# Boeing Alert Service Bulletin 747-53A2563: U.S. DOT/FAA - Service Bulletin

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2008-0107; AD 2012-04-09 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 747-53A2563](https://openairdocs.org/service-documents/boeing/747-53a2563.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin
- Pages: 281
- PDF: https://openairdocs.org/files/sha256/c5/50/c550477be235f50d44b10493c340634168769f54822d76ba6db8bcd8b2b754b2
- Page: https://openairdocs.org/service-documents/boeing/747-53a2563/file/c550477be235

## 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
Number: 747-53A2563
Original Issue: March 29, 2007
Revision 4: May 06, 2010
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for
Scribe Lines
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 © 2007 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Unpublished Work - All Rights Reserved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Copyright © Unpublished Work - See page 1 for details.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: March 29, 2007
747-53A2563Revision 4: May 06, 2010
1 of 281
4.0

### Page 2

BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
2 of 281
BOEING SERVICE BULLETIN 747-53A2563
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 2
B. Concurrent Requirements ...................................... 2 2
C. Reason ................................................ 2 2
D. Description .............................................. 2 5
E. Compliance .............................................. 2 9
F. Approval ............................................... 7 6
G. Manpower .............................................. 7 7
H. Weight and Balance Changes .................................... 7 8
I. Electrical Load Data ......................................... 7 8
J. References .............................................. 7 8
1. Existing Data: ......................................... 7 8
2. Data supplied with this Service Bulletin: ........................... 7 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 7 8
K. Publications Affected ........................................ 7 8
L. Interchangeability and Intermixability of Parts ........................... 7 9
2. MATERIAL INFORMATION ........................................ 8 1
A. Material - Price and Availability ................................... 8 1
B. Industry Support Information .................................... 8 1
C. Parts Necessary For Each Airplane ................................. 8 1
1. Kits/Parts: ........................................... 8 1
2. Parts and Materials Supplied by the Operator: ........................ 8 1
3. Parts Modified and Reidentified: ............................... 8 1
4. Parts Removed and Not Replaced: .............................. 8 1
D. Parts Necessary to Change Spares ................................. 8 1
E. Special Tooling - Price and Availability ............................... 8 1
F. Special Tooling Necessary to do this Service Bulletin ....................... 8 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 8 3
A. GENERAL INFORMATION ..................................... 8 3
B. WORK INSTRUCTIONS ....................................... 8 5
FIGURE 1: INSPECTION AREA 1 [Group 1] ............................... 1 1 6
FIGURE 2: INSPECTION AREA 1 [Group 2] ............................... 1 2 1
FIGURE 3: INSPECTION AREA 1 [Group 3, Configuration 1] ...................... 1 2 6
FIGURE 4: INSPECTION AREA 1 [Group 3, Configuration 2; Group 4] ................ 1 3 1
FIGURE 5: INSPECTION AREA 1 [Group 5] ............................... 1 3 6
FIGURE 6: INSPECTION AREA 1 [Group 6] ............................... 1 4 1
FIGURE 7: INSPECTION AREA 1 [Group 7] ............................... 1 4 6
FIGURE 8: INSPECTION AREA 1 [Group 8] ............................... 1 5 1
FIGURE 9: INSPECTION AREA 1 [Group 9] ............................... 1 5 6
FIGURE 10: INSPECTION AREA 2 [Group 1-2] .............................. 1 6 1
FIGURE 11: INSPECTION AREA 2 [Group 3-4] .............................. 1 6 5
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
3 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 4

FIGURE 12: INSPECTION AREA 2 [Group 7-8] .............................. 1 6 9
FIGURE 13: INSPECTION AREA 2 [Group 9] ............................... 1 7 3
FIGURE 14: INSPECTION AREA 3 [Group 1] ............................... 1 7 7
FIGURE 15: INSPECTION AREA 3 [Group 2] ............................... 1 8 3
FIGURE 16: INSPECTION AREA 3 [Group 3, Configuration 1] ...................... 1 8 9
FIGURE 17: INSPECTION AREA 3 [Group 3, Configuration 2; Group 4] ................ 1 9 5
FIGURE 18: INSPECTION AREA 3 [Group 5] ............................... 2 0 1
FIGURE 19: INSPECTION AREA 3 [Group 6] ............................... 2 0 7
FIGURE 20: INSPECTION AREA 3 [Group 7] ............................... 2 1 3
FIGURE 21: INSPECTION AREA 3 [Group 8] ............................... 2 1 9
FIGURE 22: INSPECTION AREA 3 [Group 9] ............................... 2 2 5
FIGURE 23: LAP JOINT INSPECTION FOR SCRIBE LINES ...................... 2 3 1
FIGURE 24: BUTT JOINT INSPECTION FOR SCRIBE LINES ...................... 2 3 2
FIGURE 25: DELETED ........................................... 2 3 4
FIGURE 26: INSPECTION OF LAP JOINT SCRIBE LINES FOR CRACKS ............... 2 3 5
FIGURE 27: INSPECTION OF BUTT JOINT SCRIBE LINES FOR CRACKS .............. 2 3 7
FIGURE 28: INSPECTION OF SCRIBE LINES AROUND THE WING-TO-BODY FAIRING FOR CRACKS
................................................. 2 3 8
FIGURE 29: INSPECTION FOR SCRIBE LINES AROUND EXTERNAL DOUBLERS ......... 2 3 9
FIGURE 30: INSPECTION FOR SCRIBE LINES IN SKIN GENERAL INSPECTION AREAS ..... 2 4 0
FIGURE 31: INSPECTION OF SCRIBE LINES AROUND EXTERNAL DOUBLERS FOR CRACKS . . 242
FIGURE 32: INSPECTION OF SCRIBE LINES IN SKIN GENERAL INSPECTION AREAS FOR CRACKS
................................................. 2 4 5
FIGURE 33: INSPECTION AREA 2 [Group 5-6] .............................. 2 4 6
FIGURE 34: INSPECTION FOR SCRIBE LINES AT THE EDGE OF THE DOOR 3 UPPER AFT CORNER
LARGE DOUBLER ...................................... 2 5 0
FIGURE 35: INSPECTION OF SCRIBE LINES AROUND THE DOOR 3 UPPER AFT CORNER LARGE
DOUBLER FOR CRACKS .................................. 2 5 3
Appendix A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN. 256
Appendix B: REPORTING SYSTEM - LIMITED RETURN TO SERVICE PROCEDURE FOR SCRIBED
AIRPLANES .......................................... 2 6 2
Appendix C: AIRPLANE FUSELAGE SCRIBE LINE SUMMARY TABLES ................ 2 6 4
Appendix D: SCRIBE SAMPLE ....................................... 2 6 7
Appendix E: AIRPLANES DELIVERED WITH FILLET SEALED LAP JOINTS .............. 2 6 9
APPENDIX F: LAP JOINT REPAIRS ..................................... 2 7 8
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
4 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 5

Commercial 
Airplanes
747
Service Bulletin
Revision Transmittal SheetNumber: 747-53A2563Original Issue: March 29, 2007
Revision 4: May 06, 2010
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for
Scribe Lines
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
No more work is necessary on Group 5, Group 7, and Group 9 airplanes inspected in accordance with Revision
3 of this service bulletin as a result of Revision 4. If scribe lines were found previously and are being inspected
as part of the Limited Return to Service (LRTS) program, do the repeat inspections in accordance with Revision
4.
More work is necessary on Group 1, Group 2, Group 3, Group 4, Group 6, and Group 8 airplanes previously
inspected in Area 3 in accordance with the original issue, Revision 2, or Revision 3 of this service bulletin. At
the time given in Paragraph 1.E., Compliance, Table 29, inspect certain lap splices in accordance with Paragraph
3.B., Work Instructions, PART 19. At any location where scribe lines were found previously and are being
inspected as part of the Limited Return to Service (LRTS) program, do the repeat inspections in accordance
with Revision 4.
No airplanes were added to this service bulletin effectivity.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2007-NM-087-AD, is related to this
service bulletin.
REASON FOR REVISION
This revision is sent to give affected operators improved repeat inspection interval data for lap joint and butt
joint areas that have been found to have scribe damage which will be or are being inspected under the Limited
Return to Service (LRTS) inspection program.
Inspection of the S-18L lap splice from STA 1780 - STA 1920 (on the Main Deck Side Cargo Door) for scribe
lines has been added to inspection Area 3. This change only affects Group 2, Group 3 Configuration 2, Group
4, Group 6, and Group 8 airplanes.
Inspection of the S-34R lap splice from STA 1810 - STA 1920 (on the aft lower lobe cargo door) for scribe lines
has been added to inspection Area 3. This change only affects Group 1 and Group 2 airplanes.
Inspection of the S-6L and S-6R lap splice from STA 1000 - STA 1220 for scribe lines has been added to
inspection Area 3. This change only affects Group 3 and Group 4 airplanes.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
5 of 281

### Page 6

In addition, general repair instructions for lap joint locations with scribe lines, but no cracks, have been added.
These instructions are in new PART 17 in Paragraph 3.B., and in new Appendix F. General repair instructions
for lap joint locations with scribe lines and cracks have also been added. These instructions are in new PART
18 in Paragraph 3.B., and in new Appendix F.
Analysis by Boeing has also determined that inspections for scribe lines is not necessary at the thresholds for
Main Entry Door 1 - 5, the Upper Deck Entry Door (Stretched Upper Deck airplanes only) and the Bulk Cargo
Door. In addition, inspections for scribe lines are not necessary at the Bulk Cargo Door corner reinforcement
doublers. These areas have been removed from Paragraph 3.B., PART 7. Instructions for the continued inspection
of scribe lines in these areas that were found in accordance with earlier versions of this service bulletin have
been added to Paragraph 3.B., PART 16 and to new Tables 27 and 28 in Paragraph 1.E., Compliance.
References to Revision 1 have been removed throughout this service bulletin. Revision 1 was released on the
MyBoeingFleet website for a short time in 2007, but was permanently removed due to missing illustrations. The
FAA considers Revision 1 to be not FAA-approved as published.
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
March 29, 2007Original Issue:
November 08, 2007Revision 1:
January 03, 2008Revision 2:
June 11, 2009Revision 3:
May 06, 2010Revision 4:
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
6 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 7

Commercial 
Airplanes
747
Service Bulletin
SummaryNumber: 747-53A2563Original Issue: March 29, 2007
Revision 4: May 06, 2010
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for
Scribe Lines
CONCURRENT REQUIREMENTS
None.
BACKGROUND
This service bulletin gives instructions for the inspection and repair of scribe lines in the fuselage skin at lap
joints, butt joints, decals, at external doublers and around other external features such as antennas and pitot-static
ports. Fatigue cracks can develop in the skin at scribe line locations. Fatigue cracks in the skin that remain
undetected could grow large and cause sudden decompression.
A scribe line is a narrow, shallow, distinct line of damage typically between 0.001 to 0.006 inch deep, usually
associated with the removal of a fillet or gap seal. A more detailed definition of a scribe line is included in
Paragraph 3.A., Accomplishment Instructions.
At the time this service bulletin was originally released, 15 747 airplanes have been found with scribe damage
by eight operators. Scribe lines were found at lap joints, butt joints, around external doublers and antennas, and
at locations where external decals were cut. Many of the scribe lines appear to have been made when sealant
was removed as part of preparation of the airplane for repainting. No cracks have been found at scribe line
locations on 747 airplanes.
Accomplishment of the inspections shown in this service bulletin will help make sure that fatigue cracks that can
form in the fuselage at scribe lines are found and repaired before they can become large and cause sudden
loss of cabin pressure.
Boeing Service Related Problem (SRP) 747/747OP-SRP-53-0242 is related to this service bulletin.
ACTION (PRR 85901-66RS)
At the time shown in this service bulletin, do detailed inspections of the fuselage skin at certain lap joints, butt
joints, and at certain external doubler locations and other external features for scribe lines.
If no scribe lines are found, no more work is required as a result of this service bulletin.
If scribe lines are found, the scribe lines must be inspected for cracks in accordance with this service bulletin.
If cracks are found, repair the cracks before any more flight-cycles in accordance with this service bulletin. If no
cracks are found, repair the scribe lines before any more flight-cycles in accordance with this service bulletin.
As an alternative to scribe line repair, if no cracks are found the scribe lines can be reinspected in accordance
with the Limited Return to Service (LRTS) Plan shown in the service bulletin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
7 of 281

### Page 8

Refer to Paragraph 1.D., Description for details.
EFFECTIVITY
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F,
747SP, and 747SR airplanes. Refer to Paragraph 1.A.1. Airplanes, for the list of affected airplanes.
COMPLIANCE
See Service Bulletin Paragraph 1.E. for compliance information.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2007-NM-087-AD is related to this service
bulletin.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service
bulletin.
MANPOWER
Elapsed HoursTotal Task HoursAirplanes
1021020747SP
1141140All other 747
NOTE: More time will be required for repairs or additional inspections if scribe lines or cracks are found.
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
None.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
8 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 9 (OCR)

BOEING SERVICE BULLETIN 747-53A2563
DO A DETAILED INSPECTION FOR SCRIBE
LINES IN THE SKIN ALONG LAP JOINTS,
BUTT JOINTS, AROUND EXTERNAL REPAIR
AND CUTOUT REINFORCEMENT DOUBLERS,
AND AROUND OTHER FEATURES ON THE
PRESSURIZED SKIN.
100..0000
1337215
Original Issue: March 29, 2007
Revision 4: May 06, 2010  BOEING PROPRIETARY -  747-53A2563
Copyright © Unpublished Work - See page 1 for details.  9 of 281

### Page 10

BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
10 of 281
BOEING SERVICE BULLETIN 747-53A2563
BLANK PAGE

### Page 11

Commercial 
Airplanes
747
Service Bulletin
Number: 747-53A2563
Original Issue: March 29, 2007
Revision 4: May 06, 2010
ATA System: 5331
SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin and Butt Joint Splice Straps for
Scribe Lines
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. Refer to PRR85901-66RS for data about
this change.
DESCRIPTIONCONFIGURATIONGROUP
All 747-100, 747-100B, 747-200B, and 747SR airplanes without a
Stretched Upper Deck or a Main Deck Side Cargo Door.
-1
All 747-100, 747-100B, 747-200B, and 747SR airplanes without a
Stretched Upper Deck but with a Main Deck Side Cargo Door.
-2
All 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D
airplanes with a Stretched Upper Deck, but no Main Deck Side Cargo
Door, except 747-400ER airplanes.
-3
Not modified to the BCF (Boeing Converted Freighter) configuration.1
Modified to the BCF (Boeing Converted Freighter) configuration.2
All 747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D
airplanes with a Stretched Upper Deck, and a Main Deck Side Cargo
Door.
-4
All 747-200F airplanes with a nose cargo door, but no Main Deck
Side Cargo Door.
-5
All 747-200F and 747-400F airplanes with a nose cargo door and a
Main Deck Side Cargo Door, except 747-400ER Freighter airplanes.
-6
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
11 of 281

### Page 12

DESCRIPTIONCONFIGURATIONGROUP
All 747-200C airplanes with a nose cargo door, but no Main Deck
Side Cargo Door.
-7
All 747-200C airplanes with a nose cargo door and a Main Deck Side
Cargo Door.
-8
All 747SP airplanes.-9
Airplane Models:
747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400,
747-400D, 747-400F, 747SP, 747SR
GroupVariable Number
1RA001
2RA002
1RA003 - RA005
2RA006
1RA007 - RA010
2RA011
1RA012 - RA014
2RA015
1RA016 - RA025
2RA026
1RA027
2RA028 - RA030
1RA031 - RA032
2RA033
1RA034
2RA101 - RA103
1RA104 - RA110
2RA111 - RA112
1RA113 - RA115
2RA161 - RA163
1RA164
1RA201 - RA203
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
12 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 13

GroupVariable Number
1RA216 - RA217
1RA245 - RA246
1RA251 - RA266
1RA301 - RA318
1RA351 - RA360
1RA369 - RA373
2RA401 - RA405
1RA406 - RA418
1RA501 - RA502
1RA521 - RA523
2RA524
1RA525 - RA528
1RA532 - RA548
1RA551 - RA552
1RA559 - RA561
1RA581 - RA582
1RA585
1RA601 - RA602
2RA631 - RA635
1RA651 - RA652
1RA671 - RA677
1RA701 - RA702
1RA721 - RA731
1RA741 - RA745
2RA749 - RA750
1RA761 - RA762
1RA781 - RA783
2RA784
2RA901 - RA902
1RA903 - RA909
2RA910 - RA916
1RB001 - RB016
2RB041
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
13 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 14

GroupVariable Number
1RB042
2RB043
1RB044
1RB071 - RB075
1RB101 - RB102
2RB411 - RB413
2RB421
1RB601 - RB603
2RB604 - RB605
1RB606
2RB607
1RB681 - RB695
2RB696
1RB697
1RB711
1RB721 - RB723
1RB741 - RB748
1RD001 - RD004
1RD021 - RD022
2RD041 - RD044
1RD045 - RD054
2RD055
1RD056 - RD059
1RD071 - RD072
1RD081
2RD082 - RD083
1RD091 - RD092
1RD101 - RD104
1RD121 - RD127
1RD131 - RD141
2RD142
1RD143
2RD144
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
14 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 15

GroupVariable Number
1RD166 - RD167
1RD171 - RD172
1RD181 - RD183
2RD201 - RD204
1RD221 - RD224
2RD225
1RD226
2RD227
1RD231 - RD232
2RD233 - RD235
1RD241 - RD243
1RD251 - RD262
1RD271 - RD272
1RD291 - RD292
2RD301 - RD302
1RD311
1RD351 - RD357
2RD358
2RD361 - RD366
3RD381 - RD383
2RD411 - RD412
1RD413 - RD414
1RD421 - RD426
1RD431 - RD432
2RD433 - RD434
1RD435
2RD441 - RD442
1RD451 - RD456
2RD461
1RD471 - RD475
1RD513 - RD519
2RD531 - RD533
2RD551
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
15 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 16

GroupVariable Number
2RD561
2RD571
2RD581 - RD583
2RD591 - RD593
4RD601 - RD607
2RD621 - RD623
2RD641 - RD649
2RD651 - RD659
2RD661
2RD671
2RD681 - RD682
2RD691 - RD692
2RD701 - RD702
4RD721 - RD722
2RD741 - RD742
2RD751 - RD755
2RD761
2RD771 - RD775
2RD781 - RD783
2RD791 - RD792
1RE001
9RG001 - RG009
9RG091
9RG095
9RG101 - RG104
9RG121 - RG126
9RG141 - RG142
9RG161 - RG164
9RG171 - RG174
9RG191 - RG193
9RG211 - RG213
9RG221 - RG222
9RH101 - RH102
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
16 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 17

GroupVariable Number
9RH111 - RH112
9RH121 - RH122
7RJ131 - RJ133
7RJ151 - RJ152
8RJ301 - RJ303
8RJ321 - RJ322
8RJ331 - RJ333
6RL401 - RL403
6RL411 - RL420
6RL651 - RL655
6RL751 - RL752
3RM001 - RM007
3RM010 - RM013
3RM021 - RM024
3RM026 - RM030
3RM036 - RM045
3RM051 - RM053
3RM071
3RM081 - RM084
3RM091
3RM096 - RM097
3RM116 - RM117
3RM126 - RM132
3RM136 - RM147
3RM156 - RM158
3RM166 - RM177
3RM191 - RM192
3RM231 - RM233
3RM241 - RM246
3RM261 - RM264
3RM316 - RM318
3RM331 - RM333
3RM341
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
17 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 18

GroupVariable Number
3RM351 - RM355
3RM366 - RM367
3RM401 - RM403
3RM426
3RM431
3RM441 - RM443
3RM445
4RM801 - RM803
4RM811 - RM813
6RM851 - RM858
6RM861 - RM862
6RM871 - RM876
6RM881 - RM887
6RM891 - RM899
6RM901 - RM905
6RM911
5RR001 - RR004
6RR005
6RR021 - RR025
6RR031
5RR201
6RR202 - RR206
6RR221 - RR226
6RR261
5RR262
6RR263 - RR267
6RR301 - RR310
6RR331 - RR332
6RR336
6RR341 - RR345
6RR361 - RR362
6RR421 - RR422
6RR431 - RR432
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
18 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 19

GroupVariable Number
6RR441 - RR442
6RR451
6RR501 - RR504
6RR521 - RR522
6RR526
6RR531
6RR551 - RR556
6RR561
6RR566
6RR701
6RR721 - RR724
6RR746 - RR748
6RR851 - RR856
6RR861 - RR862
6RR951 - RR952
3RS001 - RS002
3RS201
3RS211 - RS212
3RS221 - RS222
3RS231 - RS241
3RS251 - RS259
3RS263
3RS265 - RS268
3RS271 - RS276
3RS291 - RS292
3RS301 - RS306
3RS311 - RS320
3RS331 - RS333
3RS341 - RS342
3RS699
4RS701 - RS703
4RS711 - RS713
4RS721 - RS722
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
19 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 20

GroupVariable Number
4RS731 - RS732
4RS741 - RS743
4RS751 - RS752
4RS761 - RS762
4RS771
4RS781 - RS782
4RS786
4RT001 - RT014
4RT021 - RT022
4RT031 - RT035
4RT041 - RT047
4RT061
4RT071 - RT075
4RT101 - RT103
4RT121
4RT131 - RT137
4RT151 - RT152
4RT161 - RT168
3RT401 - RT412
3RT431 - RT447
3RT451 - RT455
4RT456
3RT457 - RT469
3RT471 - RT499
3RT501 - RT507
4RT508
3RT509 - RT535
3RT551 - RT568
3RT571
4RT572
3RT573 - RT591
3RT601 - RT654
4RT655
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
20 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 21

GroupVariable Number
3RT656 - RT657
3RT671 - RT673
3RT681 - RT682
3RT691 - RT699
3RT701 - RT704
3RT711 - RT717
3RT741 - RT757
3RT776 - RT777
3RT781
4RT782
3RT783 - RT784
3RT801 - RT803
3RT811 - RT814
3RT831 - RT837
3RT861 - RT864
3RT876 - RT880
3RT931 - RT932
3RT945 - RT949
3RT951 - RT952
4RT953 - RT954
3RT955
3RT966 - RT967
3RU001 - RU006
3RU016 - RU017
3RU031 - RU032
3RU051 - RU052
3RU059 - RU062
3RU081 - RU083
3RU101 - RU102
3RU121 - RU132
3RU801 - RU809
3RU831 - RU841
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
21 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 22

2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
This service bulletin gives instructions for the inspection and repair of scribe lines in the fuselage skin
at lap joints, butt joints, decals, at external doublers and around other external features such as antennas
and pitot-static ports. Fatigue cracks can develop in the skin at scribe line locations. Fatigue cracks in
the skin that remain undetected could grow large and cause sudden decompression.
A scribe line is a narrow, shallow, distinct line of damage typically between 0.001 to 0.006 inch deep,
usually associated with the removal of a fillet or gap seal. A more detailed definition of a scribe line is
included in Paragraph 3.A., Accomplishment Instructions.
At the time this service bulletin was originally released, 15 747 airplanes have been found with scribe
damage by eight operators. Scribe lines were found at lap joints, butt joints, around external doublers
and antennas, and at locations where external decals were cut. Many of the scribe lines appear to
have been made when sealant was removed as part of preparation of the airplane for repainting. No
cracks have been found at scribe line locations on 747 airplanes.
Accomplishment of the inspections shown in this service bulletin will help make sure that fatigue cracks
that can form in the fuselage at scribe lines are found and repaired before they can become large and
cause sudden loss of cabin pressure.
NOTE: Revision 1 was released on the MyBoeingFleet website on November 01, 2007. However,
because of missing illustrations, Revision 1 was permanently removed from MyBoeingFleet
on November 06, 2007. Paper copies of Revision 1 were not distributed by Boeing.
Revision 2 is sent to:
1. Re-issue the changes made in Revision 1.
2. Add illustrations that were missing in Revision 1.
3. Revise Paragraph 1.E., Compliance, Tables 1, 2, and 3 to remove the recommendation to repair
or replace scribed parts before 25,000 total flight cycles (for Area 1) and before 35,000 total flight
cycles (for Area 2 and Area 3). This recommendation was added in Revision 1, but has been
removed in Revision 2. Repair or replacement of scribed parts is only required if cracks are found.
Revision 2 adds the following illustrations that were missing from Revision 1:
Figure 3, Sheet 1 (illustration number 1332648)
Figure 3, Sheet 3 (illustration number 1332755)
Figure 4, Sheet 1 (illustration number 1332786)
Figure 4, Sheet 3 (illustration number 1332823)
Figure 16, Sheet 1 (illustration number 1333713)
Figure 20, Sheet 4 (illustration number 1334380)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
22 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 23

Figure 22, Sheet 1 (illustration number 1334793)
Figure 26, Sheet 1 (illustration number 1335321)
Figure 31, Sheet 1 (illustration number 1335371)
NOTE: Illustration numbers are shown in the lower right corner of each illustration.
Because Revision 1 of this service bulletin has been removed from MyBoeingFleet, all changes that
were made in Revision 1 are now included in Revision 2, except for the changes to Paragraph 1.E.,
Compliance, Tables 1, 2, and 3. A description of the changes is shown below. The vertical lines that
were applied to show changes in Revision 1 are also shown in Revision 2.
These sections were changed:
1. In Paragraph 1.D., Description, affected Maintenance Zones have been listed for affected airplane
models.
2. In Paragraph 1.E., Compliance, the repeat intervals for inspection of some lap joint locations has
been revised. Many affected locations with a 250 flight-cycle repeat inspection interval specified
in the original issue of this service bulletin now have a 500 flight-cycle or higher repeat inspection
interval. The new intervals are shown in Tables 4, 5, 7, 8, 10 - 12, and 15 in Paragraph 1.E.,
Compliance.
3. In Paragraph 3.B., Part 5, the instructions have been changed to specify that removal of paint and
primer from affected butt joint splice plates is not recommended. Removal of the sealant only from
the gap in the affected butt joints is necessary.
Revision 3 is sent to change the initial inspection threshold at certain lap joints and to change the repeat
inspection intervals (including some reductions in inspection intervals) for many lap joint inspection
areas. These changes are shown in Tables 4 through 15 in Paragraph 1.E., Compliance. Also as part
of these changes, some lap joints have been moved between the existing inspection areas (Areas 1,
2, and 3) and others have been removed completely from this service bulletin. These inspection areas
are shown in revised Figures 1 through 22 and 33.
In addition, the following changes have been made:
1. The requirement to do inspections for scribe lines along the perimeter of the wing-to-body fairing
has been removed. The PART 6 instructions in the Work Instructions were changed to be applicable
only to previously discovered scribe lines, and the areas were removed from all applicable figures.
The content of inspection Figure 25 was removed. Repeat inspections for cracks at previously
discovered scribe lines along the wing-to-body fairing may still be necessary in accordance with
Paragraph 1.E., Compliance Table 17.
2. Blending in accordance with the applicable SRM has been removed from this service bulletin as
a recommended scribe line repair method. Boeing does not consider blending to be an appropriate
repair for most scribe lines.
3. In Paragraph 1.E., Compliance, Table 22 has been added. Table 22 gives compliance information
for more work which is necessary on Group 3 and Group 4 airplanes that were inspected in Area
1 in accordance with the original issue of this service bulletin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
23 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 24

4. In Paragraph 1.E., Compliance, Table 23 and Table 24 have been added. Table 23 gives compliance
information for more work which is necessary on airplanes that were inspected in Area 1 in
accordance with the original issue or Revision 2 of this service bulletin. Table 24 gives compliance
information for more work which is necessary on airplanes that were inspected in Area 2 in
accordance with the original issue or Revision 2 of this service bulletin.
5. In Paragraph 1.E., Table 25 was added. Table 25 gives compliance information for inspections
for scribe lines and cracks along the edge of a doubler that may be installed at the upper aft corner
of the Main Entry Door 3 cutout. This inspection area is part of Area 3.
6. In Paragraph 1.E., Table 26 was added. Table 26 gives compliance information for inspections of
scribe lines that have been previously found at any main entry door cutout other than the upper
aft corner of the Main Entry Door 3 cutout.
7. In Paragraph 3.B., Work Instructions, PART 12 has been added. PART 12 gives work instructions
for inspections for scribe lines and cracks along the edge of a doubler that may be installed at the
upper aft corner of the Main Entry Door 3 cutout. This inspection area is part of Area 3.
8. In Paragraph 3.B., Work Instructions, PART 13 has been added. PART 13 gives work instructions
for more work which is necessary on Group 3 and Group 4 airplanes that were inspected in Area
1 in accordance with the original issue of this service bulletin.
9. In Paragraph 3.B., Work Instructions, PART 14 and PART 15 have been added. PART 14 gives
work instructions for more work which is necessary on airplanes that were inspected in Area 1 in
accordance with the original issue or Revision 2 of this service bulletin. PART 15 gives work
instructions for more work which is necessary on airplanes that were inspected in Area 2 in
accordance with the original issue or Revision 2 of this service bulletin.
10. In Paragraph 3.B., Work Instructions, PART 16 has been added. PART 16 gives work instructions
for the inspection of scribe lines that were previously discovered in accordance with the instructions
in the original issue or Revision 2 of this service bulletin for cracks.
11. References to FAA Notice of Proposed Rulemaking (NPRM) 2007-NM-087-AD were added.
Revision 4 is sent to give affected operators improved repeat inspection interval data for lap joint and
butt joint areas that have been found to have scribe damage which will be or are being inspected under
the Limited Return to Service (LRTS) inspection program. Inspection of the S-18L lap splice from STA
1780 - STA 1920 (on the Main Deck Side Cargo Door) for scribe lines has been added to inspection
Area 3. This change only affects Group 2, Group 3 Configuration 2, Group 4, Group 6, and Group 8
airplanes. Inspection of the S-34R lap splice from STA 1810 - STA 1920 (on the aft lower lobe cargo
door) for scribe lines has been added to inspection Area 3. This change only affects Group 1 and Group
2 airplanes. Inspection of the S-6L and S-6R lap splice from STA 1000 - STA 1220 for scribe lines has
been added to inspection Area 3. This change only affects Group 3 and Group 4 airplanes. In addition,
general repair instructions for lap joint locations with scribe lines, but no cracks, have been added.
These instructions are in new PART 17 in Paragraph 3.B., and in new Appendix F. General repair
instructions for lap joint locations with scribe lines and cracks have also been added. These instructions
are in new PART 18 in Paragraph 3.B., and in new Appendix F. Analysis by Boeing has also determined
that inspections for scribe lines is not necessary at the thresholds for Main Entry Door 1 - 5, the Upper
Deck Entry Door (Stretched Upper Deck airplanes only) and the Bulk Cargo Door. In addition, inspections
for scribe lines are not necessary at the Bulk Cargo Door corner reinforcement doublers. These areas
have been removed from Paragraph 3.B., PART 7. Instructions for the continued inspection of scribe
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
24 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 25

lines in these areas that were found in accordance with earlier versions of this service bulletin have
been added to Paragraph 3.B., PART 16 and to new Tables 27 and 28 in Paragraph 1.E., Compliance.
References to Revision 1 have been removed throughout this service bulletin. Revision 1 was released
on the MyBoeingFleet website for a short time in 2007, but was permanently removed due to missing
illustrations. The FAA considers Revision 1 to be not FAA-approved as published.
Boeing Service Related Problem (SRP) 747/747OP-SRP-53-0242 is related to this service bulletin.
D. Description
A review of fleet activity shows two separate situations that are suspected to have resulted in fuselage
scribe line damage:
1. Paint stripping and repainting of airplanes. In the process of stripping and preparing the airplane
for paint, tools are used to remove sealant and paint buildup at lap joints, butt joints, and at external
doublers. Tools like scrapers (steel, wood, hard plastic etc.), knives, or utility knives can cause
scribe lines.
2. Fuselage graphic decals. To install decals across lap joints or repairs, investigation into maintenance
practices has shown the decals have been cut in place, using some form of knife, to allow the
decal to lie flush to the skin at these stepped locations. This operation can result in scribe lines at
the decal cut location. Based on service reports, sharp tools have also been used for close trimming
of the decal's outline. This type of decal trimming can also cause scribe lines.
The above maintenance operations can each lead to scribe line damage and subsequent premature
fatigue cracks.
Since scribe line damage can occur at any time during the service life of an airplane and at many
locations, this inspection takes into account both total airplane flight-cycles and the structural criticality
of scribe line locations.
Criticality of location allows this service bulletin to address the most critical areas first and to provide
less critical areas with appropriately reduced compliance requirements. Initial inspections for the
existence of scribe damage addresses the fatigue crack thresholds for each location. This service
bulletin uses areas to address the varying criticality of scribe line locations. Each piece of structure
susceptible to scribe line damage is assigned to an area - Area 1, Area 2, and Area 3. Area 1 has the
lowest fatigue crack threshold, Area 3 has the highest. The affected structure in each Area (for each
group of airplanes) is identified in individual figures in this service bulletin.
NOTE: Fuselage locations other than those shown in Areas 1, 2, or 3 may have scribe damage, but
those locations have been deemed non-critical and therefore no special inspections per this
service bulletin are needed.
At or before the scribe line inspection thresholds shown in Paragraph 1.E., Compliance, paint and
sealant are removed at the affected area locations. Detailed inspections of the skin or butt joint splice
straps are performed at these locations for scribe lines.
If no scribe lines are found, no more work is required as a result of this service bulletin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
25 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 26

If scribe lines are found, the scribe lines must be inspected for cracks in accordance with this service
bulletin. If cracks are found, repair the cracks before any more flight-cycles in accordance with this
service bulletin. If no cracks are found, repair the scribe lines before any more flight-cycles in accordance
with this service bulletin. As an alternative to scribe line repair, if no cracks are found the scribe lines
can be reinspected in accordance with the Limited Return to Service (LRTS) Program shown in the
service bulletin. The LRTS program allows airplanes to return to flight with continued inspections until
scribe lines are repaired.
If scribe lines are found prior to the applicable area inspection thresholds, steps are provided in
Paragraph 3.B. to address the specific local findings.
747-400ER airplanes and 747-400F airplanes after line number 1314 are not included in this service
bulletin. These airplanes may have different stress levels in the fuselage skin than the other airplanes
included in this service bulletin, and require additional analysis by Boeing. Depending on the results
of this analysis, those airplanes may be added to this service bulletin in a future revision.
Revision 3 - More work is necessary on airplanes previously inspected in Area 1 or Area 2 in accordance
with the original issue or Revision 2 of this service bulletin. At the time given in Paragraph 1.E.,
Compliance, Table 23 (for Area 1) and Table 24 (for Area 2) do detailed inspections at certain lap joint
locations for scribe lines in accordance with Paragraph 3.B., PART 14 (for Area 1) and with Paragraph
3.B., PART 15 (for Area 2). In addition, more work is necessary on Stretched Upper Deck (Group 3
and 4) airplanes previously inspected in Area 1 in accordance with the original issue of this service
bulletin. On these airplanes, the area of the STA 1283 butt joint from S-4.5 to S-6 on both sides of the
airplane was added to inspection Area 1 as part of Revision 2 of this service bulletin. This butt joint
area should be inspected in accordance with Paragraph 3.B., PART 13 at the time given in Paragraph
1.E., Compliance, Table 22. Also, more work is necessary on Group 1, 2, and 7 airplanes that were
previously inspected in Area 1 in accordance with the original issue or Revision 2 of this service bulletin.
On these airplanes, the area of the STA 1961 butt joint from S-40R to S-42R was added to inspection
Area 1 as part of Revision 2 of this service bulletin. This butt joint area should be inspected in accordance
with Paragraph 3.B., PART 14 at the time given in Paragraph 1.E., Compliance, Table 23.
Revision 4: No more work is necessary on Group 5, Group 7, and Group 9 airplanes inspected in
accordance with Revision 3 of this service bulletin as a result of Revision 4. If scribe lines were found
previously and are being inspected as part of the Limited Return to Service (LRTS) program, do the
repeat inspections in accordance with Revision 4.
Revision 4: More work is necessary on Group 1, Group 2, Group 3, Group 4, Group 6, and Group 8
airplanes previously inspected in Area 3 in accordance with the original issue, Revision 2, or Revision
3 of this service bulletin. At the time given in Paragraph 1.E., Compliance, Table 29, inspect certain
lap splices in accordance with Paragraph 3.B., Work Instructions, PART 19. At any location where
scribe lines were found previously and are being inspected as part of the Limited Return to Service
(LRTS) program, do the repeat inspections in accordance with Revision 4.
PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION
RESULTS WHEN EACH INSPECTION IS COMPLETE.
Send your report to: BOEING COMMERCIAL AIRPLANES GROUP ATTENTION: MANAGER, AIRLINE
SUPPORT
Please include in your report a record of all scribe damage that was found, including the damage
location, total flight-cycles and flight-hours, number of flight-cycles since scribing (if available), and
depth of scribe lines. If scribe line depth is found to be less than 0.001 inch, it is adequate to report the
depth as "less than 0.001 inch". Appendix C shows a method of recording scribe data.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
26 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 27

The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 123, 124,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 225, 226, 231, 232, 233, 234, 241,
242, 243, 244, 251, 252, 253, 254, 261, 262,
263, 264, 271, 272, 273, 274
747-100, 747-100B, 747-200B,
747SR
Group 2:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 123, 124,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 225, 226, 231, 232, 233, 234, 241,
242, 243, 244, 251, 252, 253, 254, 261, 262,
263, 264, 271, 272, 273, 274
747-100, 747-200B, 747SR
Group 3:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 123, 124,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 225, 226, 231, 232, 241, 242, 243,
244, 251, 252, 253, 254, 261, 262, 263, 264,
271, 272, 273, 274
747-100B SUD, 747-200B, 747-
300, 747-400, 747-400D
Group 4:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 123, 124,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 225, 226, 231, 232, 241, 242, 243,
244, 251, 252, 253, 254, 261, 262, 263, 264,
271, 272, 273, 274
747-200B, 747-300, 747-400
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
27 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 28

Group 5-6:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 123, 124,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 225, 226, 231, 232, 233, 234, 241,
242, 243, 244, 251, 252, 253, 254, 261, 262,
263, 264, 271, 272, 273, 274
747-200F
Group 6:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 123, 124,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 231, 232, 233, 234, 241, 242, 243,
244, 251, 252, 253, 254, 261, 262, 263, 264,
271, 272, 273, 274
747-400F
Group 7-8:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 123, 124,
125, 126, 127, 128, 141, 142, 143, 144, 145,
146, 147, 148, 151, 152, 211, 212, 221, 222,
223, 224, 225, 226, 231, 232, 233, 234, 241,
242, 243, 244, 251, 252, 253, 254, 261, 262,
263, 264, 271, 272, 273, 274
747-200C
Group 9:
Affected Maintenance Zones
ZoneModel
112, 115, 116, 117, 118, 121, 122, 125, 126,
127, 128, 141, 142, 143, 144, 145, 146, 147,
148, 151, 152, 211, 212, 221, 222, 223, 224,
225, 226, 231, 232, 241, 242, 243, 244, 251,
252, 253, 254, 261, 262, 263, 264
747SP
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
28 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 29

E. Compliance
Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2007-NM-087-AD is related to
this service bulletin.
Inspection Exemptions. Certain inspections are not required under these conditions:
1. If the operator can show that the airplane has never been stripped or repainted since delivery from
Boeing, then the scribe line exploratory inspections in Areas 1, 2, and 3 are not required at lap
and butt joints, cargo door hinges, thresholds, main deck side cargo door external straps, and all
doublers unless a decal has been applied. Exploratory inspections at the other features such as
antenna fairings and decals may still be required. If decals have been installed over a lap joint or
external doubler, do the Area 1, Area 2, and Area 3 inspections at affected locations common to
the areas covered by the decal, even if no fillet seal has ever been removed.
2. If the operator can show that the airplane has never been stripped or repainted under the
wing-to-body fairings since delivery from Boeing, then the lap joint, butt joint, and external doubler
and cutout reinforcement doubler inspections in the areas under the wing-to-body fairing are not
required.
3. For each repair, if the operator can show that the airplane has never been stripped or repainted
since the repair has been installed, then the repair inspections for that specific repair are not
required.
4. If the operator can show that the removal of sealant at all times since delivery has been
accomplished in accordance with the sealant removal process in Appendix A of this service bulletin,
then the lap joint, butt joint, and external doubler and cutout reinforcement doubler inspections are
not required, except as noted in Note 1., above, where decals have been applied.
Boeing recommends that operators do exploratory inspections for scribe lines at the times given in the
tables that follow:
NOTE: Exploratory inspections refer to the thresholds used to determine if scribe damage
exists.
1.
2. Fuselage skin lap splice threshold and interval inspection values shown as left or
right sides also apply to cargo door lap splices, unless stated otherwise.
3. For the given Lap Joint Body Station (STA) locations that are near the edge of a
cutout, the intent is to inspect the lap joint to the edge of the cutout.
4. Appendix E contains a list of 747 airplanes that were delivered with fillet sealed lap
joints. Operators should be aware that the lap joints on other airplanes may have
been fillet sealed after delivery from Boeing.
In the tables that follow, repeat inspection intervals are shown for areas defined as Area 1, Area 2, and
Area 3 in Paragraph 3.B., Work Instructions. Areas defined as Area 3 only require inspections if cracking
is found at an Area 2 location. This service bulletin does not require any directed inspections for scribe
lines at any of the areas not included in Area 1, Area 2, or Area 3.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
29 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 30

NOTE: If, at any location, the new repeat inspection interval is less than that given in the original issue
or Revision 2 of this service bulletin, do the next repeat inspection at that location at the interval
given in Revision 4, but do not exceed 500 flight-cycles after the date of Revision 4. All of the
repeat inspection intervals in Revision 4 of this service bulletin are the same as or greater
than the repeat inspection intervals in Revision 3.
Table 1 - Area 1 Exploratory Inspections
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-500 flight-cycles af-
ter the original is-
sue date on this
service bulletin
-Do detailed inspections of
the fuselage skin or butt
joint splice straps in Area 1
for scribe lines in accor-
dance with Paragraph 3.B.,
PART 1.
Airplanes with more than
20,000 total flight-cycles as
of the original issue date on
this service bulletin.
-1,000 flight-cycles
after the original is-
sue date on this
service bulletin
-Airplanes with more than
17,500 total flight-cycles, but
no more than 20,000 total
flight-cycles, as of the origi-
nal issue date on this ser-
vice bulletin.
-1,500 flight-cycles
after the original is-
sue date on this
service bulletin
15,000 total
flight-cycles
Airplanes with 17,500 total
flight-cycles or less as of the
original issue date on this
service bulletin.
---No more action is neces-
sary in Area 1.
No scribe lines found
-Before any more flight-cyclesMeasure the depth of the
scribe lines. Do detailed,
HFEC, and ultrasonic in-
spections of the scribe lines
for cracks in accordance
with Paragraph 3.B., PART
1.
Scribe lines found
-Before any more flight-cyclesRepair cracks in accor-
dance with Paragraph 3.B.,
PART 1. Do detailed inspec-
tions of the fuselage skin or
butt joint splice straps in
Area 2 for scribe lines in
accordance with Paragraph
3.B., PART 2.
Cracks found
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
30 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 31

Table 1 - Area 1 Exploratory Inspections
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before any more flight-cyclesRepair scribe lines in accor-
dance with Paragraph 3.B.,
PART 1, or
No crack found
Refer to Tables 4
- 20 for repeat in-
spection inter-
vals.
-Do repeat detailed, HFEC,
and ultrasonic inspections
of the unrepaired scribe
lines for cracks in accor-
dance with Paragraph 3.B.,
PART 11.
Table 2 - Area 2 Exploratory Inspections
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before any more flight-cyclesDo detailed inspections
of the fuselage skin or
butt joint splice straps in
Area 2 for scribe lines in
accordance with Para-
graph 3.B., PART 2.
Any airplane with a crack found
at a scribe line in Area 1
500 flight-cy-
cles after the
original issue
date on this
service bulletin
-Airplanes with more than
27,500 total flight-cycles as of
the original issue date on this
service bulletin, unless previ-
ously accomplished as re-
quired by Table 1 Inspections.
1,000 flight-cy-
cles after the
original issue
date on this
service bulletin
25,000 total
flight-cycles
Airplanes with 27,500 total
flight-cycles or less as of the
original issue date on this ser-
vice bulletin, unless previously
accomplished as required by
Table 1 Inspections.
---No more action is neces-
sary in Area 2.
No scribe lines found
-Before any more flight-cyclesMeasure the depth of the
scribe lines. Do detailed,
HFEC, and ultrasonic in-
spections of the scribe
lines for cracks in accor-
dance with Paragraph
3.B., PART 2.
Scribe lines found
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
31 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 32

Table 2 - Area 2 Exploratory Inspections
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before any more flight-cyclesRepair cracks in accor-
dance with Paragraph
3.B., PART 2. Do detailed
inspections of the fuse-
lage skin or butt joint
splice straps in Area 3 for
scribe lines in accor-
dance with Paragraph
3.B., PART 3.
Cracks found
-Before any more flight-cyclesRepair scribe lines in ac-
cordance with Paragraph
3.B., PART 2, or
No crack found
Refer to Tables 4
- 20 for repeat in-
spection inter-
vals.
-Do repeat detailed,
HFEC, and ultrasonic in-
spections of the unre-
paired scribe lines for
cracks in accordance with
Paragraph 3.B., PART
11.
Table 3 - Area 3 Exploratory Inspections
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before any more flight-cyclesDo detailed inspections of
the fuselage skin or butt
joint splice straps in Area
3 for scribe lines in accor-
dance with Paragraph
3.B., PART 3.
Any airplane with a crack
found at a scribe line in Area
2
---No more action is neces-
sary in Area 3.
No scribe lines found
-Before any more flight-cyclesMeasure the depth of the
scribe lines. Do detailed,
HFEC, and ultrasonic in-
spections of the scribe
lines for cracks in accor-
dance with Paragraph
3.B., PART 3.
Scribe lines found
-Before any more flight-cyclesRepair cracks in accor-
dance with Paragraph
3.B., PART 3.
Cracks found
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
32 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 33

Table 3 - Area 3 Exploratory Inspections
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before any more flight-cyclesRepair scribe lines in ac-
cordance with Paragraph
3.B., PART 3, or
No crack found
Refer to Tables 4
- 20 and 25 for
repeat inspection
intervals.
-Do repeat detailed, HFEC,
and ultrasonic inspections
of the unrepaired scribe
lines for cracks in accor-
dance with Paragraph
3.B., PART 11.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
33 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 34

Group 1:
Table 4 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,250 flight-cyclesSTA 741 - STA 941S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cy-
cles
STA 1000 - STA 1241 (a)S-4 L and R
1,500 flight-cyclesSTA 1480 - STA 2360
1,500 flight-cyclesSTA 340 - STA 400S-6 L and R
3,000 flight-cyclesSTA 520 - STA 741
1,500 flight-cyclesSTA 741 - STA 881
3,200 flight-cyclesSTA 881 - STA 1000
1,500 flight-cyclesSTA 400 - STA 520S-6L (if no
crew door is
installed)
Optional: 4,500
flight-cycles (b)
4,500 flight-cyclesSTA 400 - STA 520S-6L (if a crew
door is in-
stalled)
4,500 flight-cyclesSTA 400 - STA 520S-6R
4,000 flight-cyclesSTA 520 - STA 741S-12 L and R
3,200 flight-cyclesSTA 741 - STA 1000
1,500 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 1741 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,500 flight-cyclesSTA 220 - STA 520S-14 L and R
4,500 flight-cyclesSTA 135 - STA 400S-19L
3,000 flight-cyclesSTA 135 - STA 220S-19R
2,500 flight-cyclesSTA 220 - STA 400
1,400 flight-cyclesSTA 520 - STA 741S-19 L and R
1,500 flight-cyclesSTA 1480 - STA 1660
2,000 flight-cyclesSTA 1741 - STA 2181
1,400 flight-cyclesSTA 2285 - STA 2360
1,100 flight-cyclesSTA 135 - STA 400S-23 L and R
4,000 flight-cyclesSTA 741 - STA 800
2,000 flight-cyclesSTA 1350 - STA 1480
1,500 flight-cyclesSTA 1700 - STA 1741
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
34 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 35

Group 1:
Table 4 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 1741 - STA 1961 1,500 flight-cycles
3,200 flight-cyclesSTA 2285 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 1480 - STA 1660
1,250 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2231
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 1480 - STA 1660
1,100 flight-cyclesSTA 1961 - STA 2181
4,000 flight-cyclesSTA 2181 - STA 2231
10,000 flight-cy-
cles
STA 135 - Canted BulkheadS-34 L and R
7,500 flight-cyclesCanted Bulkhead - STA 400
3,200 flight-cyclesSTA 400 - STA 520
1,250 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,400 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
1,000 flight-cyclesSTA 520 - STA 560S-34R
1,300 flight-cyclesSTA 560 - STA 670
1,100 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
1,300 flight-cyclesSTA 1810 - STA 1920
5,000 flight-cyclesSTA 1920 - STA 1961
3,200 flight-cyclesSTA 1961 - STA 1980
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 520 - Front Spar BulkheadS-39L
10,000 flight-cy-
cles
STA 520 - STA 560 (a)S-39R
5,000 flight-cyclesSTA 670 - STA 741 (a)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
35 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 36

Group 1:
Table 4 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,500 flight-cyclesSTA 741 - Front Spar Bulkhead
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
2,500 flight-cyclesSTA 1741 - STA 1800S-40R
4,500 flight-cyclesSTA 1920 - STA 1961
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,400 flight-cyclesSTA 520 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,500 flight-cyclesSTA 1741 - STA 1961S-46L
1,000 flight-cyclesSTA 2181 - STA 2360
1,100 flight-cyclesSTA 1741 - STA 1961S-46R
1,100 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 1961 - STA 2181S-46 L and R
(a) This location was part of Area 1 or Area 2 in the original issue and Revision 2 of this service bulletin,
but was removed from Area 1 or Area 2 as part of Revision 3. Repeat inspections in this location are
required only if crack-free scribe damage more than 0.004 inch deep, but not more than 0.006 inch
deep, was found in this location during inspections in accordance with the original issue or Revision 2
of this service bulletin.
(b) A repeat interval of 4,500 flight-cycles is allowed in this area only, provided there is no visible scribe
damage in the lower skin between STA 340 and STA 520 that is within 0.10 inch from the edge of the
upper skin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
36 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 37

Group 2:
Table 5 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,250 flight-cyclesSTA 741 - STA 941S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cy-
cles
STA 1000 - STA 1241 (a)S-4 L and R
1,500 flight-cyclesSTA 1480 - STA 1700S-4L
1,500 flight-cyclesSTA 2000 - STA 2360
1,500 flight-cyclesSTA 1480 - STA 2360S-4R
1,500 flight-cyclesSTA 340 - STA 400S-6 L and R
3,000 flight-cyclesSTA 520 - STA 741
1.500 flight-cyclesSTA 741 - STA 881
3,200 flight-cyclesSTA 881 - STA 1000
1,500 flight-cyclesSTA 400 - STA 520S-6L (if no
crew door is
installed)
Optional: 4,500
flight-cycles (b)
4,500 flight-cyclesSTA 400 - STA 520S-6L (if a crew
door is in-
stalled)
4,500 flight-cyclesSTA 400 - STA 520S-6R
4,000 flight-cyclesSTA 520 - STA 741S-12 L and R
3,200 flight-cyclesSTA 741 - STA 1000
1,500 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 1961 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 1741 - STA 1961S-12R
1,500 flight-cyclesSTA 220 - STA 520S-14 L and R
1,750 flight-cyclesSTA 1780 - STA 1920S-18L
1,400 flight-cyclesSTA 520 - STA 741S-19 L and R
1,500 flight-cyclesSTA 1480 - STA 1660
2,000 flight-cyclesSTA 1961 - STA 2181
1,400 flight-cyclesSTA 2285 - STA 2360
4,500 flight-cyclesSTA 135 - STA 400S-19L
3,000 flight-cyclesSTA 135 - STA 220S-19R
2,500 flight-cyclesSTA 220 - STA 400
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
37 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 38

Group 2:
Table 5 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
2,000 flight-cyclesSTA 1741 - STA 1961
1,100 flight-cyclesSTA 135 - STA 400S-23 L and R
4,000 flight-cyclesSTA 741 - STA 800
2,000 flight-cyclesSTA 1350 - STA 1480
1,500 flight-cyclesSTA 1700 - STA 1741
3,200 flight-cyclesSTA 2285 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 1480 - STA 1660
1,250 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2231
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 1480 - STA 1660
1,500 flight-cyclesSTA 1741 - STA 1961
1,100 flight-cyclesSTA 1961 - STA 2181
4,000 flight-cyclesSTA 2181 - STA 2231
10,000 flight-cy-
cles
STA 135 - Canted BulkheadS-34 L and R
7,500 flight-cyclesCanted Bulkhead - STA 400
3,200 flight-cyclesSTA 400 - STA 520
1,250 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,400 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
1,000 flight-cyclesSTA 520 - STA 560S-34R
1,300 flight-cyclesSTA 560 - STA 670
1,100 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
1,300 flight-cyclesSTA 1810 - STA 1920
5,000 flight-cyclesSTA 1920 - STA 1961
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
38 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 39

Group 2:
Table 5 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 1961 - STA 1980 3,200 flight-cycles
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 520 - Front Spar BulkheadS-39L
10,000 flight-cy-
cles
STA 520 - STA 560 (a)S-39R
5,000 flight-cyclesSTA 670 - STA 741 (a)
1,500 flight-cyclesSTA 741 - Front Spar Bulkhead
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
2,500 flight-cyclesSTA 1741 - STA 1800S-40R
4,500 flight-cyclesSTA 1920 - STA 1961
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,400 flight-cyclesSTA 520 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,500 flight-cyclesSTA 1741 - STA 1961S-46L
1,000 flight-cyclesSTA 2181 - STA 2360
1,100 flight-cyclesSTA 1741 - STA 1961S-46R
1,100 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 1961 - STA 2181S-46 L and R
(a) This location was part of Area 1 or Area 2 in the original issue and Revision 2 of this service bulletin,
but was removed from Area 1 or Area 2 as part of Revision 3. Repeat inspections in this location are
required only if crack-free scribe damage more than 0.004 inch deep, but not more than 0.006 inch
deep, was found in this location during inspections in accordance with the original issue or Revision 2
of this service bulletin.
(b) A repeat interval of 4,500 flight-cycles is allowed in this area only, provided there is no visible scribe
damage in the lower skin between STA 340 and STA 520 that is within 0.10 inch from the edge of the
upper skin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
39 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 40

Group 1-2:
Table 6 - Butt Splice Repeat Inspection Intervals
Repeat Interval (Not
to Exceed)
Butt Splice AreaActionCondition
From - ToStation
2,000 flight-cyclesS-0 to S-6, L and RSTA 340Do Detailed and
HFEC or LFEC in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cyclesS-23 to S-39, L and RSTA 400
5,000 flight-cyclesS-39 to S-44, L and R
2,000 flight-cyclesS-23 to S-34, L and RSTA 520
2,000 flight-cyclesS-39 to S-44, L and R
2,000 flight-cyclesS-6 to S-12, L and RSTA 741
1,500 flight-cyclesS-0 to S-4, L and RSTA 1240
3,200 flight-cyclesS-4 to S-12, L and R
1,500 flight-cyclesS-12 to S-19, L and R
1,500 flight-cyclesS-0 to S-4, L and RSTA 1480
2,000 flight-cyclesS-4 to S-9, L and R
1,500 flight-cyclesS-0 to S-19, L and RSTA 1741
1,500 flight-cyclesS-23 to S-34, L and R
3,200 flight-cyclesS-40 to S-46, L and R
1,000 flight-cyclesS-0 to S-4, L and RSTA 1961
1,250 flight-cyclesS-4 to S-12, L and R
3,200 flight-cyclesS-12 to S-23, L and R
1,500 flight-cyclesS-23 to S-34, L and R
5,000 flight-cyclesS-34 to S-40, L and R
1,500 flight-cyclesS-40 to S-46, L and R
5,000 flight-cyclesS-46L to S-46R
1,500 flight-cyclesS-0 to S-4, L and RSTA 2181
2,000 flight-cyclesS-4 to S-12, L and R
4,500 flight-cyclesS-12 to S-23, L and R
10,000 flight-cyclesS-23 to S-34, L and R
2,000 flight-cyclesS-34L to S-34R
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
40 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 41

Group 3, Configuration 1:
Table 7 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
2,500 flight-cyclesSTA 741- STA 1000S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 1,500 flight-cyclesSTA 1480 - STA 2181S-4 L and R
2,500 flight-cyclesSTA 2181 - STA 2360
1,500 flight-cyclesSTA 340 - STA 520S-6 L and R
3,000 flight-cyclesSTA 741 - STA 1000
1,500 flight-cyclesSTA 1000 - STA 1283
4,000 flight-cyclesSTA 520 - STA 670S-6L
2,000 flight-cyclesSTA 714 - STA 741
2,000 flight-cyclesSTA 520 - STA 670S-6R
2,500 flight-cyclesSTA 714 - STA 741
2,000 flight-cyclesSTA 520 - STA 670S-12 L and R
7,500 flight-cyclesSTA 714 - STA 741
2,500 flight-cyclesSTA 1000 - STA 1241
1,250 flight-cyclesSTA 1741 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 741 - STA 1000S-12L
2,000 flight-cyclesSTA 1480 - STA 1741
1,400 flight-cyclesSTA 741 - STA 1000S-12R
1,500 flight-cyclesSTA 1480 - STA 1741
1,500 flight-cyclesSTA 220 - STA 520S-14 L and R
4,500 flight-cyclesSTA 135 - STA 400S-19 L and R
2,000 flight-cyclesSTA 741 - STA 800
2,500 flight-cyclesSTA 1319 - STA 1350
3,000 flight-cyclesSTA 1741 - STA 1961
1,500 flight-cyclesSTA 1961 - STA 2181
1,250 flight-cyclesSTA 2280 - STA 2360
1,500 flight-cyclesSTA 520 - STA 741S-19L
2,500 flight-cyclesSTA 1480 - STA 1660
5,000 flight-cyclesSTA 2181 - STA 2230
1,000 flight-cyclesSTA 520 - STA 741S-19R
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
41 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 42

Group 3, Configuration 1:
Table 7 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 1480 - STA 1660 3,200 flight-cycles
7,500 flight-cyclesSTA 2181 - STA 2230
1,500 flight-cyclesSTA 135 - STA 400S-23 L and R
2,000 flight-cyclesSTA 1350 - STA 1480
1,500 flight-cyclesSTA 1741 - STA 1961
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 741 - STA 800
2,000 flight-cyclesSTA 1480 - STA 1660
1,250 flight-cyclesSTA 1961 - STA 2181
5,000 flight-cyclesSTA 2181 - STA 2230
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 741 - STA 800
2,500 flight-cyclesSTA 1480 - STA 1660
1,100 flight-cyclesSTA 1961 - STA 2181
10,000 flight-cyclesSTA 2181 - STA 2230
10,000 flight-cyclesSTA 135 - Canted BulkheadS-34 L and R
4,500 flight-cyclesCanted Bulkhead - STA 400
1,200 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 2181 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
1,250 flight-cyclesSTA 520 - STA 560S-34R
1,300 flight-cyclesSTA 560 - STA 670
1,200 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
1,300 flight-cyclesSTA 1810 - STA 1920
4,000 flight-cyclesSTA 1920 - STA 1980
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 520 - STA 741S-39L
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
42 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 43

Group 3, Configuration 1:
Table 7 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,500 flight-cyclesSTA 741 - Front Spar Bulkhead
2,500 flight-cyclesSTA 670 - STA 741S-39R
1,500 flight-cyclesSTA 741 - Front Spar Bulkhead
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,500 flight-cyclesSTA 520 - STA 741
1,400 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,400 flight-cyclesSTA 1741 - STA 1961S-46L
1,250 flight-cyclesSTA 1961 - STA 2181
1,000 flight-cyclesSTA 1741 - STA 1961S-46R
1,500 flight-cyclesSTA 1961 - STA 2181
1,200 flight-cyclesSTA 2181 - STA 2360S-46 L and R
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
43 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 44

Group 3, Configuration 2; Group 4:
Table 8 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
2,500 flight-cyclesSTA 741- STA 1000S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 1,500 flight-cyclesSTA 1480 - STA 2181S-4R
1,500 flight-cyclesSTA 1480 - STA 1700S-4L
1,500 flight-cyclesSTA 2000 - STA 2181
2,500 flight-cyclesSTA 2181 - STA 2360S-4 L and R
1,500 flight-cyclesSTA 340 - STA 520S-6 L and R
3,000 flight-cyclesSTA 741 - STA 1000
1,500 flight-cyclesSTA 1000 - STA 1283
4,000 flight-cyclesSTA 520 - STA 670S-6L
2,000 flight-cyclesSTA 714 - STA 741
2,000 flight-cyclesSTA 520 - STA 670S-6R
2,500 flight-cyclesSTA 714 - STA 741
2,000 flight-cyclesSTA 520 - STA 670S-12 L and R
7,500 flight-cyclesSTA 714 - STA 741
2,500 flight-cyclesSTA 1000 - STA 1240
1,250 flight-cyclesSTA 1961 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 741 - STA 1000S-12L
2,000 flight-cyclesSTA 1480 - STA 1741
1,400 flight-cyclesSTA 741 - STA 1000S-12R
1,500 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 1741 - STA 1961
1,500 flight-cyclesSTA 220 - STA 520S-14 L and R
1,750 flight-cyclesSTA 1780 - STA 1920S-18L
4,500 flight-cyclesSTA 135 - STA 400S-19 L and R
2,000 flight-cyclesSTA 741 - STA 800
2,500 flight-cyclesSTA 1319 - STA 1350
1,500 flight-cyclesSTA 1961 - STA 2181
1,250 flight-cyclesSTA 2280 - STA 2360
1,500 flight-cyclesSTA 520 - STA 741S-19L
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
44 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 45

Group 3, Configuration 2; Group 4:
Table 8 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 1480 - STA 1660 2,500 flight-cycles
5,000 flight-cyclesSTA 2181 - STA 2230
1,000 flight-cyclesSTA 520 - STA 741S-19R
3,200 flight-cyclesSTA 1480 - STA 1660
3,000 flight-cyclesSTA 1741 - STA 1961
7,500 flight-cyclesSTA 2181 - STA 2230
1,500 flight-cyclesSTA 135 - STA 400S-23 L and R
2,000 flight-cyclesSTA 1350 - STA 1480
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 741 - STA 800
2,000 flight-cyclesSTA 1480 - STA 1660
1,250 flight-cyclesSTA 1961 - STA 2181
5,000 flight-cyclesSTA 2181 - STA 2230
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 741 - STA 800
2,500 flight-cyclesSTA 1480 - STA 1660
1,500 flight-cyclesSTA 1741 - STA 1961
1,100 flight-cyclesSTA 1961 - STA 2181
10,000 flight-cyclesSTA 2181 - STA 2230
10,000 flight-cyclesSTA 135 - Canted BulkheadS-34 L and R
4,500 flight-cyclesCanted Bulkhead - STA 400
1,200 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 2181 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
1,250 flight-cyclesSTA 520 - STA 560S-34R
1,300 flight-cyclesSTA 560 - STA 670
1,200 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
45 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 46

Group 3, Configuration 2; Group 4:
Table 8 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 1810 - STA 1920 1,300 flight-cycles
4,000 flight-cyclesSTA 1920 - STA 1980
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 741 - Front Spar BulkheadS-39 L and R
1,500 flight-cyclesSTA 520 - STA 741S-39L
2,500 flight-cyclesSTA 670 - STA 741S-39R
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,500 flight-cyclesSTA 520 - STA 741
1,400 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,400 flight-cyclesSTA 1741 - STA 1961S-46L
1,250 flight-cyclesSTA 1961 - STA 2181
1,000 flight-cyclesSTA 1741 - STA 1961S-46R
1,500 flight-cyclesSTA 1961 - STA 2181
1,200 flight-cyclesSTA 2181 - STA 2360S-46 L and R
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
46 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 47

Group 3-4:
Table 9 - Butt Splice Repeat Inspection Intervals
Repeat Interval (Not
to Exceed)
Butt Splice AreaActionCondition
From - ToStation
2,000 flight-cyclesS-0 to S-6, L and RSTA 340Do Detailed and
HFEC or LFEC in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cyclesS-23 to S-39, L and RSTA 400
3,800 flight-cyclesS-39 to S-44, L and R
1,500 flight-cyclesS-6 to S-12, L and RSTA 520
2,000 flight-cyclesS-39 to S-44, L and R
2,000 flight-cyclesS-0 to S-6, L and RSTA 1220
2,000 flight-cyclesS-12 to S-19, L and RSTA 1240
1,500 flight-cyclesS-4.5 to S-6, L and RSTA 1283
1,500 flight-cyclesS-0 to S-4, L and RSTA 1480
2,000 flight-cyclesS-4 to S-9, L and R
1,500 flight-cyclesS-0 to S-4, L and RSTA 1741
2,000 flight-cyclesS-4 to S-12, L and R
5,000 flight-cyclesS-12 to S-19, L and R
10,000 flight-cyclesS-23 to S-34, L and R
1,000 flight-cyclesS-0 to S-4, L and RSTA 1961
4,000 flight-cyclesS-4 to S-12, L and R
4,500 flight-cyclesS-12 to S-19, L and R
1,500 flight-cyclesS-19 to S-23, L and R
10,000 flight-cyclesS-40L to S-40R
5,000 flight-cyclesS-0 to S-12, L and RSTA 2181
5,000 flight-cyclesS-12 to S-19, L and R
5,000 flight-cyclesS-34 to S-46, L and R
10,000 flight-cyclesS-46L to S-46R
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
47 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 48

Group 5:
Table 10 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,250 flight-cyclesSTA 741 - STA 941S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cy-
cles
STA 1000 - STA 1241 (a)S-4 L and R
1,500 flight-cyclesSTA 1480 - STA 2360
1,500 flight-cyclesSTA 340 - STA 400S-6 L and R
2,000 flight-cyclesSTA 520 - STA 741
1,500 flight-cyclesSTA 741 - STA 881
3,000 flight-cyclesSTA 881 - STA 1000
1,500 flight-cyclesSTA 400 - STA 520S-6L (if no
crew door is
installed)
Optional: 2,000
flight-cycles (b)
2,000 flight-cyclesSTA 400 - STA 520S-6L (if a crew
door is in-
stalled)
2,000 flight-cyclesSTA 400 - STA 520S-6R
2,000 flight-cyclesSTA 520 - STA 741S-12 L and R
2,500 flight-cyclesSTA 1000 - STA 1241
1,500 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 1741 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 741 - STA 1000S-12L
1,400 flight-cyclesSTA 741 - STA 1000S-12R
1,500 flight-cyclesSTA 135 - STA 520S-14 L and R
2,000 flight-cyclesSTA 741 - STA 1000S-19L and R
2,500 flight-cyclesSTA 1241 - STA 1350
1,500 flight-cyclesSTA 1480 - STA 1741
2,000 flight-cyclesSTA 1741 - STA 1961
1,500 flight-cyclesSTA 1961 - STA 2181
4,500 flight-cyclesSTA 135 - STA 400S-19L
1,400 flight-cyclesSTA 520 - STA 741
5,000 flight-cyclesSTA 2181 - STA 2231
1,250 flight-cyclesSTA 2285 - STA 2360
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
48 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 49

Group 5:
Table 10 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
S-19R 2,500 flight-cyclesSTA 135 - STA 400
1,000 flight-cyclesSTA 520 - STA 741
1,250 flight-cyclesSTA 2181 - STA 2360
1,100 flight-cyclesSTA 135 - STA 400S-23L and R
2,000 flight-cyclesSTA 1350 - STA 1480
1,500 flight-cyclesSTA 1480 - STA 1961
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 741 - STA 1000
1,250 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2231
3,200 flight-cyclesSTA 2285 - STA 2360
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 741 - STA 1000
1,100 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2360
10,000 flight-cy-
cles
STA 135 - Nose Cargo Door
Portal
S-34 L and R
4,500 flight-cyclesNose Cargo Door Portal - STA
400
3,200 flight-cyclesSTA 400 - STA 520
1,200 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 2181 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
1,100 flight-cyclesSTA 520 - STA 560S-34R
1,300 flight-cyclesSTA 560 - STA 670
1,100 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
1,300 flight-cyclesSTA 1810 - STA 1920
2,000 flight-cyclesSTA 1920 - STA 1961
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
49 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 50

Group 5:
Table 10 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 1961 - STA 1980 3,200 flight-cycles
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 520 - STA 741S-39L
10,000 flight-cy-
cles
STA 520 - STA 560 (a)S-39R
2,500 flight-cyclesSTA 560 - STA 741
1,500 flight-cyclesSTA 741 - Front Spar BulkheadS-39 L and R
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
2,500 flight-cyclesSTA 1741 - STA 1800S-40R
4,500 flight-cyclesSTA 1920 - STA 1961
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,400 flight-cyclesSTA 520 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,250 flight-cyclesSTA 1961 - STA 2181S-46 L and R
1,400 flight-cyclesSTA 1741 - STA 1961S-46L
1,000 flight-cyclesSTA 2181 - STA 2360
1,000 flight-cyclesSTA 1741 - STA 1961S-46R
1,100 flight-cyclesSTA 2181 - STA 2360
(a) This location was part of Area 1 or Area 2 in the original issue and Revision 2 of this service bulletin, but
was removed from Area 1 or Area 2 as part of Revision 3. Repeat inspections in this location are required
only if crack-free scribe damage more than 0.004 inch deep, but not more than 0.006 inch deep, was
found in this location during inspections in accordance with the original issue or Revision 2 of this service
bulletin.
(b) A repeat interval of 2,000 flight-cycles is allowed in this area only, provided there is no visible scribe
damage in the lower skin between STA 340 and STA 520 that is within 0.10 inch from the edge of the
upper skin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
50 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 51

Group 6:
Table 11 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,250 flight-cyclesSTA 741 - STA 941S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cy-
cles
STA 1000 - STA 1241 (a)S-4 L and R
1,500 flight-cyclesSTA 1480 - STA 1700S-4L
1,500 flight-cyclesSTA 2000 - STA 2360
1,500 flight-cyclesSTA 1480 - STA 2360S-4R
1,500 flight-cyclesSTA 340 - STA 400S-6 L and R
2,000 flight-cyclesSTA 520 - STA 741
1,500 flight-cyclesSTA 741 - STA 881
3,000 flight-cyclesSTA 881 - STA 1000
1,500 flight-cyclesSTA 400 - STA 520S-6L (if no
crew door is
installed)
Optional: 2,000
flight-cycles (b)
2,000 flight-cyclesSTA 400 - STA 520S-6L (if a crew
door is in-
stalled)
2,000 flight-cyclesSTA 400 - STA 520S-6R
2,000 flight-cyclesSTA 520 - STA 741S-12 L and R
2,500 flight-cyclesSTA 1000 - STA 1241
1,500 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 1961 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 741 - STA 1000S-12L
1,400 flight-cyclesSTA 741 - STA 1000S-12R
1,250 flight-cyclesSTA 1741 - STA 1961
1,500 flight-cyclesSTA 135 - STA 520S-14 L and R
1,750 flight-cyclesSTA 1780 - STA 1920S-18L
2,000 flight-cyclesSTA 741 - STA 1000S-19L and R
2,500 flight-cyclesSTA 1241 - STA 1350
1,500 flight-cyclesSTA 1480 - STA 1741
1,500 flight-cyclesSTA 1961 - STA 2181
4,500 flight-cyclesSTA 135 - STA 400S-19L
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
51 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 52

Group 6:
Table 11 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 520 - STA 741 1,400 flight-cycles
5,000 flight-cyclesSTA 2181 - STA 2231
1,250 flight-cyclesSTA 2285 - STA 2360
2,500 flight-cyclesSTA 135 - STA 400S-19R
1,000 flight-cyclesSTA 520 - STA 741
2,000 flight-cyclesSTA 1741 - STA 1961
1,250 flight-cyclesSTA 2181 - STA 2360
1,100 flight-cyclesSTA 135 - STA 400S-23L and R
2,000 flight-cyclesSTA 1350 - STA 1480
1,500 flight-cyclesSTA 1480 - STA 1741
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 741 - STA 1000
1,250 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2231
3,200 flight-cyclesSTA 2285 - STA 2360
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 741 - STA 1000
1,500 flight-cyclesSTA 1741 - STA 1961
1,100 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2360
10,000 flight-cy-
cles
STA 135 - Nose Cargo Door
Portal
S-34 L and R
4,500 flight-cyclesNose Cargo Door Portal - STA
400
3,200 flight-cyclesSTA 400 - STA 520
1,200 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 2181 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
1,100 flight-cyclesSTA 520 - STA 560S-34R
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
52 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 53

Group 6:
Table 11 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 560 - STA 670 1,300 flight-cycles
1,100 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
1,300 flight-cyclesSTA 1810 - STA 1920
2,000 flight-cyclesSTA 1920 - STA 1961
3,200 flight-cyclesSTA 1961 - STA 1980
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 520 - STA 741S-39L
10,000 flight-cy-
cles
STA 520 - STA 560 (a)S-39R
2,500 flight-cyclesSTA 560 - STA 741
1,500 flight-cyclesSTA 741 - Front Spar BulkheadS-39 L and R
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
2,500 flight-cyclesSTA 1741 - STA 1800S-40R
4,500 flight-cyclesSTA 1920 - STA 1961
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,400 flight-cyclesSTA 520 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,250 flight-cyclesSTA 1961 - STA 2181S-46 L and R
1,400 flight-cyclesSTA 1741 - STA 1961S-46L
1,000 flight-cyclesSTA 2181 - STA 2360
1,000 flight-cyclesSTA 1741 - STA 1961S-46R
1,100 flight-cyclesSTA 2181 - STA 2360
(a) This location was part of Area 1 or Area 2 in the original issue and Revision 2 of this service bulletin, but
was removed from Area 1 or Area 2 as part of Revision 3. Repeat inspections in this location are required
only if crack-free scribe damage more than 0.004 inch deep, but not more than 0.006 inch deep, was
found in this location during inspections in accordance with the original issue or Revision 2 of this service
bulletin.
(b) A repeat interval of 2,000 flight-cycles is allowed in this area only, provided there is no visible scribe
damage in the lower skin between STA 340 and STA 520 that is within 0.10 inch from the edge of the
upper skin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
53 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 54

Group 7:
Table 12 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,250 flight-cyclesSTA 741 - STA 941S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cy-
cles
STA 1000 - STA 1241 (a)S-4 L and R
1,500 flight-cyclesSTA 1480 - STA 2360
1,500 flight-cyclesSTA 340 - STA 400S-6 L and R
2,000 flight-cyclesSTA 520 - STA 741
1,500 flight-cyclesSTA 741 - STA 881
3,000 flight-cyclesSTA 881 - STA 1000
1,500 flight-cyclesSTA 400 - STA 520S-6L (if no
crew door is
installed)
Optional: 2,000
flight-cycles (b)
2,000 flight-cyclesSTA 400 - STA 520S-6L (if a crew
door is in-
stalled)
2,000 flight-cyclesSTA 400 - STA 520S-6R
2,000 flight-cyclesSTA 520 - STA 741S-12 L and R
2,500 flight-cyclesSTA 1000 - STA 1241
1,500 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 1741 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 741 - STA 1000S-12L
1,400 flight-cyclesSTA 741 - STA 1000S-12R
1,500 flight-cyclesSTA 135 - STA 520S-14 L and R
2,000 flight-cyclesSTA 741 - STA 800S-19 L and R
2,500 flight-cyclesSTA 1319 - STA 1350
1,500 flight-cyclesSTA 1480 - STA 1664
2,000 flight-cyclesSTA 1741 - STA 1961
1,500 flight-cyclesSTA 1961 - STA 2181
1,250 flight-cyclesSTA 2285 - STA 2360
4,500 flight-cyclesSTA 135 - STA 400S-19L
1,400 flight-cyclesSTA 520 - STA 741
5,000 flight-cyclesSTA 2181 - STA 2231
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
54 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 55

Group 7:
Table 12 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
S-19R 2,500 flight-cyclesSTA 135 - STA 400
1,000 flight-cyclesSTA 520 - STA 741
7,500 flight-cyclesSTA 2181 - STA 2231
1,100 flight-cyclesSTA 135 - STA 400S-23 L and R
2,000 flight-cyclesSTA 1350 - STA 1480
1,500 flight-cyclesSTA 1480 - STA 1664
1,500 flight-cyclesSTA 1720 - STA 1961
3,200 flight-cyclesSTA 2285 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 741 - STA 800
1,250 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2231
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 741 - STA 800
1,100 flight-cyclesSTA 1961 - STA 2181
4,000 flight-cyclesSTA 2181 - STA 2231
10,000 flight-cy-
cles
STA 135 - Nose Door PortalS-34 L and R
4,500 flight-cyclesNose Door Portal - STA 400
3,200 flight-cyclesSTA 400 - STA 520
1,200 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 2181 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
1,100 flight-cyclesSTA 520 - STA 560S-34R
1,300 flight-cyclesSTA 560 - STA 670
1,100 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
1,300 flight-cyclesSTA 1810 - STA 1920
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
55 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 56

Group 7:
Table 12 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
STA 1920 - STA 1961 2,000 flight-cycles
3,200 flight-cyclesSTA 1961 - STA 1980
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 520 - STA 741S-39L
10,000 flight-cy-
cles
STA 520 - STA 560 (a)S-39R
2,500 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 741 - Front Spar BulkheadS-39 L and R
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
2,500 flight-cyclesSTA 1741 - STA 1800S-40R
4,500 flight-cyclesSTA 1920 - STA 1961
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,400 flight-cyclesSTA 520 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,250 flight-cyclesSTA 1961 - STA 2181S-46 L and R
1,400 flight-cyclesSTA 1741 - STA 1961S-46L
1,000 flight-cyclesSTA 2181 - STA 2360
1,000 flight-cyclesSTA 1741 - STA 1961S-46R
1,100 flight-cyclesSTA 2181 - STA 2360
(a) This location was part of Area 1 or Area 2 in the original issue and Revision 2 of this service bulletin, but
was removed from Area 1 or Area 2 as part of Revision 3. Repeat inspections in this location are required
only if crack-free scribe damage more than 0.004 inch deep, but not more than 0.006 inch deep, was
found in this location during inspections in accordance with the original issue or Revision 2 of this service
bulletin.
(b) A repeat interval of 2,000 flight-cycles is allowed in this area only, provided there is no visible scribe
damage in the lower skin between STA 340 and STA 520 that is within 0.10 inch from the edge of the
upper skin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
56 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 57

Group 8:
Table 13 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
1,250 flight-cyclesSTA 741 - STA 941S-0Do detailed, HFEC,
and ultrasonic in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cy-
cles
STA 1000 - STA 1241 (a)S-4 L and R
1,500 flight-cyclesSTA 1480 - STA 1700S-4L
1,500 flight-cyclesSTA 2000 - STA 2360
1,500 flight-cyclesSTA 1480 - STA 2360S-4R
1,500 flight-cyclesSTA 340 - STA 400S-6 L and R
2,000 flight-cyclesSTA 520 - STA 741
1,500 flight-cyclesSTA 741 - STA 881
3,000 flight-cyclesSTA 881 - STA 1000
1,500 flight-cyclesSTA 400 - STA 520S-6L (if no
crew door is
installed)
Optional: 2,000
flight-cycles (b)
2,000 flight-cyclesSTA 400 - STA 520S-6L (if a crew
door is in-
stalled)
2,000 flight-cyclesSTA 400 - STA 520S-6R
2,000 flight-cyclesSTA 520 - STA 741S-12 L and R
2,500 flight-cyclesSTA 1000 - STA 1241
1,500 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 1961 - STA 2181
1,500 flight-cyclesSTA 2181 - STA 2360
1,250 flight-cyclesSTA 741 - STA 1000S-12L
1,400 flight-cyclesSTA 741 - STA 1000S-12R
1,250 flight-cyclesSTA 1741 - STA 1961
1,500 flight-cyclesSTA 135 - STA 520S-14 L and R
1,750 flight-cyclesSTA 1780 - STA 1920S-18L
2,000 flight-cyclesSTA 741 - STA 800S-19 L and R
2,500 flight-cyclesSTA 1319 - STA 1350
1,500 flight-cyclesSTA 1480 - STA 1664
1,500 flight-cyclesSTA 1961 - STA 2181
1,250 flight-cyclesSTA 2285 - STA 2360
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
57 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 58

Group 8:
Table 13 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
S-19L 4,500 flight-cyclesSTA 135 - STA 400
1,400 flight-cyclesSTA 520 - STA 741
5,000 flight-cyclesSTA 2181 - STA 2231
2,500 flight-cyclesSTA 135 - STA 400S-19R
1,000 flight-cyclesSTA 520 - STA 741
2,000 flight-cyclesSTA 1741 - STA 1961
7,500 flight-cyclesSTA 2181 - STA 2231
1,100 flight-cyclesSTA 135 - STA 400S-23 L and R
2,000 flight-cyclesSTA 1350 - STA 1480
1,500 flight-cyclesSTA 1480 - STA 1664
1,500 flight-cyclesSTA 1720 - STA 1741
3,200 flight-cyclesSTA 2285 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-23L
3,000 flight-cyclesSTA 741 - STA 800
1,250 flight-cyclesSTA 1961 - STA 2181
3,200 flight-cyclesSTA 2181 - STA 2231
1,400 flight-cyclesSTA 520 - STA 741S-23R
3,200 flight-cyclesSTA 741 - STA 800
1,500 flight-cyclesSTA 1741 - STA 1961
1,100 flight-cyclesSTA 1961 - STA 2181
4,000 flight-cyclesSTA 2181 - STA 2231
10,000 flight-cy-
cles
STA 135 - Nose Door PortalS-34 L and R
4,500 flight-cyclesNose Door Portal - STA 400
3,200 flight-cyclesSTA 400 - STA 520
1,200 flight-cyclesSTA 741 - Front Spar Bulkhead
1,250 flight-cyclesSTA 1480 - STA 1741
1,250 flight-cyclesSTA 2181 - STA 2360
1,200 flight-cyclesSTA 520 - STA 741S-34L
1,250 flight-cyclesSTA 1741 - STA 2181
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
58 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 59

Group 8:
Table 13 - Lap Splice Repeat Inspection Intervals
Repeat Interval
(Not to Exceed)
Lap Joint AreaActionCondition
From - ToStringer
S-34R 1,100 flight-cyclesSTA 520 - STA 560
1,300 flight-cyclesSTA 560 - STA 670
1,100 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 1741 - STA 1810
1,300 flight-cyclesSTA 1810 - STA 1920
2,000 flight-cyclesSTA 1920 - STA 1961
3,200 flight-cyclesSTA 1961 - STA 1980
1,200 flight-cyclesSTA 2034 - STA 2181
1,500 flight-cyclesSTA 520 - STA 741S-39L
10,000 flight-cy-
cles
STA 520 - STA 560 (a)S-39R
2,500 flight-cyclesSTA 670 - STA 741
1,500 flight-cyclesSTA 741 - Front Spar BulkheadS-39 L and R
1,500 flight-cyclesSTA 1480 - STA 1741S-40 L and R
1,200 flight-cyclesSTA 1741 - STA 1961S-40L
2,500 flight-cyclesSTA 1741 - STA 1800S-40R
4,500 flight-cyclesSTA 1920 - STA 1961
1,250 flight-cyclesSTA 400 - STA 520S-44 L and R
1,400 flight-cyclesSTA 520 - Front Spar Bulkhead
1,250 flight-cyclesSTA 135 - Canted BulkheadS-45 L and R
1,250 flight-cyclesSTA 1961 - STA 2181S-46 L and R
1,400 flight-cyclesSTA 1741 - STA 1961S-46L
1,000 flight-cyclesSTA 2181 - STA 2360
1,000 flight-cyclesSTA 1741 - STA 1961S-46R
1,100 flight-cyclesSTA 2181 - STA 2360
(a) This location was part of Area 1 or Area 2 in the original issue and Revision 2 of this service bulletin, but
was removed from Area 1 or Area 2 as part of Revision 3. Repeat inspections in this location are required
only if crack-free scribe damage more than 0.004 inch deep, but not more than 0.006 inch deep, was
found in this location during inspections in accordance with the original issue or Revision 2 of this service
bulletin.
(b) A repeat interval of 2,000 flight-cycles is allowed in this area only, provided there is no visible scribe
damage in the lower skin between STA 340 and STA 520 that is within 0.10 inch from the edge of the
upper skin.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
59 of 281
BOEING SERVICE BULLETIN 747-53A2563

### Page 60

Group 5-8:
Table 14 - Butt Splice Repeat Inspection Intervals
Repeat Interval (Not
to Exceed)
Butt Splice AreaActionCondition
From - ToStation
2,000 flight-cyclesS-0 to S-6, L and RSTA 340Do Detailed and
HFEC or LFEC in-
spections of the
scribe lines for
cracks.
Scribe lines found,
but not repaired 10,000 flight-cyclesS-23 to S-39, L and RSTA 400
3,800 flight-cyclesS-39 to S-44, L and R
1,500 flight-cyclesS-6 to S-12, L and RSTA 520
2,000 flight-cyclesS-23 to S-34, L and R
2,000 flight-cyclesS-39 to S-44, L and R
2,000 flight-cyclesS-6 to S-12, L and RSTA 741
1,500 flight-cyclesS-0 to S-4, L and RSTA 1240
3,200 flight-cyclesS-4 to S-12, L and R
1,500 flight-cyclesS-12 to S-19, L and R
1,500 flight-cyclesS-0 to S-4, L and RSTA 1480
2,000 flight-cyclesS-4 to S-9, L and R
1,500 flight-cyclesS-0 to S-19, L and RSTA 1741
1,500 flight-cyclesS-23 to S-34, L and R
3,200 flight-cyclesS-40 to S-46, L and R
1,000 flight-cyclesS-0 to S-4, L and RSTA 1961
1,250 flight-cyclesS-4 to S-12, L and R
3,200 flight-cyclesS-12 to S-19, L and R
1,500 flight-cyclesS-19 to S-34, L and R
5,000 flight-cyclesS-34 to S-40, L and R
1,500 flight-cyclesS-40 to S-46, L and R
5,000 flight-cyclesS-46L to S-46R
1,500 flight-cyclesS-0 to S-4, L and RSTA 2181
2,000 flight-cyclesS-4 to S-12, L and R
4,500 flight-cyclesS-12 to S-23, L and R
10,000 flight-cyclesS-23 to S-34, L and R
2,000 flight-cyclesS-34L to S-34R
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 29, 2007
747-53A2563Revision 4: May 06, 2010
60 of 281
BOEING SERVICE BULLETIN 747-53A2563

The text continues at https://openairdocs.org/service-documents/boeing/747-53a2563/file/c550477be235.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. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.