# Boeing Alert Service Bulletin 747-53A2450: Boeing - Service Bulletin - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2013-0097; AD 2013-17-08 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-53A2450](https://openairdocs.org/service-documents/boeing/747-53a2450.md) - Title as filed: Boeing - Service Bulletin - Pages: 97 - PDF: https://openairdocs.org/files/sha256/49/bb/49bb1b7771478440a115d9df15c751c5078e3c72b59bc2cfee1adf417b48f695 - Page: https://openairdocs.org/service-documents/boeing/747-53a2450/file/49bb1b777147 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2450 Original Issue: May 04, 2000 Revision 7: November 02, 2011 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inspection - Stringers 15 Through 31 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all export laws. 9E991ECCN: BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2000 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: May 04, 2000 747-53A2450Revision 7: November 02, 2011 1 of 97 4.0 ### Page 2 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 2 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 Summary ...................................................... 7 1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1 1. Airplanes ............................................ 1 1 2. Spares Affected ........................................ 2 1 B. Concurrent Requirements ...................................... 2 1 C. Reason ................................................ 2 1 D. Description .............................................. 2 5 E. Compliance .............................................. 2 6 F. Approval ............................................... 2 9 G. Manpower .............................................. 3 0 H. Weight and Balance Changes .................................... 3 1 I. Electrical Load Data ......................................... 3 1 J. References .............................................. 3 1 1. Existing Data: ......................................... 3 1 2. Data supplied with this Service Bulletin: ........................... 3 2 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 2 K. Publications Affected ........................................ 3 2 L. Interchangeability and Intermixability of Parts ........................... 3 2 2. MATERIAL INFORMATION ........................................ 3 3 A. Material - Price and Availability ................................... 3 3 B. Industry Support Information .................................... 3 5 C. Parts Necessary For Each Airplane ................................. 3 5 1. Kits/Parts: ........................................... 3 5 2. Parts and Materials Supplied by the Operator: ........................ 4 0 3. Parts Modified and Reidentified: ............................... 4 3 4. Parts Removed and Not Replaced: .............................. 4 3 D. Parts Necessary to Change Spares ................................. 4 3 E. Special Tooling - Price and Availability ............................... 4 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 4 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5 A. GENERAL INFORMATION ..................................... 4 5 B. WORK INSTRUCTIONS ....................................... 4 6 FIGURE 1: DELETED ............................................ 4 8 FIGURE 2: ACCESS / RESTORATION FOR CONFIGURATION WITH PASSENGERS IN THE AFT BODY .................................................. 4 9 FIGURE 3: ACCESS / RESTORATION FOR CONFIGURATION WITH CARGO IN THE AFT BODY . 51 FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION .............. 5 3 FIGURE 5: INSPECTION - GROUP 1 AND GROUP 3 .......................... 6 0 FIGURE 6: INSPECTION - GROUP 2 AND GROUP 4 .......................... 7 4 FIGURE 7: FASTENER INSTALLATION .................................. 8 8 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 3 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 4 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT BLANK PAGE ### Page 5 Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2450Original Issue: May 04, 2000 Revision 7: November 02, 2011 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inspection - Stringers 15 Through 31 This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2, Revision 3, Revision 4, Revision 5 or Revision 6 of this service bulletin. Continue repeat inspections in accordance with Revision 7 of this service bulletin. Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2009-18-07, AD 2010-01-01 and AD 2010-20-08 are related to this service bulletin. REASON FOR REVISION This revision is sent to add High Frequency Eddy Current inspection of the aft edge of the STA 2231 Frame Aft Inner Chord, of the forward edge of the STA 2231 Frame Forward Inner Chord and of the forward and aft edges of the STA 2231 Frame Strap. This revision is also sent to extend the existing inspection area to include the STA 2231 Frame between stringers 15 and 16. Instructions are added to remove and reinstall a fitting to give access to a trapped fastener location and to add alternative inspections for airplanes with SRM repairs installed. Airplanes RM128, RT456, RT461, RT501, RT506-RT510, RT513, RT516, RT518-RT520, RT524, RT528, RT572, RT573-RT579, RT642, RT655-RT657, RT751, RT752, RT781, RT782, RT837, RT967 are moved from group 2 to group 4. These airplanes have been converted to Boeing Converted Freighter airplanes. These sections were changed: 1. Paragraph 1.A. Effectivity: Airplanes RM128, RT456, RT461, RT501, RT506-RT510, RT513, RT516, RT518-RT520, RT524, RT528, RT572, RT573-RT579, RT642, RT655-RT657, RT751, RT752, RT781, RT782, RT837, RT967 are moved from group 2 to group 4. 2. Paragraph 1.C., Reason: Revision information is added. 3. Paragraph 1.D., Description: Revision information is added. 4. Paragraph 1.E., Compliance: New inspection requirements are added. Post repair inspections are clarified. 5. Paragraph 1.F., Approval: New approval information is added. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 5 of 97 ### Page 6 6. Paragraph 1.G., Manpower: Manpower estimates are updated. 7. Paragraph 1.J., References: References are added to 'Existing Data'. A drawing is added to 'Installation Drawings Used in the Preparation of this Service Bulletin'. 8. Paragraph 2.A. Material - Price and Availability: Price and availability data is updated. New kits are added. 9. Paragraph 2.C.1., Kits/Parts: Two new top kits and a supplemental are added. 10. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: New fasteners are added. 11. Paragraph 3.A., General Information: Notes are added. 12. Paragraph 3.B., Work Instructions: Steps are added to remove and reinstall access panels. Steps are added to give the new inspection requirements. Instruction for repeat inspection is clarified. 13. Figure 3: Insulation blanket removal is clarified. 14. Figure 4: Instructions are added to remove fitting to give access to trapped fastener location. Fastener removal locations are added. 15. Figures 5 and 6: HFEC inspection of the aft edge of the STA 2231 Frame Aft Inner Chord, of the forward edge of the STA 2231 Frame Forward Inner Chord and of the forward and aft edges of the STA2231 Frame Strap is added. Outer reveal panel removal step is deleted. Inspection area is increased up to stringer S-15 for some inspections. Alternative inspections are added for airplanes with SRM reveal repairs installed. 16. Figure 7: Instructions are added to reinstall fitting that was removed to give access to trapped fastener location. Fastener installation locations are added. Some fastener part numbers are changed. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. REVISION HISTORY May 04, 2000Original Issue: July 06, 2000Revision 1: January 04, 2001Revision 2: July 24, 2003Revision 3: October 09, 2003Revision 4: January 29, 2009Revision 5: August 26, 2010Revision 6: November 02, 2011Revision 7: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 6 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 7 Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2450Original Issue: May 04, 2000 Revision 7: November 02, 2011 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inspection - Stringers 15 Through 31 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 Accomplishment of this service bulletin will make sure that the body frame at station 2231 at stringers 15 through 31 does not have cracks which could cause damage to adjacent body structure which could result in rapid depressurization of the airplane. This frame is the forward edge frame for the number 5 main entry door opening. Frame cracks that are not found and repaired could extend with continued operation and fully cut the frame. If the frame becomes fully cut, skin cracks could occur which could cause a rapid depressurization of the airplane. Before the release of the original issue of this service bulletin, four operators reported cracks in the strap and inner chord angle at station 2231 frame. Refer to Paragraph 1.C., Reason, for additional service history. Between the release of Revision 1 and Revision 2, seven operators have reported cracks in the strap, reveal, and inner chord angle at station 2231 frame on thirteen airplanes. Refer to Paragraph 1.C., Reason, for details. Between the release of Revision 2 and Revision 7 of this service bulletin, there have been further reports of cracking in the station 2231 frame on 120 airplanes. Refer to Paragraph 1.C., Reason, for details. A structural reassessment of the 747 airplane was conducted under the requirements of Federal Aviation Administration (FAA) Advisory Circular 91-56, in accordance with Federal Aviation Regulation (FAR) 25.571 as amended in 1978, to ensure safe operation of 747 airplanes throughout their operational life. From this requirement, the main entry door forward edge frame at body station 2231 was determined to be significant, in that it is critical to airplane structural integrity. Therefore, a flight safety inspection program which will continue throughout the operational life of the airplane is specified in this service bulletin. Airplane line numbers 1305 and on were delivered with a redesigned Station 2231 Frame which has improved fatigue durability. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 7 of 97 ### Page 8 After the release of Revision 4 of this service bulletin, Boeing received several operator reports of cracks found in the left and right side Station 2231 frame inner chord and strap between stringers 16 and 22. The inspection area as given in Revision 4 of this service bulletin did not include the frame area above stringer 23. Based on these reports, additional Boeing analysis indicated that the Station 2231 frame design improvement which was implemented in production for airplane line numbers 1305 and on, was not sufficient to prevent cracking of the frame inner chord. Between the release of Revision 6 and Revision 7 of this service bulletin, Boeing received reports from operators of cracking found above stringer 17 at locations that were not in the inspection areas given in this service bulletin. Boeing also received a report for the first time of cracking that initiated at the aft edge of the inner chord rather than initiating at a fastener location. Boeing Structural Item Interim Advisory (SIIA) SIIA 747-93 is related to this service bulletin. Boeing Service Related Problem (SRP) 747-53-0364 is related to this service bulletin. ACTION Do a detailed inspection of the Station 2231 Frame Assembly at stringers 15 through 31. The strap, inner chord angles, and frame web are to be inspected for cracks. Also do High Frequency Eddy Current (HFEC) and Low Frequency Eddy Current Inspections of the Station 2231 Frame Assembly. Also do surface and open-hole HFEC inspections of the STA 2231 frame inner chord. If cracks are found, repair before next flight. Repair per SRM or contact Boeing for repair instructions. EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2009-18-07, AD 2010-01-01 and AD 2010-20-08 are related to this service bulletin. See Service Bulletin Paragraph 1.E. for compliance information. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection given in this service bulletin. MANPOWER Elapsed HoursTotal Task HoursAirplanes 32.00120.50Groups 1 and 2 32.00120.50Groups 3 and 4 (with two MED #5) 18.5068.50Groups 3 and 4 (with one MED #5) Refer to Paragraph 1.G., Manpower. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 8 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 9 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT MATERIAL INFORMATION None STA 2231 ACCESS • 5-151 MAIN UPPER - 5-16L SILL ACCESS → FWD • 5-171 NOTE: ACCESS IS FROM THE MAIN DECK - 5-18L AND FROM THE LOWER LOBE. DOOR 5 LEFT - 5-191 DOOR 5 RIGHT OPPOSITE INSPECTION AREA • S-20L - 5-211 - 5-221 DO A DETAILED INSPECTION - 5-23L FOR CRACKS ON THE STRAP, INNER CHORDS FORWARD AND AFT DOOR 5 LEFT 5-241 OF THE WEB AND EXPOSED WEB ADJACENT TO THE • 5-25L INNER CHORDS FROM STRINGER 15 THROUGH 31. ALSO DO HFEC AND LFEC 5-261 STATION 2231 FRAME ASSEMBLY INSPECTIONS FOR CRACKS ON MAIN DECK UP S-31L LOWER PER THIS SERVICE FLOOR MAIN BULLETIN. > FWD SILL V22507 Original Issue: May 04, 2000 Revision 7: November 02, 2011 747-53A2450 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 97 ### Page 10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 10 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT BLANK PAGE ### Page 11 Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2450 Original Issue: May 04, 2000 Revision 7: November 02, 2011 ATA System: 5312 SUBJECT: FUSELAGE - Section 46 - Body Station 2231 Frame Inspection - Stringers 15 Through 31 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 Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. DESCRIPTIONCONFIGURATIONGROUP 747-100/-200B Passenger Airplane Line Number 001-203.-1 747-100/-100B/-100B SUD/-200B/-300/-400/-400D/SR Passenger Airplanes Line Number 204-765, 767-777, 779-903, 905- 931, 933-1358. -2 747-200F Line Number 001-203.-3 747-200B/-200C/-200F/-300/-400/-400F Line Number 204-1419.-4 Airplane Models: 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SR BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 11 of 97 ### Page 12 GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 1RA245 - RA246 1RA251 - RA261 2RA262 - RA266 1RA301 - RA312 2RA313 - RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA414 2RA415 - RA418 1RA501 - RA502 1RA521 - RA527 2RA528 1RA532 - RA540 2RA541 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 - RA635 1RA651 - RA652 1RA671 - RA677 1RA701 - RA702 1RA721 - RA724 2RA725 - RA731 1RA741 - RA743 2RA744 - RA745 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 12 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 13 GroupVariable Number 4RA749 - RA750 1RA761 - RA762 1RA781 - RA782 2RA783 - RA784 1RA901 - RA916 1RB001 - RB005 2RB006 - RB012 1RB013 2RB014 - RB016 1RB041 - RB044 1RB071 - RB075 1RB101 - RB102 4RB411 - RB413 4RB421 2RB601 - RB607 2RB681 - RB697 2RB711 2RB721 - RB723 2RB741 - RB748 1RD001 - RD002 2RD003 - RD004 2RD021 - RD022 2RD041 - RD059 2RD071 - RD072 2RD081 - RD083 2RD091 - RD092 2RD101 - RD104 2RD121 - RD127 2RD131 - RD144 2RD166 - RD167 2RD171 - RD172 2RD181 - RD183 4RD201 - RD204 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 13 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 14 GroupVariable Number 2RD221 - RD227 2RD231 - RD235 2RD241 - RD243 2RD251 - RD262 2RD271 - RD272 2RD291 - RD292 2RD301 - RD302 2RD311 2RD351 - RD358 2RD361 - RD366 2RD381 - RD383 2RD411 - RD414 2RD421 - RD426 2RD431 - RD435 2RD441 - RD442 2RD451 - RD456 2RD461 2RD471 - RD475 2RD513 - RD519 4RD531 - RD533 4RD551 4RD561 4RD571 4RD581 - RD583 4RD591 - RD593 4RD601 - RD607 4RD621 - RD623 4RD641 - RD649 4RD651 - RD659 4RD661 4RD671 4RD681 - RD682 4RD691 - RD692 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 14 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 15 GroupVariable Number 4RD701 - RD702 4RD721 - RD722 4RD741 - RD742 4RD751 - RD755 4RD761 4RD771 - RD775 4RD781 - RD783 4RD791 - RD792 2RE001 2RF001 - RF006 4RJ131 - RJ133 4RJ151 - RJ152 4RJ301 - RJ303 4RJ321 - RJ322 4RJ331 - RJ333 4RL401 - RL403 4RL411 - RL436 4RL451 - RL456 4RL461 - RL462 4RL471 - RL481 4RL491 - RL492 4RL501 - RL502 4RL511 - RL516 4RL521 - RL522 4RL531 - RL534 4RL551 4RL561 - RL568 4RL571 - RL572 4RL576 - RL577 4RL579 4RL581 - RL586 4RL651 - RL655 4RL671 - RL675 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 15 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 16 GroupVariable Number 4RL681 - RL684 4RL751 - RL752 2RM001 - RM007 2RM010 - RM013 2RM021 - RM024 2RM026 - RM030 2RM036 - RM045 2RM051 - RM053 2RM071 2RM081 - RM084 2RM091 2RM096 - RM097 2RM116 - RM117 2RM126 - RM127 4RM128 2RM129 - RM132 2RM136 - RM147 2RM156 - RM158 2RM166 - RM177 2RM191 - RM192 2RM231 - RM233 2RM241 - RM246 2RM261 - RM264 2RM316 - RM318 2RM331 - RM333 2RM341 2RM351 - RM355 2RM366 - RM367 2RM401 - RM403 2RM426 2RM431 2RM441 - RM443 2RM445 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 16 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 17 GroupVariable Number 4RM801 - RM803 4RM811 - RM813 4RM851 - RM859 4RM861 - RM863 4RM871 - RM899 4RM901 - RM906 4RM911 4RR001 - RR005 4RR021 - RR025 4RR031 3RR201 4RR202 - RR206 4RR221 - RR226 4RR261 - RR267 4RR301 - RR310 4RR331 - RR332 4RR336 4RR341 - RR345 4RR361 - RR362 4RR421 - RR422 4RR431 - RR432 4RR441 - RR442 4RR451 4RR501 - RR504 4RR521 - RR522 4RR526 4RR531 4RR551 - RR556 4RR561 4RR566 4RR701 4RR721 - RR724 4RR746 - RR748 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 17 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 18 GroupVariable Number 4RR851 - RR856 4RR861 - RR862 4RR951 - RR952 2RS001 - RS002 2RS201 2RS211 - RS212 2RS221 - RS222 2RS231 - RS241 2RS251 - RS259 2RS263 2RS265 - RS268 2RS271 - RS276 2RS291 - RS292 2RS301 - RS306 2RS311 - RS320 2RS331 - RS333 2RS341 - RS342 2RS699 4RS701 - RS703 4RS711 - RS713 4RS721 - RS722 4RS731 - RS732 4RS741 - RS743 4RS751 - RS752 4RS761 - RS762 4RS771 4RS781 - RS782 4RS786 4RT001 - RT014 4RT021 - RT022 4RT031 - RT035 4RT041 - RT047 4RT061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 18 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 19 GroupVariable Number 4RT071 - RT075 4RT101 - RT103 4RT121 4RT131 - RT137 4RT151 - RT152 4RT161 - RT168 2RT401 - RT412 2RT431 - RT447 2RT451 - RT455 4RT456 2RT457 - RT460 4RT461 2RT462 - RT469 2RT471 - RT499 4RT501 2RT502 - RT505 4RT506 - RT510 2RT511 - RT512 4RT513 2RT514 - RT515 4RT516 2RT517 4RT518 - RT520 2RT521 - RT523 4RT524 2RT525 - RT527 4RT528 2RT529 - RT535 2RT551 - RT568 2RT571 4RT572 - RT579 2RT580 - RT591 2RT601 - RT630 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 19 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 20 GroupVariable Number 2RT633 - RT641 4RT642 2RT643 - RT654 4RT655 - RT657 2RT671 - RT673 2RT681 - RT682 2RT691 - RT699 2RT701 - RT704 2RT711 - RT717 2RT741 - RT742 2RT744 - RT750 4RT751 - RT752 2RT753 - RT757 2RT776 - RT777 4RT781 - RT782 2RT783 - RT784 2RT801 - RT803 2RT811 - RT814 2RT831 - RT836 4RT837 2RT861 - RT864 2RT877 - RT880 2RT931 - RT932 2RT945 - RT949 2RT951 - RT955 2RT966 4RT967 2RU001 - RU006 2RU016 - RU017 2RU031 - RU032 2RU051 - RU052 2RU059 - RU062 2RU081 - RU083 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 20 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 21 GroupVariable Number 2RU101 - RU102 2RU121 - RU132 2RU801 - RU809 2RU831 - RU841 2. Spares Affected None B. Concurrent Requirements None C. Reason Accomplishment of this service bulletin will make sure that the body frame at station 2231 at stringers 15 through 31 does not have cracks which could cause damage to adjacent body structure which could result in rapid depressurization of the airplane. This frame is the forward edge frame for the number 5 main entry door opening. Frame cracks that are not found and repaired could extend with continued operation and fully cut the frame. If the frame becomes fully cut, skin cracks could occur which could cause a rapid depressurization of the airplane. Before the release of the original issue of this service bulletin, four operators reported cracks in the strap and inner chord angle at station 2231 frame. Service history is summarized in the table below. Service History Crack LocationCycles/HoursReport strap22,257 / 294511 strap20,872 / 66,9472 forward inner chord angle14,735 / 61,7373 strap13,338 / 65,9844 Between the release of Revision 1 and Revision 2, seven operators have reported cracks in the strap, reveal, and inner chord angle at station 2231 frame on thirteen airplanes as follows: Service History Crack LocationCycles / HoursReport strap15,648 / 54,8821 inner chord17,906 / 75,0182 inner chord and strap18,325 / 49,9253 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 21 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 22 Service History Crack LocationCycles / HoursReport inner chord and strap18,507 / 76,5974 inner chord and strap19,618 / 52,8105 inner chord and strap19,740 / 80,5146 strap20,878 / 84,1027 inner chord and reveal20,921 / 84,1838 inner chord21,024 / 84,7169 strap21,703 / 73,81610 strap and reveal27,239 / 92,60711 inner chord31,990 / 60,42212 inner chord and strapNot Reported13 Between the release of Revision 2 and Revision 7, there have been further reports of cracking in the station 2231 frame on 120 airplanes. The locations of the reported cracks are summarised in the table below. Cracks were most commonly reported between 14,000 and 22,000 total flight cycles. The cracks reported before 16,000 total flight cycles were at the stringer S-26 lower main sill cutout location, which is also inspected in accordance with Boeing Service Bulletin 747-53A2494. Number of reported occurances Approximate crack location Right sideLeft side 615S-16 and S-17 24S-18 to S-22 56S-23 4381S-24 and S-25 816S-26 lower main sill cutout (a) (a) This location is also inspected in accordance with Boeing Service Bulletin 747-53A2494. A structural reassessment of the 747 airplane was conducted under the requirements of Federal Aviation Administration (FAA) Advisory Circular 91-56, in accordance with Federal Aviation Regulation (FAR) 25.571 as amended in 1978, to ensure safe operation of 747 airplanes throughout their operational life. From this requirement, the main entry door forward edge frame at body station 2231 was determined to be significant, in that it is critical to airplane structural integrity. Therefore, a flight safety inspection program which will continue throughout the operational life of the airplane is specified in this service bulletin. Airplane line numbers 1305 and on were delivered with a redesigned Station 2231 Frame which has improved fatigue durability. Revision 1 was sent to do the following: BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 22 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 23 1. Remove 747SP airplanes from the service bulletin effectivity because the configuration is different in the area concerning the service bulletin inspection. 2. Add reference to Figure 4 (Fastener Removal for Open Hole HFEC Inspection) and Figure 7 (Fastener Installation) in the Work Instructions of Paragraph 3 Accomplishment Instructions. 3. Add clarification to the LFEC Inspection of Figure 5 and Figure 6. 4. Add clarification to Group 4 effectivity by stating 747-300 Combi airplanes in addition to 747-200 Combi airplanes. As a result of additional in-service crack reports, Alert Revision 2 was sent to add instructions for surface and open-hole High Frequency Eddy Current (HFEC) inspections of the STA 2231 frame inner chord for cracks. Revision 3 was sent to do the following: 1. Change effectivity to exclude all airplanes from line numbers 1305 and on as these airplanes have had a production change incorporated which provides improved fatigue durability. 2. Add reference to SRM repair. 3. Add reference to FAA Airworthiness Directive 2001-16-02, Amendment 39-12370. 4. Add Boeing kits for fasteners removed during the incorporation of this service bulletin. 5. Clarify surface and open hole HFEC inspections in Figures 5 and 6. 6. Clarify bolt torque callouts in Figure 7. 7. Modify manpower estimate for Group 3 airplanes (with one Main Entry Door #5) and Group 4 airplanes (with one Main Entry Door #5). Revision 4 was sent to change Paragraph 1.A., Effectivity, to include all 747 airplanes line number 1 - 1304, except 747SPs. Revision 3 of this service bulletin was issued to change the airplane effectivity to all airplanes line number 1 - 1304 except 747SP airplanes. However, some affected airplanes were not included in Paragraph 1.A., Effectivity in Revision 3. Boeing received more reports of cracks found in the left and right side Station 2231 frame inner chord and strap between stringers 16 and 23. The inspection area as given in Revision 4 of this service bulletin did not include the frame area above stringer 23. Based on these reports, additional Boeing analysis indicates that the Station 2231 frame design improvement which was implemented in production for airplane line numbers 1305 and on, is not sufficient to prevent cracking of the frame inner chord. Revision 5 was sent to expand the Station 2231 frame inspection area to include stringers 16 to 22. These sections were changed: 1. Summary, revised the Background, Action, Effectivity and Compliance paragraphs. 2. Summary, revised Manpower table and illustration. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 23 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 24 3. Planning a. Paragraph 1.A., added Group Configuration table and revised airplane effectivity. b. Paragraph 1.C., revised Reason. c. Paragraph 1.D., revised Description. d. Paragraph 1.E., added new compliance table. e. Paragraph 1.F., added new approval and AMOC statement. f. Paragraph 1.G., revised manpower tables. 4. Material Information a. Paragraph 2.A., added new kit information to Material - Price and Availability tables. b. Paragraph 2.C., added new replacement and supplemental kit/part tables. 5. Accomplishment Instructions, 3.B.3. 3.B.4 and 3.B.6, revised inspection information. 6. Figure 1, deleted. Information now contained in Paragraph 1.E. 7. Figures 4, 5, 6, and 7, revised step tables and illustrations. Boeing Structural Item Interim Advisory (SIIA) SIIA 747-93 is related to this service bulletin. Revision 6 was sent to add airplane line numbers 1398 through 1419 and remove Large Cargo Freighter airplanes line number 766, 778, 904 and 932 from the service bulletin effectivity, Alternative Method of Compliance (AMOC) statements are updated and new AMOC and Notice of Proposed Rule Making (NPRM) statements are added. Also fastener part numbers are corrected. Between the release of Revision 6 and Revision 7 of this service bulletin, Boeing received reports from operators of cracking found above stringer 17 at locations that were not in the inspection areas given of this service bulletin. Boeing also received a report for the first time of cracking that initiated at the aft edge of the inner chord rather than initiating at a fastener location. Revision 7 is sent to add High Frequency Eddy Current inspection of the aft edge of the STA 2231 Frame Aft Inner Chord, of the forward edge of the STA 2231 Frame Forward Inner Chord and of the forward and aft edges of the STA 2231 Frame Strap. This revision is also sent to extend the existing inspection area to include the STA 2231 Frame between stringers 15 and 16. Instructions are added to remove and reinstall a fitting to give access to a trapped fastener location and to add alternative inspections for airplanes with SRM repairs installed. Boeing Service Related Problem (SRP) 747-53-0364 is related to this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 24 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 25 D. Description Do a detailed inspection of the Station 2231 Frame Assembly at stringers 15 through 31. The strap, inner chord angles, and frame web are to be inspected for cracks. Also do High Frequency Eddy Current (HFEC) and Low Frequency Eddy Current Inspections of the Station 2231 Frame Assembly and surface and open-hole HFEC inspections of the STA 2231 frame inner chord. If cracks are found, repair before next flight. Repair per SRM or contact Boeing for repair instructions. The airplane effectivity is divided in four groups because of differences in access and reveal configuration. At line number 204 the reveal configuration was changed. NOTE: Airplanes modified by Boeing to Special Freighter should be Group 3 airplanes (up to and including line number 203) or Group 4 airplanes (from line number 204 through line number 1419). Revision 1 - No more work is necessary on airplanes inspected or repaired as shown in the initial release of this service bulletin. Revision 2 - No more work is necessary on airplanes inspected as shown in the initial release of this service bulletin. Continue to do inspections of the STA 2231 frame as shown in Revision 2 of this service bulletin. Revision 3 - No more work is necessary on airplanes inspected as shown in the initial release, Revision 1, or Revision 2 of this service bulletin. Continue to do inspections of the STA 2231 frame as shown in Revision 3 of this service bulletin. Revision 4 - No more work is necessary on airplanes inspected as shown in the initial release, Revision 1, or Revision 2 of this service bulletin. This revision is sent to modify Paragraph 1.A., Effectivity. Operators should review this paragraph to determine effectivity. Continue to do inspections of the STA 2231 frame as shown in Revision 4 of this service bulletin. Revision 5 - More work is necessary on airplanes inspected as shown in the initial release, Revision 1, Revision 2, Revision 3 or Revision 4 of this service bulletin. The left and right side Station 2231 frame inspection area has been expanded to include stringers 16 to 23, in addition to stringers 23-31. Revision 6 - No more work is necessary on airplanes changed in accordance with the original issue, Revision 1, Revision 2, Revision 3, Revision 4 or Revision 5 of this service bulletin. Revision 7 - More work is necessary on airplanes inspected in accordance with the original issue, Revision 1, Revision 2, Revision 3, Revision 4, Revision 5 or Revision 6 of this service bulletin. Continue to do inspections of the STA 2231 frame in accordance with Revision 7 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below. Group 1: Affected Maintenance Zones ZoneModel 271, 272747-100, 747-200B BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 25 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 26 Group 2: Affected Maintenance Zones ZoneModel 271, 272747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747- 400, 747-400D, 747SR Group 3: Affected Maintenance Zones ZoneModel 271, 272747-200F Group 4: Affected Maintenance Zones ZoneModel 271, 272747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400F E. Compliance Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2009-18-07, AD 2010-01-01 and AD 2010-20-08 are related to this service bulletin. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 26 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 27 Table 1: Station 2231 Main Entry Door 5, Left and Right Side - Detailed and Low/High Frequency Eddy Current (LFEC/HFEC) Frame Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 16,000 total flight cycles or within 1,500 flight cycles after the effective date of AD 2010- 20-08, whichever occurs later. Do Detailed and low/high fre- quency eddy current (LFEC/HFEC) inspections for frame crack(s) from Stringers 16 to 23 in accordance with Work Instructions 3.B.4.a.(1), 3.B.4.b.(1), 3.B.4.c.(1) and 3.B.4.d.(1) Airplane line numbers 1-1304. -Before 16,000 total flight cycles or within 1,500 flight cycles after the effective date of AD 2001- 16-02, whichever occurs later. Do Detailed and LFEC/HFEC inspections for frame crack(s) from Stringers 23 to 31 in accor- dance with Work Instructions 3.B.4.a.(1), 3.B.4.b.(1), 3.B.4.c.(1) and 3.B.4.d.(1) -Before 16,000 total flight cycles or within 3,000 flight cycles after the Revision 7 date of this ser- vice bulletin, whichever occurs later. Do Detailed and HFEC inspec- tions for frame crack(s) from Stringers 15 to 16 in accordance with Work Instructions 3.B.4.a.(2), 3.B.4.b.(2) and 3.B.4.c.(2) -Before 16,000 total flight cycles or within 3,000 flight cycles after the Revision 7 date of this ser- vice bulletin, whichever occurs later. Do an HFEC inspection of the aft edge of the aft inner chord, of the forward edge of the for- ward inner chord and of the for- ward and aft edges of the frame strap for crack(s) from Stringers 15 to 31 in accordance with Work Instructions 3.B.4.c.(3) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 27 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 28 Table 1: Station 2231 Main Entry Door 5, Left and Right Side - Detailed and Low/High Frequency Eddy Current (LFEC/HFEC) Frame Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before 16,000 total flight cycles or within 1,500 flight cycles after the effective date of AD 2010- 20-08, whichever occurs later. Do Detailed and LFEC/HFEC inspection for frame crack(s) from Stringers 16 to 31 in accor- dance with Work Instructions 3.B.4.a.(1), 3.B.4.b.(1), 3.B.4.c.(1) and 3.B.4.d.(1) Airplane line numbers 1305 and on. -Before 16,000 total flight cycles or within 3,000 flight cycles after the Revision 7 date of this ser- vice bulletin, whichever occurs later. Do Detailed and HFEC inspec- tions for frame crack(s) from Stringers 15 to 16 in accordance with Work Instructions 3.B.4.a.(2), 3.B.4.b.(2) and 3.B.4.c.(2) -Before 16,000 total flight cycles or within 3,000 flight cycles after the Revision 7 date of this ser- vice bulletin, whichever occurs later. Do an HFEC inspection of the aft edge of the aft inner chord, of the forward edge of the for- ward inner chord and of the for- ward and aft edges of the frame strap for crack(s) from Stringers 15 to 31 in accordance with Work Instructions 3.B.4.c.(3) 3,000 flight cycles.Within 3,000 flight cycles from the last inspection. (a) (b) Do repeat Detailed and LFEC/HFEC inspection for frame crack(s) from Stringers 15 to 31 in accordance with Work Instructions 3.B.4.a., 3.B.4.b., 3.B.4.c. and 3.B.4.d. No cracks found in the inner chord(s) or frame strap. (c) -Before further flight.Repair in accordance with Work Instructions 3.B.5. Crack(s) found in the inner chord(s) and/or frame strap. (c) and 3,000 flight cycles.Within 3,000 flight cycles from the last inspection. (a) (b) Do repeat Detailed and LFEC/HFEC inspection for frame crack(s) from Stringers 15 to 31 in accordance with Work Instructions 3.B.4.a., 3.B.4.b., 3.B.4.c. and 3.B.4.d. (c) -Before further flight.Contact Boeing for repair data, and do the repair. Crack(s) found in re- paired area. (a) For airplane line numbers 1-1304, repeat inspection of frame from Stringers 15-23, repeat inspection of frame from Stringers 23-31, repeat inspection of the frame from Stringers 15-16 and repeat inspection of BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 28 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 29 Table 1: Station 2231 Main Entry Door 5, Left and Right Side - Detailed and Low/High Frequency Eddy Current (LFEC/HFEC) Frame Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition the forward and aft edges of the inner chord and frame strap from Stringers 15 to 31 can be combined, provided that repeat interval is not exceeded for any area. (b) For airplane line numbers 1305 and on, repeat inspection of frame from Stringers 16-31, repeat inspection of the frame from Stringers 15-16 and repeat inspection of the forward and aft edges of the inner chord and frame strap from Stringers 15 to 31 can be combined, provided that repeat interval is not exceeded for any area. (c) For airplanes with inner chord and/or frame strap repaired in accordance with Paragraph 3.B., Work In- structions 3.B.5. it will also be necessary to accomplish the inspections that are given in the applicable SRM repair. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. The Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the inspections and repairs with the corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance," of SB 747-53A2450, Revision 7 as an AMOC to the inspections and repairs at the STA 2231 frame required by paragraphs (g), (i), (j), (k) and (l) of AD 2009-18-07. This AMOC is valid only for areas where inspections or repairs are done in accordance with this SB. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (p) of the AD. All provisions of AD 2009-18-07 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle ACO approves the inspections and repairs with the corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance," of SB 747-53A2450, Revision 7 as an AMOC to the inspections and repairs at the STA 2231 frame required by paragraph (g) of AD 2010-01-01. This AMOC is valid only for areas where inspections or repairs are done in accordance with this SB. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (m) of the AD. All provisions or AD 2010-01-01 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 29 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 30 In addition, the Manager of the FAA Seattle ACO approves the inspections and repairs with the corresponding compliance times specified in Table 1, under paragraph 1.E., "Compliance," of SB 747-53A2450, Revision 7 as an AMOC to the inspections and repairs required by paragraphs (h), (i), and (j) of AD 2004-07-22 R1, for the inspection of Structural Significant Item (SSI) F-41A of Supplemental Structural Inspection Document (SSID) D6-35022, Revision G, at the STA 2231 frame. This AMOC only applies to the areas inspected or repaired by this SB. When this SB specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (l) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph remain fully applicable and must be complied with. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the inspections and modifications with the corresponding compliance times specified in Table 1, under Paragraph 1.E., Compliance of SB 747-53A2450, Revision 7, as an AMOC to the inspections and repairs required by paragraphs (g), (h), (i), (j), (k), (l), (m) and (n) of AD 2010-20-08. All provisions of AD 2010-20-08 that are not specifically referenced in the above statement remain fully applicable and must be complied with. G. Manpower The tables below show an estimate of the man-hours necessary to do this inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-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 examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. NOTE: Tables 1, 2, and 3 give manpower estimates for repeated inspections of the Body Station 2231 frame as shown in this service bulletin. TABLE 1 - GROUP 1 AND GROUP 2 AIRPLANES: Elapsed Time (Hours)Man-HoursNumber of PersonsTask 1.753.502Open Access 28.25 (a)113.00 (a)4Inspection 2.004.002Close Access 32.00120.50TOTAL FOR EACH AIRPLANE (a) Does not include time to inspect repairs. TABLE 2 - GROUP 3 AND GROUP 4 AIRPLANES WITH ACTIVE OR INACTIVE MAIN ENTRY DOOR 5 ON BOTH SIDES OF THE AIRPLANE: Elapsed Time (Hours)Man-HoursNumber of PersonsTask 1.753.502Open Access 28.25 (a)113.00 (a)4Inspection BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 30 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 31 TABLE 2 - GROUP 3 AND GROUP 4 AIRPLANES WITH ACTIVE OR INACTIVE MAIN ENTRY DOOR 5 ON BOTH SIDES OF THE AIRPLANE: Elapsed Time (Hours)Man-HoursNumber of PersonsTask 2.004.002Close Access 32.00120.50TOTAL FOR EACH AIRPLANE (a) Does not include time to inspect repairs. TABLE 3 - GROUP 3 AND GROUP 4 AIRPLANES WITH ACTIVE OR INACTIVE MAIN ENTRY DOOR 5 ON ONE SIDE OF THE AIRPLANE: Elapsed Time (Hours)Man-HoursNumber of PersonsTask 1.252.502Open Access 15.75 (a)63.00 (a)4Inspection 1.503.002Close Access 18.5068.50TOTAL FOR EACH AIRPLANE (a) Does not include time to inspect repairs. H. Weight and Balance Changes None. I. Electrical Load Data Not applicable. J. References 1. Existing Data: a. 747-100/200/300 Aircraft Maintenance Manual (AMM) 25-21-03, 25-55-02, 25-55-03, 25-59-01, 25-59-05. b. 747-400 Aircraft Maintenance Manual (AMM) 06-09-04, 25-21-03, 25-21-04, 25-52-04, 25-55-02, 25-59-01, 25-59-05. c. 747-100/200/300 Structural Repair Manual (SRM) 53-10-04. d. 747-400 Structural Repair Manual (SRM) 53-60-15. e. 747-400F Structural Repair Manual (SRM) 53-60-15. f. 747-400SF Structural Repair Manual (SRM) 53-60-15. g. Boeing Structural Item Interim Advisory (SIIA) 747-93. h. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00, Part 6, 53-30-00. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 31 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 32 i. 747 Supplemental Structural Inspection Document D6-35022 Item F-41. j. Federal Aviation Administration (FAA) Airworthiness Directive 2001-16-02, 2004-07-22 R1, 2009-18-07, 2010-01-01, 2010-20-08. k. Boeing Service Bulletin 747-53A2349, 747-53A2500. l. 747-100/200/300 Maintenance Planning Data (MPD) Volume 1, Foreword m. Boeing Service Related Problem (SRP) 747-53-0364 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number Support Instl - Sidewall Lining, No. 5 Doorway411U2325 Frame Instl - Fwd, STA 2231, No. 5 Main Entry Door Panel65B01849 Skin Panel Instl - STA 2181.10 to STA 2360, S-12 to S-1965B04157 Sill Instl - Main, Lwr, Entry Door No. 565B04310 Stop Installation - Fwd Frame, No. 5 Main Entry Door65B05000 Support Instl - Sidewall Lining, No. 5 Doorway65B50590 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary. L. Interchangeability and Intermixability of Parts Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 32 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 33 2. MATERIAL INFORMATION A. Material - Price and Availability The operator can supply the parts and materials shown in the kits in Paragraph 2.C., Parts Necessary for Each Airplane. As an alternative, operators can purchase the kits from Boeing Spares. 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 More Data Unit Price as of the Revision 07 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 07 date of this Service Bulletin (Calendar Days)NameKit Number This kit is no longer available. --Initial Kit (Standard Size) 015U5002-1 This kit is no longer available. --Initial Kit (First Oversize) 015U5002-2 This kit is no longer available. --Initial Kit (Second Oversize) 015U5002-3 This kit is no longer available. --Initial Kit (Standard Size) 015U5002-4 This kit is no longer available. --Initial Kit (First Oversize) 015U5002-5 This kit is no longer available. --Initial Kit (Second Oversize) 015U5002-6 Replacement for 015U5002-1 515.00550Replacement Kit (Standard Size) 015U5002-7 Add 015U5002-1 to make a 015U5002-7 105.00322Supplemental Kit (Standard Size) 015U5002-8 Replacement for 015U5002-2 6,656.00550Replacement Kit (First Oversize) 015U5002-9 Add 015U5002-2 to make a 015U5002-9 656.00322Supplemental Kit (First Oversize) 015U5002-10 Replacement for 015U5002-3 7,286.00550Replacement Kit (Second Oversize) 015U5002-11 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 33 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 34 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 More Data Unit Price as of the Revision 07 date of this Ser- vice Bulletin (US Dollars) ROLT as of the Revision 07 date of this Service Bulletin (Calendar Days)NameKit Number Add 015U5002-3 to make a 015U5002-11 534.00550Supplemental Kit (Second Oversize) 015U5002-12 Replacement for 015U5002-4 410.00550Replacement Kit (Standard Size) 015U5002-13 Add 015U5002-4 to make a 015U5002-13 54.00322Supplemental Kit (Standard Size) 015U5002-14 Replacement for 015U5002-5 3,581.00550Replacement Kit (First Oversize) 015U5002-15 Add 015U5002-5 to make a 015U5002-15 314.00322Supplemental Kit (First Oversize) 015U5002-16 Replacement for 015U5002-6 3,072.00550Replacement Kit (Second Oversize) 015U5002-17 Add 015U5002-6 to make a 015U5002-17 268.00550Supplemental Kit (Second Oversize) 015U5002-18 227.00550Additional Fasteners Kit015U5002-19 121.00550Additional Fasteners Kit015U5002-20 Additional Fasteners Kit 015U5002-( ) Second-Oversize Kit 015U5002-( ) First-Oversize Kit 015U5002-( ) Standard Size Kit 015U5002-( )Airplane Group -19 -11-9-71, 2 (optional -3 plus -12) (optional -2 plus -10) (optional -1 plus -8) 3, 4 (MED 5L and 5R) -20 -17-15-133, 4 (optional -6(optional -5(optional -4(MED 5L only) plus -18)plus -16)plus -14) The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 34 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 35 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA B. Industry Support Information Boeing warranty remedies are not available for the inspection given in this service bulletin. C. Parts Necessary For Each Airplane 1. Kits/Parts: To get the kits shown below from Boeing, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One replacement kit (or one initial kit and one supplemental kit) and one additional fastener kit are necessary for each airplane. The operator can supply the parts necessary as stated in Paragraph 2.C.2 Parts and Materials Supplied by the Operator or the operator can get the kits shown below from Boeing. To determine kit applicability for each airplane group number, refer to Paragraph 2.A., Material - Price and Availability. Initial Kit 015U5002 NotesName (a)QTY New Part Number -1 -2-3-4-5-6 .Initial Kit (Standard Size)-.....015U5002-1 .Initial Kit (First Oversize).-....015U5002-2 .Initial Kit (Second Oversize)..-...015U5002-3 .Initial Kit (Standard Size)...-..015U5002-4 .Initial Kit (First Oversize)....-.015U5002-5 .Initial Kit (Second Oversize).....-015U5002-6 (b)Bolt444222BACB30LK3K3X .Bolt.14..7.BACB30LK4K11X OPTION- ALBACB30LK4-11X .Bolt..14..7BACB30LK4K11Y OPTIONAL BACB30LK4-11Y .Bolt.10..5.BACB30LK4K8X OPTIONAL BACB30LK4-8X .Bolt..10..5BACB30LK4K8Y OPTIONAL BACB30LK4-8Y .Bolt.2..1.BACB30LK4K9X OPTION- ALBACB30LK4-9X BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 35 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 36 Initial Kit 015U5002 NotesName (a)QTY New Part Number -1 -2-3-4-5-6 .Bolt..2..1BACB30LK4K9Y OPTIONAL BACB30LK4-9Y .Bolt14..7..BACB30NT4K11 .Bolt10..5..BACB30NT4K8 .Bolt2..1..BACB30NT4K9 .Bolt.12..6.BACB30VF4BK12X .Bolt12..6..BACB30VF4K12 .Bolt..12..6BACB30VF4K12Y (b)Nut444222BACN10JC3CD .Nut383838191919BACN10JC4CD OPTION- ALBACN10YR4CD .Rivet444222BACR15BB6D5C (b)Washer444222BACW10BP31CD (b)Washer444222BACW10BP31DP .Washer26..13..BACW10BP4CD .Washer38..19..BACW10BP4DP .Washer.26..13.BACW10BP41CD .Washer.38..19.BACW10BP41DP .Washer..26..13BACW10BP42CD .Washer..38..19BACW10BP42DP (a) 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. (b) This fastener is used as part of an option to the BACR15BB6D5C rivet installation. Replacement Kit 015U5002 NotesName (a) QTY New Part Number -7 -9-11-13-15-17 Replacement Kit (Standard Size) -.....015U5002-7 Replacement Kit (First Oversize) .-....015U5002-9 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 36 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 37 Replacement Kit 015U5002 NotesName (a) QTY New Part Number -7 -9-11-13-15-17 Replacement Kit (Second Oversize) ..-..015U5002-11 Replacement Kit (Standard Size) ...-..015U5002-13 Replacement Kit (First Oversize) ....-.015U5002-15 Replacement Kit (Second Oversize) .....-015U5002-17 (b)Bolt444222BACB30LK3K3X .Bolt.30..15.BACB30LK4K11X OPTION- ALBACB30LK4-11X .Bolt..30..15BACB30LK4K11Y OPTIONAL BACB30LK4-11Y .Bolt.10..5.BACB30LK4K8X OPTIONAL BACB30LK4-8X .Bolt..10..5BACB30LK4K8Y OPTIONAL BACB30LK4-8Y .Bolt.2..1.BACB30LK4K9X OPTION- ALBACB30LK4-9X .Bolt..2..1BACB30LK4K9Y OPTIONAL BACB30LK4-9Y .Bolt30..15..BACB30NT4K11 .Bolt10..5..BACB30NT4K8 .Bolt2..1..BACB30NT4K9 .Bolt.30..15.BACB30VF4BK12X .Bolt30..15..BACB30VF4K12 .Bolt..30..15BACB30VF4K12Y (b)Nut666333BACN10JC3CD .Nut727272363636BACN10JC4CD OPTION- ALBACN10YR4CD BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 37 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 38 Replacement Kit 015U5002 NotesName (a) QTY New Part Number -7 -9-11-13-15-17 .Rivet444222BACR15BB6D5C (b)Washer444222BACW10BP31CD (b)Washer666333BACW10BP31DP .Washer42..21..BACW10BP4CD .Washer72..36..BACW10BP4DP .Washer.42..21.BACW10BP41CD .Washer.72..36.BACW10BP41DP .Washer..42..21BACW10BP42CD .Washer..72..36BACW10BP42DP (a) 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. (b) This fastener is used as part of an option to the BACR15BB6D5C rivet installation. Supplemental Kit 015U5002 NotesName (a) QTY New Part Number -8 -10-12-14-16-18 Supplemental Kit (Standard Size) -.....015U5002-8 Supplemental Kit (First Oversize) .-....015U5002-10 Supplemental Kit (Second Oversize) ..-...015U5002-12 Supplemental Kit (Standard Size) ...-..015U5002-14 Supplemental Kit (First Oversize) ....-.015U5002-16 Supplemental Kit (Second Oversize) .....-015U5002-18 .Bolt------BACB30LK3K3X .Bolt.16..8.BACB30LK4K11X OPTION- ALBACB30LK4-11X .Bolt..16..8BACB30LK4K11Y OPTIONAL BACB30LK4-11Y BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 38 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 39 Supplemental Kit 015U5002 NotesName (a) QTY New Part Number -8 -10-12-14-16-18 .Bolt..-..5BACB30LK4K8Y OPTIONAL BACB30LK4-8Y .Bolt16..8..BACB30NT4K11 .Bolt.18..9.BACB30VF4BK12X .Bolt18..9..BACB30VF4K12 .Bolt..18..9BACB30VF4K12Y .Nut222111BACN10JC3CD .Nut343434171717BACN10JC4CD OPTION- ALBACN10YR4CD Washer222111BACW10BP31DP .Washer16..8..BACW10BP4CD .Washer34..17..BACW10BP4DP .Washer.16..8.BACW10BP41CD .Washer.34..17.BACW10BP41DP .Washer..16..8BACW10BP42CD .Washer..34..17BACW10BP42DP (a) 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. Supplemental Kit 015U5002 NotesName QTY New Part Number -19 -20 Additional Fasteners Kit-.015U5002-19 Additional Fasteners Kit.-015U5002-20 (a)Bolt21BACB30FM6A13 (a)Bolt105BACB30FM6A3 (a)Bolt63BACB30FM6A4 (a)Bolt105BACB30FM6A9 (a)Bolt63BACB30MY8K4 (a)Bolt84BACB30VN6K9 (a)Bolt84BACB30VT8K10 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 39 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 40 Supplemental Kit 015U5002 NotesName QTY New Part Number -19 -20 (a)Bolt42BACB30YP8K10 Collar84BACC30BK6 Collar126BACC30BL8 Collar2814BACC30M6 Collar63BACC30M8 Washer, self-align84BACW10CA104CVS Washer, self-align84BACW10CA104CCS Washer, self-align84BACW10CA3CVS Washer, self-align84BACW10CA3CCS (a) 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. 2. Parts and Materials Supplied by the Operator: NOTE: The operator can supply the parts necessary as shown below or the operator can get kits from Boeing. Refer to Paragraph 2.A., Material - Price and Availability for kit information. FOR STANDARD SIZE BOLT REPLACEMENT NamePart Number (b)QTY (a) BoltBACB30VF4K1212 Bolt (Optional bolt is BACB30LK4-8)BACB30NT4K810 Bolt (Optional bolt is BACB30LK4-9)BACB30NT4K92 Bolt (Optional bolt is BACB30LK4-11)BACB30NT4K1114 Bolt (Optional: BACB30LK3K3X) (c)BACB30NX6K3X4 Nut (c)BACN10JC3CD4 Nut (Optional nut is BACN10YR4CD)BACN10JC4CD38 Rivet (Optional rivet is BACR15BB6D5)BACR15BB6D5C4 Washer (c)BACW10BP31DP4 Washer (c)BACW10BP31CD4 WasherBACW10BP4CD26 WasherBACW10BP4DP38 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 40 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 41 FOR STANDARD SIZE BOLT REPLACEMENT NamePart Number (b)QTY (a) (a) Quantities are per airplane with Main Entry Door #5 (active or inactive) on both sides of the airplane. (b) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners. (c) This fastener is used as part of an option to the rivet installation. FOR 1/64 OVERSIZE BOLT REPLACEMENT NamePart Number (b)QTY (a) Bolt (Optional bolt is BACB30VF4K12X)BACB30VF4BK12X12 Bolt (Optional bolt is BACB30LK4-8X)BACB30LK4K8X10 Bolt (Optional bolt is BACB30LK4-9X)BACB30LK4K9X2 Bolt (Optional bolt is BACB30LK4-11X)BACB30LK4K11X14 Bolt (Optional: BACB30LK3K3X) (c)BACB30NX6K3X4 Nut (c)BACN10JC3CD4 Nut (Optional nut is BACN10YR4CD)BACN10JC4CD (c)38 Rivet (Optional rivet is BACR15BB6D5)BACR15BB6D5C4 Washer (c)BACW10BP31DP4 Washer (c)BACW10BP31CD4 WasherBACW10BP41CD26 WasherBACW10BP41DP38 (a) Quantities are per airplane with Main Entry Door #5 (active or inactive) on both sides of the airplane. (b) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners. (c) This fastener is used as part of an option to the rivet installation. FOR 1/32 OVERSIZE BOLT REPLACEMENT NamePart Number (b)QTY (a) BoltBACB30VF4K12Y12 Bolt (Optional bolt is BACB30LK4-8Y)BACB30LK4K8Y10 Bolt (Optional bolt is BACB30LK4-9Y)BACB30LK4K9Y2 Bolt (Optional bolt is BACB30LK4-11Y)BACB30LK4K11Y14 Bolt (Optional: BACB30LK3K3X) (c)BACB30NX6K3X4 Nut (c)BACN10JC3CD4 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 41 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 42 FOR 1/32 OVERSIZE BOLT REPLACEMENT NamePart Number (b)QTY (a) Nut (Optional nut is BACN10YR4CD)BACN10JC4CD38 Rivet (Optional rivet is BACR15BB6D5)BACR15BB6D5C4 Washer (c)BACW10BP31DP4 Washer (c)BACW10BP31CD4 WasherBACW10BP42CD26 WasherBACW10BP42DP38 (a) Quantities are per airplane with Main Entry Door #5 (active or inactive) on both sides of the airplane. (b) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners. (c) This fastener is used as part of an option to the rivet installation. ALTERNATIVE FASTENERS NotesNameQTYPart Number / Specifica- tion This part is required for FIGURE 7 fastener code L. (a) Bolt2BACB30MY8K12 or BACB30MY8K12X or BACB30MY8K12Y This part is required for FIGURE 7 fastener code M. (a) Bolt4BACB30NW8K9X This part is required for FIGURE 7 fastener code L. Washer2BACC30M8 or BACC30M8 or BACC30R8. This part is required for FIGURE 7 fastener code M. Nut4BACW10BP41DP This part is required for FIGURE 7 fastener code N. Washer2BACN10JC3CD or BACN10YR3CD This part is required for FIGURE 7 fastener code M. Washer4BACN10JC4CD (a) Refer to 747 Structural Repair Manual Chapter 51 for alternate fasteners. ADDITIONAL FASTENERS (a) NotesName QTYPart Number / Specification (b)Bolt2BACB30FM6A13 (b)Bolt10BACB30FM6A3 (b)Bolt6BACB30FM6A4 (b)Bolt10BACB30FM6A9 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 42 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 43 ADDITIONAL FASTENERS (a) NotesName QTYPart Number / Specification (b)Bolt6BACB30MY8K4 (b)Bolt8BACB30VN6K9 (b)Bolt8BACB30VT8K10 (b)Bolt4BACB30YP8K10 Collar8BACC30BK6 Collar12BACC30BL8 Collar28BACC30M6 Collar6BACC30M8 Washer, self-align8BACW10CA104CVS Washer, self-align8BACW10CA104CCS Washer, self-align8BACW10CA3CVS Washer, self-align8BACW10CA3CCS (a) These fasteners are used at the open hole HFEC inspection lo- cations at stringer 16 and to reinstall the fitting removed to get access to the trapped fastener. This work was added at revision 7. (b) 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. 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 43 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 44 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: May 04, 2000 747-53A2450Revision 7: November 02, 2011 44 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 45 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches. – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch. – Angular tolerance is plus or minus 2 degrees. – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51. – Torque limits to tighten nuts and bolts are in SRM Chapter 51. 4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 6. 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. 7. This service bulletin contains only a Flight Safety Inspection. An Economics based inspection is not included in the service bulletin. 8. 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. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 45 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 46 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. B. WORK INSTRUCTIONS 1. Airplanes configured to carry passengers in the aft body (all Group 1 and Group 2 airplanes). Get access in accordance with FIGURE 2. 2. Airplanes configured to carry cargo in the aft body (Group 3 and Group 4 airplanes). Get access in accordance with FIGURE 3. NOTE: Combi and Convertible airplanes configured to carry passengers in the aft body. Get access in accordance with FIGURE 2. 3. Remove access panels 271AL (left side) and 272AR (right side, if necessary). Refer to 747-100/200/300 MPD Volume 1, Foreword or 747-400 AMM 06-09-04 for access panel location. 4. Station 2231, Stringer 15-31, Left and Right side, Inspection a. Detailed inspections: (1) Do a Detailed inspection for cracks on the frame strap (where visible), inner chords forward and aft of the web, and exposed web adjacent to the inner chords from Stringer 16 to 31. Do Detailed Inspection in accordance with FIGURE 5 (Group 1 and Group 3 airplanes) and FIGURE 6 (Group 2 and Group 4 airplanes). (2) Do a Detailed inspection for cracks on the frame strap (where visible), inner chords forward and aft of the web, and exposed web adjacent to the inner chords from Stringer 15 to 16. Do Detailed Inspection in accordance with FIGURE 5 (Group 1 and Group 3 airplanes) and FIGURE 6 (Group 2 and Group 4 airplanes). b. Open hole High Frequency Eddy Current (HFEC) inspections: (1) Do an open hole HFEC inspection of the Station 2231 Frame fastener locations for cracks from Stringer 16 to 31, except fastener locations common to upper main sill strap and stringer clip at Stringer 16, in accordance with FIGURE 4, FIGURE 5 and FIGURE 7 (Group 1 and Group 3 airplanes) and FIGURE 4, FIGURE 6 and FIGURE 7 (Group 2 and Group 4 airplanes). (2) Do an open hole HFEC inspection of the Station 2231 Frame fastener locations common to the upper main sill strap and stringer clip at stringer 16 for cracks in accordance with FIGURE 4, FIGURE 5 and FIGURE 7 (Group 1 and Group 3 airplanes) and FIGURE 4, FIGURE 6 and FIGURE 7 (Group 2 and Group 4 airplanes). BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 46 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 47 c. Surface HFEC inspections: (1) Do a surface HFEC inspection of the frame inner chords around the fastener heads from Stringer 16 to 31 in accordance with FIGURE 5 (Group 1 and Group 3 airplanes) and FIGURE 6 (Group 2 and Group 4 airplanes). (2) Do a surface HFEC inspection of the frame inner chords around the fastener heads from Stringer 15 to 16 in accordance with FIGURE 5 (Group 1 and Group 3 airplanes) and FIGURE 6 (Group 2 and Group 4 airplanes). (3) Do a surface HFEC inspection for cracking of the aft edge of the aft inner chord, of the forward edge of the forward inner chord and of the forward and aft edges of the frame strap from Stringer 15 to Stringer 31 in accordance with FIGURE 5 (Group 1 and Group 3 airplanes) and FIGURE 6 (Group 2 and Group 4 airplanes). d. Low Frequency Eddy Current (LFEC) inspection: (1) Do a subsurface Low Frequency Eddy Current Inspection for cracks of the Station 2231 Frame Strap from Stringers 16 to 31 in areas covered by the reveal. Do Low Frequency Eddy Current Inspection in accordance with FIGURE 5 (Group 1 and Group 3 airplanes) and FIGURE 6 (Group 2 and Group 4 airplanes). It is not necessary to do this inspection for areas covered by a reveal repair that was installed in accordance with 747-100/200/300 SRM 53-10-04 FIGURE 34 or FIGURE 91, 747-400 SRM 53-60-15 REPAIR 1 or REPAIR 3, 747-400F SRM 53-60-15 REPAIR 1 or REPAIR 3 or 747-400SF SRM 53-60-15 REPAIR 1 or REPAIR 3. 5. If crack(s) are found in the inner chord(s) or frame strap, repair in accordance with 747-100/200/300 SRM 53-10-04, Figure 115 or 140; 747-400 SRM 53-60-15; 747-400F SRM 53-60-15; 747-400SF SRM 53-60-15, Figure 201, Repair 2 or 5 as applicable. NOTE: After the repair, it will be necessary to do inspections of the repaired area of the frame in accordance with 747-100/200/300 SRM 53-10-04, Figure 115 or 140; 747-400 SRM 53-60-15; 747-400F SRM 53-60-15; 747-400SF SRM 53-60-15, Figure 201, Repair 2 or 5 as applicable. 6. Repeat Detailed inspection and low/high frequency eddy current (LFEC/HFEC) inspections in accordance with Paragraph 1.E., Compliance. 7. Install access panels 271AL (left side) and 272AR (right side, if necessary). Refer to 747-100/200/300 MPD Volume 1, Foreword or 747-400 AMM 06-09-04 for access panel location. 8. Airplanes configured to carry passengers in the aft body (all Group 1 and Group 2 airplanes). Do the restoration in accordance with FIGURE 2. 9. Airplanes configured to carry cargo in the aft body (Group 3 and Group 4 airplanes). Do the restoration in accordance with FIGURE 3. NOTE: Combi and Convertible airplanes configured to carry passengers in the aft body. Do the restoration in accordance with FIGURE 2. 10. Put the airplane back to a serviceable condition. BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7: November 02, 2011 47 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 48 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT THIS FIGURE IS DELETED. INFORMATION IS NOW CONTAINED IN PARAGRAPH 1.E., COMPLIANCE. 1972398 FIGURE 1: DELETED (SHEET 1 OF 1) Original Issue: May 04, 2000 Revision / November 02, 2011 BOEING PROPRIETARY - 747-53A2450 Copyright © Unpublished Work - See page 1 for details. 48 of 97 ### Page 49 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one side of the airplane. ACCESS MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Refer to 747-100/200/300 AMM 25- 21-03 or 747-400 AMM 25-21-03 as an accepted procedure. 1-Lower Transition Panel Remove1 Refer to 747-100/200/300 AMM 25- 21-03 or 747-400 AMM 25-21-03 as an accepted procedure. 1-Side Lining Door Panel Remove2 FIGURE 2: ACCESS / RESTORATION FOR CONFIGURATION WITH PASSENGERS IN THE AFT BODY (SHEET 1 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7 November 02, 2011 49 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 50 ACCESS MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Refer to 747-100/200/300 AMM 25- 59-05 or 747-400 AMM 25-21-04 as an accepted procedure. (a) --Insulation BlanketsPull Back3 Refer to 747-100/200/300 AMM 25- 55-02 or 747-400 AMM 25-55-02 as an accepted procedure. --Bulk Cargo Compart- ment Aft Bulkhead Access Panel Open4 Refer to 747-100/200/300 AMM 25- 55-03 or 747-400 AMM 25-52-04 as an accepted procedure. (b) --Insulation BlanketsPull Back5 (a) In upper lobe, pull back insulation blankets on Station 2231 Frame from between Stringer 15 to floor level. Insulation blankets not shown in figure. (b) In lower lobe, pull back insulation blankets on Station 2231 Frame from between underside of floor to Stringer 31. RESTORATION MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Refer to 747-100/200/300 AMM 25- 55-03 or 747-400 AMM 25-52-04 as an accepted procedure. --Insulation BlanketsInstall6 Refer to 747-100/200/300 AMM 25- 55-02 or 747-400 AMM 25-55-02 as an accepted procedure. --Bulk Cargo Compart- ment Aft Bulkhead Access Panel Close7 (not shown)--Insulation BlanketsInstall8 Refer to 747-100/200/300 AMM 25- 59-05 or 747-400 AMM 25-21-04 as an accepted procedure. Refer to 747-100/200/300 AMM 25- 21-03 or 747-400 AMM 25-21-03 as an accepted procedure. 1-Side Lining Door Panel Install9 Refer to 747-100/200/300 AMM 25- 21-03 or 747-400 AMM 25-21-03 as an accepted procedure. 1-Lower Transition Panel Install10 FIGURE 2: ACCESS / RESTORATION FOR CONFIGURATION WITH PASSENGERS IN THE AFT BODY (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7 November 02, 2011 50 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 51 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT X10 ACCESS, UPPER LOBE 38 29 ACCESS, UPPER LOBE MAIN DECK FLOOR ACCESS TO LOWER LOBE → FWD FROM BULK CARGO AREA MAIN ENTRY DOOR 5 LEFT ACCESS, REMOVALS AND INSTALLATION LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE ON COMBI, CONVERTIBLE AND AND SPECIAL FREIGHTER AIRPLANES The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one side of the airplane. ACCESS STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Remove Sidewall Lining Panel 1 Refer to 747-100/200/300 AMM 25- 59-01 or 747-400 AMM 25-59-01 as an accepted procedure. FIGURE 3: ACCESS / RESTORATION FOR CONFIGURATION WITH CARGO IN THE AFT BODY (SHEET 1 OF 2) Original Issue: May 04, 2000 Revision 7 November 02, 2011 BOEING PROPRIETARY - 747-53A2450 Copyright © Unpublished Work - See page 1 for details. 51 of 97 ### Page 52 ACCESS MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Refer to 747-100/200/300 AMM 25- 59-01 or 747-400 AMM 25-59-01 as an accepted procedure. 1-Lower Transition Panel Remove2 Refer to 747-100/200/300 AMM 25- 59-05 or 747-400 AMM 25-59-05 as an accepted procedure. (a) --Insulation BlanketsPull Back3 Refer to 747-100/200/300 AMM 25- 55-02 or 747-400 AMM 25-55-02 as an accepted procedure. --Bulk Cargo Compart- ment Aft Bulkhead Access Panel Open4 Refer to 747-100/200/300 AMM 25- 55-03 or 747-400 AMM 25-52-04 as an accepted procedure. (b) --Insulation BlanketsPull Back5 (a) In the upper lobe, pull back insulation blankets on Station 2231 Frame from between Stringer 15 to floor level. Insulation blankets not shown in figure. (b) In lower lobe, pull back insulation blankets on Station 2231 Frame from between underside of floor to Stringer 31. RESTORATION MORE DATAQTYIDENTIFICATIONNAMETASKSTEP Refer to 747-100/200/300 AMM 25- 55-03 or 747-400 AMM 25-52-04 as an accepted procedure. --Insulation BlanketsInstall6 Refer to 747-100/200/300 AMM 25- 55-02 or 747-400 AMM 25-55-02 as an accepted procedure. --Bulk Cargo Compart- ment Aft Bulkhead Access Panel Close7 (not shown)--Insulation BlanketsInstall8 Refer to 747-100/200/300 AMM 25- 59-05 or 747-400 AMM 25-59-05 as an accepted procedure. Refer to 747-100/200/300 AMM 25- 59-01 or 747-400 AMM 25-59-01 as an accepted procedure. 1-Lower Transition Panel Install9 Refer to 747-100/200/300 AMM 25- 59-01 or 747-400 AMM 25-59-01 as an accepted procedure. 1-Sidewall Lining PanelInstall10 FIGURE 3: ACCESS / RESTORATION FOR CONFIGURATION WITH CARGO IN THE AFT BODY (SHEET 2 OF 2) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7 November 02, 2011 52 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 53 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT STA 2231 SEE 1 UP S-16L > FWD S-17L DOOR 5 LEFT DOOR 5 RIGHT OPPOSITE S-181 CON PASSENGER, COMBI, CONVERTIBLE AND SPECIAL FREIGHTER AIRPLANES) - 5-191 STA 2231 -20 -5-23L -221 _BRACKET S 23 5 LEF • 241 DOOR 5-251 - 8-251 5-261 MAIN DECK S-31L LOWER FLOOR MAIN SILL • FWD FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION (SHEET 1 OF 7) Original Issue: May 04, 2000 Revision 7 November 02, 2011 747-53A2450 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 97 ### Page 54 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT STA 2231 - 5-16L CUPPER MAIN SILL) - 5-17L -S-22L - 5-24L ￾-25L > FWD 1497933 FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION (SHEET 2 OF 7) Original Issue: May 04, 2000 Revision 7 November 02, 2011 BOEING PROPRIETARY - 747-53A2450 Copyright © Unpublished Work - See page 1 for details. 54 of 97 ### Page 55 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT S-23L S-26L S-24L 752-5 792-S MAIN DECK FLOOR UP S-29L S-30L S-31L LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE 100 VIEW LOOKING FORWARD A-A V39162 FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION (SHEET 3 OF 7) Original Issue: May 04, 2000 Revision 7 November 02, 2011 BOEING PROPRIETARY - 747-53A2450 Copyright © Unpublished Work - See page 1 for details. 55 of 97 ### Page 56 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT , UPPER MAIN SILL S-16L S-17L S-18L S-19L S-201 LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE S-21L VIEW LOOKING FORWARD B~B UP • INBD S-22L 1498027 FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION (SHEET 4 OF 7) Original Issue: May 04, 2000 Revision 7 November 02, 2011 747-53A2450 Copyright © Unpublished Work - See page 1 for details. BOEING PROPRIETARY - 56 of 97/ ### Page 57 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT 4) 6 LOCATIONS S-19L INBD C-C - REFERENCE FASTENER SOME STRUCTURE NOT SHOWN FOR CLARITY FWD STA INBD 2231 2073160 -- REFERENCE FASTENER D-D FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION (SHEET 5 OF 7) Original Issue: May 04, 2000 Revision 7 November 02, 2011 747-53A2450 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 97 ### Page 58 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one side of the airplane. The figure shows reveal configuration for Group 2 and Group 4 airplanes. CAUTION: USE CARE TO NOT DAMAGE THE HOLES WHEN REMOVING FASTENERS. THIS SERVICE BULLETIN ALLOWS FOR INSTALLATION OF BOLTS IN CLOSE REAM HOLES TO FACILITATE REPEATED OPEN-HOLE HIGH FREQUENCY EDDY CURRENT INSPECTIONS. THE USE OF CLOSE REAM RATHER THAN TRANSITION FIT HOLES ALLOWS BOLTS TO BE REMOVED AND REINSTALLED WITHOUT THE NEED TO MAKE THE HOLES OVERSIZE. HOWEVER, THIS CAN ONLY BE ACCOMPLISHED BY CAREFUL REMOVAL OF THE FASTENERS. MORE DATAQTYIDENTIFICATIONNAMETASKSTEP (a)(b)48-FastenerRemove1 22-FastenerRemove/Keep2 -5-RivetRemove3 -19-FastenerRemove4 FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION (SHEET 6 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7 November 02, 2011 58 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 59 MORE DATAQTYIDENTIFICATIONNAMETASKSTEP -1-Fitting - stop back-upRemove/Keep5 Remove/keep any loose shims or fillers. --Shims and fillersRemove/Keep -1-FastenerRemove/Keep6 (a) Determine if a STANDARD SIZE, 1/64 OVERSIZE, or 1/32 OVERSIZE bolt was removed. This infor- mation will be used to determine the replacement fastener at the Station 2231 Frame Assembly in- terface with the horizontal stringer strap (aft row). (b) Discard fastener for initial accomplishment of this service bulletin. For subsequent inspections, ex- amine the bolt, including the threads. Replace if the finish is damaged. Re-use of fastener is acceptable if no damage found on fastener. FIGURE 4: FASTENER REMOVAL FOR OPEN HOLE HFEC INSPECTION (SHEET 7 OF 7) BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 04, 2000 747-53A2450Revision 7 November 02, 2011 59 of 97 BOEING SERVICE BULLETIN 747-53A2450 ALERTALERT ### Page 60 (OCR) BOEING SERVICE BULLETIN 747-53A2450 ALERT ALERT STA 2231 SEE C 5-15L UP S-16L • FWD S-171 DOOR 5 LEFT • 5-18L DOOR 5 RIGHT OPPOSITE ON PASSENGER, COMBI, CONVERTIBLE AND SPECIAL 5-191 FREIGHTER AIRPLANES SEE 5-201 - 5-211 SEE • 5-231 DOOR 5 LEFT 5-251 5-241 5-261 MAIN DECK FLOOR NITW OMIN TIS V22742 FIGURE 5: INSPECTION - GROUP 1 AND GROUP 3 (SHEET 1 OF 14) Original Issue: May 04, 2000 Revision 7 November 02, 2011 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 10 09 The text continues at https://openairdocs.org/service-documents/boeing/747-53a2450/file/49bb1b777147.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. 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