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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2451 Original Issue: October 05, 2000 Revision 2: June 13, 2014 ATA System: 5312 SUBJECT: FUSELAGE - Section 42 - Door Number 2 Forward Edge Frame at Body Station 800
- Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2000 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 1 of 163
6.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 2 of 163 BOEING SERVICE BULLETIN 747-53A2451
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 2 0 E. Compliance .............................................. 2 1 F. Approval ............................................... 2 5 G. Manpower .............................................. 2 5 H. Weight and Balance Changes .................................... 2 9 I. Electrical Load Data ......................................... 2 9 J. References .............................................. 2 9
1. Existing Data: ......................................... 2 9
2. Data Supplied with this Service Bulletin: ........................... 3 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 0
4. Process Data: ......................................... 3 0 K. Publications Affected ........................................ 3 0 L. Interchangeability and Intermixability of Parts ........................... 3 1 M. Software Accomplishment Summary ................................ 3 1
2. MATERIAL INFORMATION ........................................ 3 3 A. Material - Price and Availability ................................... 3 3 B. Industry Support Information .................................... 3 3 C. Parts Necessary for Each Airplane ................................. 3 3
1. Kits/Parts: ........................................... 3 3
2. Parts and Materials Supplied by the Operator: ........................ 3 3
3. Parts Modified and Reidentified: ............................... 4 7
4. Parts Removed and Not Replaced: .............................. 4 8 D. Parts Necessary to Change Spares ................................. 4 8 E. Special Tooling - Price and Availability ............................... 4 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 0 FIGURE 1: THIS FIGURE IS DELETED .................................. 5 7 FIGURE 2: ACCESS ............................................ 5 8 FIGURE 3: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL [Group 1] ................. 6 4 FIGURE 4: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL [Group 2] ................. 6 7 FIGURE 5: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL [Group 3] ................. 7 0 FIGURE 6: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL - INSPECTION [Group 1] ........ 7 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 7: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL - INSPECTION [Group 2] ........ 7 7 FIGURE 8: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL - INSPECTION [Group 3] ........ 8 2 FIGURE 9: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL - FASTENER REMOVAL [Group 4] . . 87 FIGURE 10: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL - INSPECTION [Group 4] ........ 9 0 FIGURE 11: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL - INSPECTION [Group 5] ........ 9 5 FIGURE 12: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL [Group 6] ................ 1 0 1 FIGURE 13: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL - INSPECTION [Group 6] ....... 1 0 4 FIGURE 14: DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 14 AND STRINGER 18 - FASTENER REMOVAL [Group 5] ................ 1 0 9 FIGURE 15: LEFT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 18 AND DOOR STOP NO. 5 - FASTENER REMOVAL ............ 1 1 2 FIGURE 16: LEFT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 18 AND DOOR STOP NO. 5 - INSPECTION ................. 1 1 5 FIGURE 17: LEFT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 5 AND DOOR STOP NO. 1 - FASTENER REMOVAL ......... 1 2 0 FIGURE 18: LEFT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 5 AND DOOR STOP NO. 1 - INSPECTION .............. 1 2 3 FIGURE 19: LEFT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 1 AND STRINGER 30 - FASTENER REMOVAL ............ 1 2 8 FIGURE 20: LEFT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 1 AND STRINGER 30 - INSPECTION ................. 1 3 1 FIGURE 21: RIGHT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 18 AND DOOR STOP NO. 5 - FASTENER REMOVAL ............ 1 3 6 FIGURE 22: RIGHT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN STRINGER 18 AND DOOR STOP NO. 5 - INSPECTION ................. 1 3 9 FIGURE 23: RIGHT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 5 AND DOOR STOP NO. 1 - FASTENER REMOVAL ......... 1 4 4 FIGURE 24: RIGHT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 5 AND DOOR STOP NO. 1 - INSPECTION .............. 1 4 7 FIGURE 25: RIGHT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 1 AND STRINGER 30 - FASTENER REMOVAL ............ 1 5 2 FIGURE 26: RIGHT SIDE DOOR NUMBER 2 FORWARD EDGE FRAME AT BODY STATION 800 BETWEEN DOOR STOP NO. 1 AND STRINGER 30 - INSPECTION ................. 1 5 5 APPENDIX A: ADDENDUM - FLIGHT SAFETY SECTION ......................... 1 6 0 APPENDIX B: LOGIC DIAGRAM - INSPECTION OF DOOR NUMBER 2 FORWARD EDGE FRAME AT STA 800 BETWEEN STRINGER 14 AND STRINGER 18 .................... 1 6 2 APPENDIX C: LOGIC DIAGRAM - INSPECTION OF DOOR NUMBER 2 FORWARD EDGE FRAME AT STA 800 BETWEEN STRINGER 18 AND STRINGER 30 .................... 1 6 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 4 of 163 BOEING SERVICE BULLETIN 747-53A2451
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2451Original Issue: October 05, 2000 Revision 2: June 13, 2014 ATA System: 5312 SUBJECT: FUSELAGE - Section 42 - Door Number 2 Forward Edge Frame at Body Station 800
- Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-16-08, is related to this service bulletin.
More work is necessary on the airplane(s) inspected in accordance with the original issue or Revision 1 of this service bulletin. Inspection of the STA 800 frame inner chord between stringer 18 and stringer 30 is necessary.
Large Cargo Freighter (LCF) Airplanes RT743, RT876, RT631 and RT632 were removed from this service bulletin effectivity.
REASON FOR REVISION This revision is sent to expand the inspection area to include the STA 800 frame inner chord between stringer 18 and stringer 30. Additionally a new inspection threshold for STA 800 frame inner chord between stringer 18 and stringer 30 has been added.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. Summary, Background - added Planning Data table and additional service history.
2. Summary, revised Summary illustration.
3. Summary, revised Compliance to reference a new Airworthiness Directive (AD) .
4. Paragraph 1.A.1., Airplanes - RT743, RT876, RT631 and RT632 were removed.
5. Paragraph 1.E., Compliance, revised Compliance paragraph to reference a new Airworthiness Directive (AD) and compliance tables to give new inspection areas and new inspection thresholds.
6. Paragraph 1.F., Approval - deleted a paragraph and added a paragraph.
7. Paragraph 1.G., Manpower - Revised manpower tables.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 5 of 163
8. Paragraph 1.J., Existing Data - added references.
9. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - added fasteners.
10. Paragraph 3.A., General Information - Revised and added general notes.
11. Paragraph 3.B., Work Instructions - Revised work instructions to include new inspection areas.
12. Figure 1 - Deleted, information is now included in compliance tables and Appendix B and Appendix C.
13. Figure 2 - Title revised and steps added.
14. Figure 3 to Figure 14 - Figure title revised.
15. New Figures 15 to 26 - Showing fastener removal and new inspection areas between stringer 18 and stringer 30.
16. Figures 6-26 - Alternative hole sizing added
17. Appendix B and Appendix C - New logic diagrams are added.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY October 05, 2000Original Issue:
November 10, 2005Revision 1:
June 13, 2014Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 6 of 163 BOEING SERVICE BULLETIN 747-53A2451
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2451Original Issue: October 05, 2000 Revision 2: June 13, 2014 ATA System: 5312 SUBJECT: FUSELAGE - Section 42 - Door Number 2 Forward Edge Frame at Body Station 800
- Inspection and Repair
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 800, between stringers 14 through 30, 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 2 main entry door opening. Frame cracks that are not found and repaired could extend with continued operation and fully sever the frame. If the frame becomes severed, skin cracks could occur which could cause a rapid depressurization of the airplane.
Two operators have reported cracks in the strap and inner chord angle at station 800 frame. The 747-100SR fatigue test airplane had a severed inner chord angle and strap. Refer to Paragraph 1.C., Reason, for additional service history.
Since the initial release of this service bulletin, Boeing has received several additional reports of STA 800 frame strap and inner chord angle cracks. Inner chord angle cracks between 0.4 and 0.8 inch long were found on three airplanes with 15,735 - 16,428 flight-cycles. An inner chord angle crack 0.05 inch long was found on one airplane with 9,675 flight-cycles.
In addition, the STA 800 frame aft inner chord angle was found to be cracked near S-17 on a Stretched Upper Deck (SUD) 747-300 airplane with 23,475 total flight-cycles. As a result of this report, Boeing examined the 747-400 Fatigue Test airplane and found significant damage in this area, including severed inner chord angles on both the left and right sides, at 54,000 test cycles.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 7 of 163
Since the release of revision 1 of this service bulletin, Boeing has received several additional reports of cracks found at the STA 800 frame on the left and right side Main Entry Door (MED) forward and aft inner chord angles and frame straps. One operator reported cracks on the left and right side STA 800 frame, S-17 common to the aft inner chord angle fastener holes. The crack lengths were between 0.0625 and 1.00 inches long. The airplane had approximately 11,950 flight cycles. Another operator reported 8 cracks found on the right side STA 800 frame common to the aft inner chord angle fastener holes. Four of the cracks were found between S-18R and S-20R, which is outside the inspection areas of revision 1 of this service bulletin.
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 800 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.
The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-53-0419 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Do a detailed inspection of the Station 800 Frame Assembly between stringers 14 through 30. The inner chord strap, angles, and frame web are to be inspected for cracks. Also do surface and open-hole High Frequency Eddy Current (HFEC) Inspections of the Station 800 Frame Assembly. If any crack is found contact the Boeing Company for repair instructions and do the repair.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 8 of 163 BOEING SERVICE BULLETIN 747-53A2451
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EFFECTIVITY All 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D and 747SR airplanes.
Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
NOTE: 747-100 and 747-200 airplanes converted to special freighter by Boeing are included in the effectivity of this service bulletin.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-16-08, is related to this service bulletin.
The effective date of AD 2007-16-08 is September 13, 2007.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections given in this service bulletin.
MANPOWER See service bulletin Paragraph 1.G.
MATERIAL INFORMATION Operator supplied Parts Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 9 of 163 BOEING SERVICE BULLETIN 747-53A2451
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BOEING SERVICE BULLETIN 747-53A2451
ALERT ALERT GROUP 1 AND 3 GROUP 2, 4, 5, AND 6
CRACK IN
CRACK IN
STRAP AND
ACCESS AFT ANGLE AFT ANGLE STRAP AND
STR STR 17 17 UP UP → FWD →→FWD
UPPER DECK FLOOR BEAM
INSPECTION (IF INSTALLED) AREA S-14
- S-15 DOOR 2 LEFT • S-16 DOOR 2 RIGHT OPPOSITE - S-17 S-18 LIFE RAFT 5-19
LOCATION -S-20 / STOP #9
UPPER SILL
• S-22
• S-23 STOP #8 / S-24 S-27 S-28
- S-29 DO A DETAILED INSPECTION FOR CRACKS ON THE - S-30
INNER CHORD STRAP, ANGLES AND EXPOSED WEB
ADJACENT TO THE INNER CHORD BETWEEN STRINGER 14 AND 30. ALSO DO HFEC INSPECTIONS FOR CRACKS ON STATION 800 FRAME ASSEMBLY. 780 STA > FWD STA 800 STA STA 840 STA 820 LEFT SIDE SHOWN V33568 854 RIGHT SIDE OPPOSITE Original Issue: October 05, 2000 Revision 2: June 13, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2451 Work - See page 1 for details. 10 of 163
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2451 Original Issue: October 05, 2000 Revision 2: June 13, 2014 ATA System: 5312 SUBJECT: FUSELAGE - Section 42 - Door Number 2 Forward Edge Frame at Body Station 800
- Inspection and Repair
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 This service bulletin is for the airplanes shown below.
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 747SR, 747-100, 747-100B, 747-200B, and 747-200C without a Stretched Upper Deck (SUD), that have a tension tie installed at STA
800.
-1 747SR, 747-100, 747-100B, 747-200B, and 747-200C without a Stretched Upper Deck (SUD), that were delivered with an upper deck floor beam installed at STA 800.
-2 747SR, 747-100, 747-100B, 747-200B, and 747-200C airplanes without a Stretched Upper Deck (SUD), that were modified after delivery to remove the tension tie and install an upper deck floor beam at STA 800.
-3 747-100B SUD and 747-300 airplanes which were delivered with a Stretched Upper Deck (SUD).
-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 11 of 163
DESCRIPTIONCONFIGURATIONGROUP 747-400 and 747-400D airplanes, which were delivered with a Stretched Upper Deck (SUD).
-5 747-200B airplanes that were modified by Boeing to the Stretched Upper Deck (SUD) configuration.
-6 Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D, 747SR GroupVariable Number 1RA001 - RA034 1RA101 - RA115 1RA161 - RA164 1RA201 - RA203 1RA216 - RA217 3RA245 - RA246 1RA251 - RA266 3RA301 - RA317 2RA318 1RA351 - RA360 1RA369 - RA373 1RA401 - RA418 1RA501 - RA502 1RA521 - RA528 1RA532 - RA544 3RA545 - RA548 1RA551 - RA552 1RA559 - RA561 1RA581 - RA582 1RA585 1RA601 - RA602 1RA631 - RA635 1RA651 - RA652 3RA671 - RA675 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 2000 747-53A2451Revision 2: June 13, 2014 12 of 163 BOEING SERVICE BULLETIN 747-53A2451