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 33 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 015U1914**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-15 -14**  **-13 -12**  **-11** Top Kit - Door 5 Cutout Aft UpperCorner Large Repair - Group 4 . - . . . 015U1914-14

Top Kit - Door 5 Cutout Aft UpperCorner Large Repair - Group 5 - . . . . 015U1914-15

KIT

. . . . 1 675U0001-10 KIT

. . 1 1

. 675U0001-11 KIT

. . . 1

. 675U0001-12 KIT

. 1

. . . 675U0001-13 KIT

. 1

. . . 675U0001-14 KIT 1

. . . . 675U0001-15 KIT

. . . . 1 675U0001-9
**Kit 675U0001 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -4**  **-3 -2**  **-1** KIT

. . . - 675U0001-1 KIT

. . - . 675U0001-2 KIT

. - . . 675U0001-3 KIT

- . . . 675U0001-4 UPR AFT DEPRESSOR . 1

. 1 65B04856-25
UPR AFT DEPRESSOR 1

. 1

. 65B04856-26
UPR AFT DEPRESSOR . 1

. 1 65B04856-27
UPR AFT DEPRESSOR 1

. 1

. 65B04856-28
SHIM 1 1 1 1 65B04856-31 DOUBLER

. 1

. 1 675U0002-1 FILLER

. 1

. 1 675U0002-13 FILLER 1

. 1

. 675U0002-14

BOEING PROPRIETARY - 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**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-4 -3**  **-2 -1**  DOUBLER 1

. 1

. 675U0002-2 TRIPLER

. 1

. 1 675U0002-3 TRIPLER 1

. 1

. 675U0002-4 QUADRUPLER

. 1

. 1 675U0002-5 QUADRUPLER 1

. 1

. 675U0002-6 BOLT 1 1 1 1 BACB30MY5K3 BOLT 1 1 1 1 BACB30MY5K8 BOLT 2 2 2 2 BACB30MY8K7 BOLT 17 17 11 11 BACB30NW6K10X BOLT 8 8

. . BACB30NW6K10Y BOLT 15 15 13 13 BACB30NW6K11X BOLT 41 41 41 41 BACB30NW6K12X BOLT 1 1 1 1 BACB30NW6K13X BOLT 1 1 1 1 BACB30NW6K14X BOLT 2 2 3 3 BACB30NW6K5X BOLT 2 2 1 1 BACB30NW6K5Y BOLT 4 4 2 2 BACB30NW6K6X BOLT 30 30 11 11 BACB30NW6K7X BOLT 5 5 5 5 BACB30NW6K8 BOLT 1 1 20 20 BACB30NW6K8X BOLT 18 18

. . BACB30NW6K8Y BOLT 14 14 12 12 BACB30NW6K9X BOLT 2 2

. . BACB30NW8K10Y BOLT 3 3 3 3 BACB30NW8K11X BOLT 20 20 18 18 BACB30NW8K12X BOLT 6 6 4 4 BACB30NW8K13X BOLT 2 2 2 2 BACB30NW8K14X BOLT 7 7 6 6 BACB30NW8K15X BOLT 8 8 8 8 BACB30NW8K16X BOLT 7 7 7 7 BACB30NW8K17X BOLT 22 22 22 22 BACB30NW8K3

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 35 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-4 -3**  **-2 -1**  BOLT 74 74 74 74 BACB30NW8K4 BOLT 9 9 9 9 BACB30NW8K5 BOLT 36 36 42 42 BACB30NW8K6 BOLT 6 6

. . BACB30NW8K6Y BOLT 7 7 24 24 BACB30NW8K7 BOLT

. . 2 2 BACB30NW8K8 BOLT 4 4 4 4 BACB30NW8K8X BOLT 2 2

. . BACB30NW8K8Y BOLT 3 3 75 75 BACB30NW8K9 BOLT 8 8 4 4 BACB30NW8K9X BOLT 66 66

. . BACB30NW8K9Y COLLAR 2 2 2 2 BACC30M5 COLLAR 120 120 130 130 BACC30M6 COLLAR 247 247 317 317 BACC30M8 COLLAR 33 33 1 1 BACC30R6 COLLAR 77 77

. . BACC30R8 FILLER 1 1 1 1 BACF3F011M030NF FILLER 1 1 1 1 BACF3F011M042NF FILLER 1 1 1 1 BACF3F023M024NF FILLER 1 1 1 1 BACF3F023M036NF FILLER 1 1 1 1 BACF3F065X069NN RIVET 2 2 2 2 BACR15BB5D5C RIVET 1 1 1 1 BACR15BB5D7C RIVET 1 1 1 1 BACR15BB5D9C RIVET 2 2 2 2 BACR15BB8D12C RIVET 1 1 1 1 BACR15GF6D9 SHIM 1 1 1 1 BACS40R010E010F SHIM 1 1 1 1 BACS40R065E069F WASHER, SELFALIGN 30 30 21 21 BACW10CA104CC WASHER, SELFALIGN 30 30 21 21 BACW10CA31PV

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 36 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-4 -3**  **-2 -1**  WASHER, SELFALIGNING 15 15 12 12 BACW10CA41PV
WASHER 15 15 12 12 BACW10CA5CC RIVET 7 7 7 7 MS20615-6MP13 RIVET 4 4 4 4 MS20615-6MP18 RIVET 1 1 1 1 MS20615-8MP14 RIVET 1 1 1 1 MS20615-8MP15
**Kit 675U0001 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -7**  **-6 -5**  KIT

. . - 675U0001-5 KIT

. - . 675U0001-6 KIT

- . . 675U0001-7 UPR AFT DEPRESSOR 1

. 1 65B04856-25
UPR AFT DEPRESSOR . 1

. 65B04856-26
UPR AFT DEPRESSOR 1

. 1 65B04856-27
UPR AFT DEPRESSOR . 1

. 65B04856-28
SHIM 1 1 1 65B04856-31 DOUBLER 1

. 1 675U0002-1 FILLER

. . 1 675U0002-13 FILLER

. 1

. 675U0002-14 DOUBLER

. 1

. 675U0002-2 TRIPLER 1

. 1 675U0002-3 TRIPLER

. 1

. 675U0002-4 QUADRUPLER 1

. 1 675U0002-5 QUADRUPLER

. 1

. 675U0002-6 BOLT

. 1 1 BACB30MY5K3 BOLT

. 1 1 BACB30MY5K8

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 37 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-7 -6**  **-5** BOLT

. 2 2 BACB30MY8K7 BOLT 14 9 9 BACB30NW6K10X BOLT

. 8 8 BACB30NW6K10Y BOLT 12 12 12 BACB30NW6K11X BOLT 38 27 27 BACB30NW6K12X BOLT

. 4 4 BACB30NW6K15X BOLT 4 4 4 BACB30NW6K5X BOLT 2 1 1 BACB30NW6K5Y BOLT 4 6 6 BACB30NW6K6X BOLT 1 2 2 BACB30NW6K6Y BOLT 9 9 9 BACB30NW6K7X BOLT 5 5 5 BACB30NW6K8 BOLT 17 18 18 BACB30NW6K8Y BOLT 11 11 11 BACB30NW6K9X BOLT

. 2 2 BACB30NW8K10Y BOLT 3 3 3 BACB30NW8K11X BOLT 20 20 20 BACB30NW8K12X BOLT 4 4 4 BACB30NW8K13X BOLT 2 2 2 BACB30NW8K14X BOLT 7 7 7 BACB30NW8K15X BOLT 8 8 8 BACB30NW8K16X BOLT 7 7 7 BACB30NW8K17X BOLT 22 22 22 BACB30NW8K3 BOLT 79 74 74 BACB30NW8K4 BOLT 9 9 9 BACB30NW8K5 BOLT 37 36 36 BACB30NW8K6 BOLT 8 6 6 BACB30NW8K6Y BOLT 21 24 24 BACB30NW8K7 BOLT 4 4 4 BACB30NW8K8X BOLT 3 2 2 BACB30NW8K8Y BOLT 3 3 3 BACB30NW8K9

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 38 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-7 -6**  **-5** BOLT 4 4 4 BACB30NW8K9X BOLT 68 68 68 BACB30NW8K9Y COLLAR

. 2 2 BACC30M5 COLLAR 103 106 106 BACC30M6 COLLAR 240 240 240 BACC30M8 COLLAR 20 32 32 BACC30R6 COLLAR 80 79 79 BACC30R8 FILLER

. 1 1 BACF3F011M030NF FILLER

. 1 1 BACF3F011M042NF FILLER

. 1 1 BACF3F023M024NF FILLER

. 1 1 BACF3F023M036NF FILLER 1 1 1 BACF3F065X069NN RIVET

. 2 2 BACR15BB5D5C RIVET

. 1 1 BACR15BB5D7C RIVET

. 1 1 BACR15BB5D9C RIVET 2 2 2 BACR15BB8D12C RIVET 1 1 1 BACR15GF6D9 SHIM 1 1 1 BACS40R010E010F SHIM 1 1 1 BACS40R065E069F WASHER, SELFALIGN 13 13 13 BACW10CA104CC WASHER, SELFALIGN 13 13 13 BACW10CA31PV WASHER, SELFALIGNING 15 15 15 BACW10CA41PV
WASHER 15 15 15 BACW10CA5CC RIVET 7 7 7 MS20615-6MP13 RIVET 4 4 4 MS20615-6MP18 RIVET 1 1 1 MS20615-8MP14 RIVET 1 1 1 MS20615-8MP15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 39 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-12 -11**  **-10 -9**  KIT

. . - . 675U0001-10 KIT

. - . . 675U0001-11 KIT

- . . . 675U0001-12 KIT

. . . - 675U0001-9 UPR AFT DEPRESSOR . 1

. 1 65B04856-25
UPR AFT DEPRESSOR 1

. 1

. 65B04856-26
UPR AFT DEPRESSOR . 1

. 1 65B04856-27
UPR AFT DEPRESSOR 1

. 1

. 65B04856-28
SHIM 1 1 1 1 65B04856-31 TRIPLER 1

. 1

. 675U0002-10 QUADRUPLER

. 1

. 1 675U0002-11 QUADRUPLER 1

. 1

. 675U0002-12 FILLER

. 1

. 1 675U0002-13 FILLER 1

. 1

. 675U0002-14 DOUBLER

. 1

. 1 675U0002-7 DOUBLER 1

. 1

. 675U0002-8 TRIPLER

. 1

. 1 675U0002-9 BOLT 1 1 1 1 BACB30MY5K3 BOLT 1 1 1 1 BACB30MY5K8 BOLT 2 2 2 2 BACB30MY8K7 BOLT 19 19 13 13 BACB30NW6K10X BOLT 8 8

. . BACB30NW6K10Y BOLT 16 16 14 14 BACB30NW6K11X BOLT 48 48 48 48 BACB30NW6K12X BOLT 1 1 1 1 BACB30NW6K13X BOLT 1 1 1 1 BACB30NW6K14X BOLT 4 4

. . BACB30NW6K4Y BOLT 3 3 3 3 BACB30NW6K5X

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 40 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-12 -11**  **-10 -9**  BOLT 8 8 7 7 BACB30NW6K5Y BOLT 8 8 2 2 BACB30NW6K6X BOLT 4 4

. . BACB30NW6K6Y BOLT 13 13 13 13 BACB30NW6K7X BOLT 1 1

. . BACB30NW6K7Y BOLT 4 4 4 4 BACB30NW6K8 BOLT

. . 19 19 BACB30NW6K8X BOLT 18 18

. . BACB30NW6K8Y BOLT 16 16 14 14 BACB30NW6K9X BOLT 2 2

. . BACB30NW8K10Y BOLT 3 3 3 3 BACB30NW8K11X BOLT 20 20 18 18 BACB30NW8K12X BOLT 6 6 4 4 BACB30NW8K13X BOLT 2 2 2 2 BACB30NW8K14X BOLT 7 7 6 6 BACB30NW8K15X BOLT 8 8 8 8 BACB30NW8K16X BOLT 7 7 7 7 BACB30NW8K17X BOLT 22 22 22 22 BACB30NW8K3 BOLT 84 84 83 83 BACB30NW8K4 BOLT 21 21 21 21 BACB30NW8K5 BOLT 90 90 94 94 BACB30NW8K6 BOLT

. . 2 2 BACB30NW8K6X BOLT 6 6

. . BACB30NW8K6Y BOLT 24 24 24 24 BACB30NW8K7 BOLT

. . 2 2 BACB30NW8K8 BOLT 4 4 4 4 BACB30NW8K8X BOLT 2 2

. . BACB30NW8K8Y BOLT 3 3 74 74 BACB30NW8K9 BOLT 4 4 4 4 BACB30NW8K9X BOLT 70 70

. . BACB30NW8K9Y COLLAR 2 2 2 2 BACC30M5

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 41 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-12 -11**  **-10 -9**  COLLAR 139 139 142 142 BACC30M6 COLLAR 319 319 392 392 BACC30M8 COLLAR 48 48 7 7 BACC30R6 COLLAR 81 81

. . BACC30R8 FILLER 1 1 1 1 BACF3F023M024NF FILLER 1 1 1 1 BACF3F023M036NF FILLER 1 1 1 1 BACF3F069X078NN RIVET 2 2 2 2 BACR15BB5D5C RIVET 1 1 1 1 BACR15BB5D7C RIVET 1 1 1 1 BACR15BB5D9C RIVET 2 2 2 2 BACR15BB8D12C RIVET 1 1 1 1 BACR15GF6D9 SHIM 1 1 1 1 BACS40R010E010F SHIM 1 1 1 1 BACS40R069E078F WASHER, SELFALIGN 33 33 24 24 BACW10CA104CC WASHER, SELFALIGN 33 33 24 24 BACW10CA31PV WASHER, SELFALIGNING 15 15 12 12 BACW10CA41PV
WASHER 15 15 12 12 BACW10CA5CC RIVET 7 7 7 7 MS20615-6MP13 RIVET 4 4 4 4 MS20615-6MP18 RIVET 1 1 1 1 MS20615-8MP14 RIVET 1 1 1 1 MS20615-8MP15
**Kit 675U0001 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -15**  **-14 -13**  KIT

. . - 675U0001-13 KIT

. - . 675U0001-14 KIT

- . . 675U0001-15

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 42 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-15 -14**  **-13** UPR AFT DEPRESSOR 1

. 1 65B04856-25
UPR AFT DEPRESSOR . 1

. 65B04856-26
UPR AFT DEPRESSOR 1

. 1 65B04856-27
UPR AFT DEPRESSOR . 1

. 65B04856-28
SHIM 1 1 1 65B04856-31 TRIPLER

. 1

. 675U0002-10 QUADRUPLER 1

. 1 675U0002-11 QUADRUPLER

. 1

. 675U0002-12 FILLER

. . 1 675U0002-13 FILLER

. 1

. 675U0002-14 DOUBLER 1

. 1 675U0002-7 DOUBLER

. 1

. 675U0002-8 TRIPLER 1

. 1 675U0002-9 BOLT

. 1 1 BACB30MY5K3 BOLT

. 1 1 BACB30MY5K8 BOLT

. 2 2 BACB30MY8K7 BOLT 13 9 9 BACB30NW6K10X BOLT

. 8 8 BACB30NW6K10Y BOLT 13 12 12 BACB30NW6K11X BOLT 44 44 44 BACB30NW6K12X BOLT

. 4 4 BACB30NW6K15X BOLT

. 4 4 BACB30NW6K4Y BOLT 4 4 4 BACB30NW6K5X BOLT 7 7 7 BACB30NW6K5Y BOLT 3 5 5 BACB30NW6K6X BOLT

. 6 6 BACB30NW6K6Y BOLT 14 14 14 BACB30NW6K7X BOLT

. 1 1 BACB30NW6K7Y

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 43 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-15 -14**  **-13** BOLT 4 4 4 BACB30NW6K8 BOLT 3 3 3 BACB30NW6K8X BOLT 18 18 18 BACB30NW6K8Y BOLT 11 11 11 BACB30NW6K9X BOLT

. 2 2 BACB30NW8K10Y BOLT 3 3 3 BACB30NW8K11X BOLT 20 20 20 BACB30NW8K12X BOLT 4 4 4 BACB30NW8K13X BOLT 2 2 2 BACB30NW8K14X BOLT 7 7 7 BACB30NW8K15X BOLT 8 8 8 BACB30NW8K16X BOLT 7 7 7 BACB30NW8K17X BOLT 22 22 22 BACB30NW8K3 BOLT 85 81 81 BACB30NW8K4 BOLT 21 21 21 BACB30NW8K5 BOLT 93 90 90 BACB30NW8K6 BOLT 8 6 6 BACB30NW8K6Y BOLT 21 24 24 BACB30NW8K7 BOLT 4 4 4 BACB30NW8K8X BOLT 3 2 2 BACB30NW8K8Y BOLT 3 3 3 BACB30NW8K9 BOLT 4 4 4 BACB30NW8K9X BOLT 66 68 68 BACB30NW8K9Y COLLAR

. 2 2 BACC30M5 COLLAR 116 119 119 BACC30M6 COLLAR 316 318 318 BACC30M8 COLLAR 28 44 44 BACC30R6 COLLAR 79 79 79 BACC30R8 FILLER

. 1 1 BACF3F023M024NF FILLER

. 1 1 BACF3F023M036NF FILLER 1 1 1 BACF3F069X078NN

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 44 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT Kit 675U0001**  **Notes Existing Part**  **Number Name**  **QTY New Part Number**  **-15 -14**  **-13** RIVET

. 2 2 BACR15BB5D5C RIVET

. 1 1 BACR15BB5D7C RIVET

. 1 1 BACR15BB5D9C RIVET 2 2 2 BACR15BB8D12C RIVET 1 1 1 BACR15GF6D9 SHIM 1 1 1 BACS40R010E010F SHIM 1 1 1 BACS40R069E078F WASHER, SELFALIGN 13 13 13 BACW10CA104CC WASHER, SELFALIGN 13 13 13 BACW10CA31PV WASHER, SELFALIGNING 15 15 15 BACW10CA41PV
WASHER 15 15 15 BACW10CA5CC RIVET, SOLID 7 7 7 MS20615-6MP13 RIVET, SOLID 4 4 4 MS20615-6MP18 RIVET, SOLID 1 1 1 MS20615-8MP14 RIVET, SOLID 1 1 1 MS20615-8MP15 2. Parts and Materials Supplied by the Operator
**Notes Name**  **QTY Part Number /**  **Specification** 4 to 10 necessary, depending on airplane group andseal depressor configuration, for each open-hole HFEC inspection done in accordance with FIGURE 5 and/or FIGURE 6. (b) Rivet 4 - 10 BACR15CE6D8

(a) Sealant 1 pint BMS 5-95 (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 45 of 76 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 46 of 76 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 47 of 76 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 48 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 49 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**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:**Right Side Left Side**  **Group** 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).
**Trim Detail Location Drawing**  **Group** View 1D13 in Zone B28 Drawing 675U0001, Sheet 1 1 View 1D13 in Zone E27 Drawing 675U0001, Sheet 2 2, 3 View 2D13 in Zone B27 Drawing 675U0001, Sheet 3 4 View 1D13 in Zone B28 Drawing 675U0001, Sheet 4 5 d. Install seal depressors and a doubler, tripler and a quadrupler, and reinstall the gutter in accordance with the applicable Boeing drawings.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 50 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**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:**Right Side Left Side**  **Group** 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.
**Trim Detail Location Drawing**  **Group** View 1D14 in Zone B28 Drawing 675U0001, Sheet 5 1 View 1D13 in Zone E27 Drawing 675U0001, Sheet 6 2, 3 View 3D13 in Zone B27 Drawing 675U0001, Sheet 7 4 View 1D14 in Zone B28 Drawing 675U0001, Sheet 8 5

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 51 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 52 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 53 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 54 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.
**More Data Qty**  **Identification Name**  **Task Step**  Do a detailed Inspection at the aft upper corner of the door 5 cutout, for any repair installed in the area shown. (a) - - Fuselage Skin Inspect 1

(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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 55 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT FIGURE 2: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY**  **DOOR 5 CUTOUT (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 56 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT FIGURE 2: EDGE MARGIN MEASUREMENT AT THE AFT UPPER CORNER OF THE LEFT MAIN ENTRY**  **DOOR 5 CUTOUT (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 57 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.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Fastener Edge Margin Measure 1 (a)

- - Fastener Edge Margin Record (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 58 of 76 **BOEING SERVICE BULLETIN 747-53A2839 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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 59 of 76 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 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.
**More Data Qty**  **Identification Name**  **Task Step**  Do a detailed Inspection at the aft upper corner of the door 5 cutout, for any repair installed in the area shown. (a) - - Fuselage Skin Inspect 1

(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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 61 of 76 **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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 62 of 76 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 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.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Fastener Edge Margin Measure 1 (a)

- - Fastener Edge Margin Record (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 64 of 76 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 65 of 76 **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 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 66 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.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Door Corner Structure Inspect 1 Four or five locations at each door cutout, depending on sealdepressor configuration. - - Rivet Remove 2

(b)

- - Fuselage Skin Assem- bly and Bear Strap Inspect
Four or five locations at each door cutout,depending on existing seal depressor configuration. (c) - BACR15CE6D8 Rivet Install (New)

(d)

- - Fuselage Skin Assem- bly Inspect 3 (d)

- - Bear Strap Inspect (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 67 of 76 **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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 68 of 76 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 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.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Door Corner Structure Inspect 1 Four or five locations at each door cutout, depending on sealdepressor configuration. - - Rivet Remove 2

(b)

- - Fuselage Skin Assem- bly and Bear Strap Inspect
Four or five locations at each door cutout, depending on sealdepressor configuration. (c) - BACR15CE6D8 Rivet Install (New)

(d)

- - Fuselage Skin Assem- bly Inspect 3 (d)

- - Bear Strap Inspect (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 70 of 76 **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 1 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 71 of 76 **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 72 of 76 **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 3 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 73 of 76 **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 4 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 74 of 76 **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 5 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 75 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.
**More Data Qty**  **Identification Name**  **Task Step**  (a)

- - Repaired or Modified Area Inspect 1 (b)

- - Fuselage Skin Inspect 2 (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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 06, 2012 747-53A2839 76 of 76 **BOEING SERVICE BULLETIN 747-53A2839 ALERT**  **ALERT**