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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2876 Original Issue: October 22, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 46 - Crown Skin Under Dorsal Fairing - Inspection, Repair, and Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: October 22, 2014 747-53A2876 1 of 71

4.0

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 22, 2014 747-53A2876 2 of 71 BOEING SERVICE BULLETIN 747-53A2876

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Table of Contents

Summary5

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F. Approval ............................................... 2 8 G. Manpower .............................................. 2 8 H. Weight and Balance Changes .................................... 3 0 I. Electrical Load Data ......................................... 3 0 J. References .............................................. 3 0

1. Existing Data: ......................................... 3 0

2. Data Supplied with this Service Bulletin: ........................... 3 1

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 1 K. Publications Affected ........................................ 3 1 L. Interchangeability and Intermixability of Parts ........................... 3 2 M. Software Accomplishment Summary ................................ 3 2

2. MATERIAL INFORMATION ........................................ 3 3 A. Material - Price and Availability ................................... 3 3 B. Industry Support Information .................................... 3 3 C. Parts Necessary for Each Airplane ................................. 3 3

1. Kits/Parts ............................................ 3 3

2. Parts and Materials Supplied by the Operator ........................ 3 4

3. Parts Modified and Reidentified ................................ 3 6

4. Parts Removed and Not Replaced .............................. 3 6 D. Parts Necessary to Change Spares ................................. 3 6 E. Special Tooling - Price and Availability ............................... 3 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 6

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 9 FIGURE 1: DETAILED INSPECTION FOR WEAR OR CRACKS WITH THE DORSAL FAIRING REMOVED .................................................. 5 0 FIGURE 2: APPLICATION OF TEFLON COATING ............................ 5 1 FIGURE 3: RUB STRIP MODIFICATION ................................. 5 3 FIGURE 4: GAP MEASUREMENT AND DETAILED INSPECTION FOR WEAR OR CRACKS WITH THE DORSAL FAIRING INSTALLED ................................ 6 1 FIGURE 5: EXTERNAL DOUBLER REPAIR ............................... 6 3 FIGURE 6: SURFACE HFEC INSPECTION OF REPAIR DOUBLER .................. 6 8 APPENDIX A: PART DEMAND INTENT ................................... 7 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 22, 2014 747-53A2876 4 of 71 BOEING SERVICE BULLETIN 747-53A2876

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2876Original Issue: October 22, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 46 - Crown Skin Under Dorsal Fairing - Inspection, Repair, and Modification

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of this service bulletin will detect skin damage from the dorsal fairing forward of the vertical stabilizer. The fuselage skin is subject to skin damage in the area of the dorsal fairing which can lead to cracking.

Undetected cracking in Section 46 could reach sufficient length to cause in-flight depressurization of the airplane.

During inspection for skin damage due to wear from the vertical stabilizer seals in accordance with Service Bulletin 747-53A2478, two operators found significant skin damage from the dorsal fairing just forward of the area inspected by Service Bulletin 747-53A2478 at Station (STA) 2280. The two airplanes with damage had 45,707 total flight hours and 71,702 total flight hours.

Boeing has determined that the skin damage occurred from inadequate clearance between crown skin and the lower aft corners of the dorsal fairing. Affected airplanes are limited to line numbers that were delivered with or retrofitted with 174U9000 series dorsal fairing assemblies. Airplanes with other dorsal fairing configurations are not expected to develop skin wear.

This service bulletin gives instructions for operators of affected airplanes to inspect the skin for wear under the dorsal fairing and repair any damage that may have already occurred. This service bulletin also gives instructions to measure the clearance between the crown skin and lower edge of the dorsal fairing, and trim or adjust the dorsal fairing to provide more clearance, as necessary. Accomplishment of these actions will ensure that skin wear from the dorsal fairing does not lead to cracking and possible depressurization of the airplane.

Boeing Service Related Problem (SRP) 747-SRP-53-0442 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 747 FTD 53-13011 is related to this service bulletin.

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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 22, 2014 747-53A2876 5 of 71

ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNo.Spares Affected Paragraph 1.E., Compliance and Paragraph

1.F., Approval Yes.AD Related Paragraph 1.H., Weight and Balance ChangesYes.Weight and Balance Change Paragraph 1.I., Electrical Load DataNo.Electrical Load Changed Paragraph 1.K., Publications AffectedYes.Publications Affected Paragraph 1.K., Publications AffectedNo.Airplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYes.Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes.Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No.Special Tooling Required ACTION (PRR 85901-130RS) Get access and remove the dorsal fairing. Do a detailed inspection of the skin under the dorsal fairing for wear or cracks.

If no skin crack or wear is found, apply teflon coating to the skin under the dorsal fairing and repeat the detailed inspection for skin wear or cracks at the interval specified. As an option, install Corrosion Resistant Steel (CRES) rub strips under the dorsal fairing as a preventive modification.

If any skin wear is found, do a blend repair or install a repair doubler depending on the depth of the skin wear.

If any skin crack is found, install a repair doubler or contact Boeing for repair instructions and do the repair.

If a blend repair is done, do initial and repetitive post-repair detailed and high frequency eddy current (HFEC) inspections for cracks in the blended area of the skin, and do detailed inspection for wear or cracks in the unrepaired areas of the skin under the dorsal fairing. If any crack or wear is found in a previously repaired area, contact Boeing for repair instructions and do the repair.

If a repair doubler is installed, do initial and repetitive post-repair detailed and HFEC inspections for cracks in the repair doubler, and do detailed inspection for wear or cracks in the unrepaired areas of the skin under the dorsal fairing. If any crack is found in a previously repaired area, contact Boeing for repair instructions and do the repair.

Upon re-installation of the fairing, make sure the clearance between the crown skin and the lower edge of the dorsal fairing meets the gap requirements specified in the applicable Aircraft Maintenance Manual (AMM). If necessary, trim the lower edge of the dorsal fairing or adjust the installation shims as specified in the AMM in order to meet the gap requirements.

EFFECTIVITY 747-100, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, and 747-400F airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 22, 2014 747-53A2876 6 of 71 BOEING SERVICE BULLETIN 747-53A2876

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COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Operator Supplied Parts/Materials.

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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 22, 2014 747-53A2876 7 of 71 BOEING SERVICE BULLETIN 747-53A2876

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Page 8OCROpen in PDF

BOEING SERVICE BULLETIN 747-53A2876

ALERT ALERT

VERTICAL

STABILIZER DORSAL

FAIRING STA 2280 ~ STA 2260 STA 2240 S-2R — STA 2220 STA S-1R 2200 BLO S-1L S-2L 2180 STA AREA INSPECTION

REMOVE THE DORSAL FAIRING AND DO A DETAILED INSPECTION FOR ANY CRACK OR WEAR IN THE SKIN UNDER THE EDGE OF THE DORSAL FAIRING.

IF NO CRACK OR WEAR IS FOUND, APPLY TEFLON COATING AND DO REPEAT DETAILED INSPECTIONS. INSTALLATION OF A RUB STRIP IS OPTIONAL.

IF ANY CRACK OR WEAR IS FOUND, DO A BLEND REPAIR OR DOUBLER REPAIR, AS NECESSARY. INSTALLATION OF A RUB STRIP IS OPTIONAL. DO INITIAL AND REPEAT POST-REPAIR DETAILED AND HIGH FREQUENCY EDDY CURRENT INSPECTIONS. IF ANY CRACK OR WEAR IS FOUND IN PREVIOUSLY REPAIRED 2315481 AREA, CONTACT BOEING FOR REPAIR INSTRUCTIONS AND DO THE REPAIR.

Original Issue: October 22, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2876 Work - See page 1 for details. 8 of 71

Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2876 Original Issue: October 22, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Section 46 - Crown Skin Under Dorsal Fairing - Inspection, Repair, and Modification

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is applicable to 747-100, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, and 747-400F airplanes, line numbers 1017-1419, 27, 45, 75, 88, 135, 141, 163, 165, 470, 471, 437, 375, 465, 357, 374, 377, 378, 379, 412, 442, 594, 595, 642, 644, 651, 397, 474, 491, 271, 276, 336, 344, 369, 389, 539, 669, 712, 400, 878, 258, 261, 269, 308, 444, 680, 682, 968, 1002, 1008, 587, 600, 657, 735, 737, 763, 770, 783, 850, 854, 896, 938, 992, 1014, 743, 775, 792, 705, 728, 771, 788, 813, 834, 849, 873, 877, 887, 925, 930, 937, 949, 970, 993, 1007, 831, 852, 859, 860, 921, 923, 953, 955, 962, 981, 1010, 725, 732, 782, 888, 969, 769, 777, 833, 890, 945, 950, 1001, 827, 861, 926, 957 in 2(two) Group(s). The Variable Numbers and Group Information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to PRR 85901-130RS for data about this change.

DESCRIPTIONCONFIGURATIONGROUP 747-400, 747-400D, and 747-400F airplanes, line numbers 1017-1419. These airplanes were delivered with a 174U9000 series dorsal fairing assembly.

-1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 22, 2014 747-53A2876 9 of 71

DESCRIPTIONCONFIGURATIONGROUP 747-100, 747-200B, 747-200C, 747-200F, 747-300, 747-400, and 747-400F airplanes that have had a 174U9000 series dorsal fairing installed in accordance with one of the following Boeing Master Change service bulletins: 747-55-2037, 747-55-2038, 747-55-2040, 747-55-2041, 747-55-2044, 747-55-2047, 747-55-2049, or 747-55-2064.

-2 Airplane Models:

747-100, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F GroupVariable Number 2RA351 2RA353 2RA358 2RA369 - RA373 2RD056 - RD057 2RD241 - RD243 2RD251 - RD262 2RD381 - RD383 2RD601 - RD607 1RF001 - RF006 2RJ321 - RJ322 1RL401 - RL403 1RL411 - RL436 1RL451 - RL456 1RL461 - RL462 1RL471 - RL481 1RL491 - RL492 1RL501 - RL502 1RL511 - RL516 1RL521 - RL522 1RL531 - RL534 1RL551 1RL561 - RL568 1RL571 - RL572 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: October 22, 2014 747-53A2876 10 of 71 BOEING SERVICE BULLETIN 747-53A2876

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GroupVariable Number 1RL576 - RL577 1RL579 1RL581 - RL586 1RL651 - RL655 1RL671 - RL675 1RL681 - RL684 1RL751 - RL752 1RM001 - RM007 1RM010 - RM013 1RM021 - RM024 1RM026 - RM030 1RM036 - RM045 1RM051 - RM053 1RM071 1RM081 - RM084 1RM091 1RM096 - RM097 1RM116 - RM117 1RM126 - RM132 1RM136 - RM147 1RM156 - RM158 1RM166 - RM177 1RM191 - RM192 1RM231 - RM233 1RM241 - RM246 1RM261 - RM264 1RM316 - RM318 1RM331 - RM333 1RM341 1RM351 - RM355 1RM366 - RM367 1RM401 - RM403 1RM426 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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GroupVariable Number 1RM431 1RM441 - RM443 1RM445 1RM801 - RM803 1RM811 - RM813 1RM851 - RM859 1RM861 - RM863 1RM871 - RM899 1RM901 - RM906 1RM911 2RR005 2RR310 2RR341 - RR345 2RR431 - RR432 2RR701 2RR721 - RR722 1RR723 - RR724 1RR746 - RR748 1RR851 - RR856 1RR861 - RR862 1RR951 - RR952 2RS711 - RS713 2RT001 - RT011 1RT012 - RT014 2RT031 - RT033 1RT034 - RT035 1RT135 - RT137 1RT151 - RT152 1RT165 - RT168 1RT442 - RT447 2RT451 - RT467 1RT468 - RT469 1RT497 - RT499 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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