# Boeing Alert Service Bulletin 747-53A2443: U.S. DOT/FAA - Boeing Service Bulletin - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2014-0170; AD 2014-23-11 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-53A2443](https://openairdocs.org/service-documents/boeing/747-53a2443.md) - Title as filed: U.S. DOT/FAA - Boeing Service Bulletin - Pages: 107 - PDF: https://openairdocs.org/files/sha256/37/c9/37c9689b1d2ed6b5ae1efbf231051ce781c7b0854e3d17949bba6fba5063aaf0 - Page: https://openairdocs.org/service-documents/boeing/747-53a2443/file/37c9689b1d2e ## 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: 747-53A2443 Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam 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 © 2002 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 Unpublished Work.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: May 09, 2002 747-53A2443Revision 2: August 02, 2013 1 of 107 3.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 2 of 107 BOEING SERVICE BULLETIN 747-53A2443 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 ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 2 0 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1 1. Existing Data: ......................................... 2 1 2. Data Supplied with this Service Bulletin: ........................... 2 2 3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 4 M. Software Accomplishment Summary ................................ 2 4 2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary for Each Airplane ................................. 2 5 1. Kits/Parts: ........................................... 2 5 2. Parts and Materials Supplied by the Operator: ........................ 3 1 3. Parts Modified and Reidentified: ............................... 3 4 4. Parts Removed and Not Replaced: .............................. 3 4 D. Parts Necessary to Change Spares ................................. 3 4 E. Special Tooling - Price and Availability ............................... 3 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 4 3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: LOGIC DIAGRAMS - GROUPS 1 AND 2 ........................... 4 1 FIGURE 2: ACCESS AND RESTORATION - GROUPS 1 AND 2 .................... 4 5 FIGURE 3: ACCESS AND RESTORATION - STATION 380 FLOOR BEAM - GROUP 2 [Group 2] . . 49 FIGURE 4: FLOOR BEAM MODIFICATION (PRIMARY AND ALTERNATIVE) - GROUPS 1 AND 2 . 54 FIGURE 5: FLOOR BEAM - DETAILED INSPECTION .......................... 5 9 FIGURE 6: FLOOR BEAM - OPEN HOLE HFEC INSPECTIONS - STRAPS REMOVED ....... 6 4 FIGURE 7: FLOOR BEAM UPPER CHORD - SURFACE HFEC INSPECTION ............. 6 7 FIGURE 8: FLOOR BEAM - OPEN HOLE HFEC INSPECTION - STRAPS NOT REMOVED ..... 7 0 FIGURE 9: STA 340 - 520 UPPER DECK FLOOR BEAMS - HOLE ZERO-TIMING (PRIMARY PREVENTIVE MODIFICATION INSTALLED) ................................. 7 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 3 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 4 FIGURE 10: STA 420 - 520 UPPER DECK FLOOR BEAMS - HOLE ZERO-TIMING (ALTERNATIVE PREVENTIVE MODIFICATION INSTALLED) ........................ 9 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 4 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 5 Commercial Airplanes 747 Service Bulletin Revision Transmittal SheetNumber: 747-53A2443Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Modification This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2004-07-22 R1 and AD 2005-13-05 are related to this service bulletin. More work is necessary on airplanes changed as given in the Original Issue or Revision 1 of this service bulletin if the initial (preventive) modification was done before 15,000 total flight cycles. Airplanes that had the initial (preventive) modification done before 15,000 total flight cycles will require a second modification (fastener hole zero-timing) within 20,000 flight cycles after the initial (preventive) modification. Accomplishment of the second modification will allow continued operation to the Limit of Validity (LOV) of 35,000 total flight cycles. No more work is necessary on airplanes changed as given in the Original Issue or Revision 1 of this service bulletin if the initial (preventive) modification was done at or after 15,000 total flight cycles. REASON FOR REVISION This revision is sent to add a recommendation to not accomplish the preventive modification before 15,000 total flight cycles due to post modification requirements, to add a floor beam second modification (hole zero-timing) and to add an Alternative Preventive Modification at floor beam locations where access is not available to remove fasteners that are trapped by the frame. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. These sections were changed: 1. Summary Section: Updated Action section to reflect new requirements. Added WFD note. Added Summary Planning Table. Updated Material Information. Revised Summary illustration text to reflect changed actions. 2. In Paragraph 1.A., Effectivity: Group Configuration Table; Group 1, deleted airplane line number 1268. 3. In Paragraph 1.C., Reason: Added revision information. 4. In Paragraph 1.D., Description: Updated the action descriptions to reflect new requirements, added "More work" statement. 5. In Paragraph 1.G., Manpower: Added manpower estimates for floor beam hole zero-timing modification. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 5 of 107 ### Page 6 6. In Paragraph 1.J., References: Added new references related to this revision. 7. In Paragraph 1.J.2.a., Drawings - Drawing sheets are revised to change hole sizes. 8. In Paragraph 1.M., Software Accomplishment Summary: Added new section. 9. In Paragraph 2.C.2, Parts and Materials Supplied by the Operator: Added parts for the floor beam hole zero-timing modification. 10. In Paragraph 3.A., General Information: Updated general notes to current requirements. 11. In Paragraph 3.B., PART 2 and PART 3, Inspection and Preventive Modification: Added Note which defines the Primary and Alternative Preventive Modifications. 12. In Paragraph 3.B., PART 4 and PART 5, After-Modification Repeat Detailed and Surface HFEC Inspections: Added new follow-on requirement. 13. Paragraph 3.B., PART 6., After-Modification - Floor Beam Hole Zero-Timing: New section added. 14. Figure 1: Updated Logic Diagram and added new sheets for new compliance tasks and times. 15. Figure 4: Added new Steps for accomplishment of the Alternative Preventive Modification. 16. Figure 6: Updated view. 17. Figure 7: Updated view. 18. Figure 8: Step 1 and 2, corrected STA locations in Notes column and corrected the quantity of fasteners called out in Table 1. 19. Figure 9: Added new Figure for floor beam hole zero-timing with the Primary Preventive Modification installed. 20. Figure 10: Added new Figure for floor beam hole zero-timing with the Alternative Preventive Modification installed. The data given in Information Notice 747-53-2443 IN 01 is included in this revision. IN 01 was issued to advise that in the Group Configuration Table the line number range specified for Group 1 is for Group 2 and the line number range specified for Group 2 is for Group 1. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. REVISION HISTORY May 09, 2002Original Issue: June 25, 2009Revision 1: August 02, 2013Revision 2: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 6 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 7 Commercial Airplanes 747 Service Bulletin SummaryNumber: 747-53A2443Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Modification CONCURRENT REQUIREMENTS None. BACKGROUND Accomplishment of the Inspections and the Preventive Modification shown in this service bulletin will ensure the structural integrity of the STA 340 through 520 upper deck floor beams. Cracks in these floor beams that are not found and repaired could extend and fully sever the floor beam adjacent to the body frame. This can lead to large deflection or deformation of the floor and of the body skin, frames, and stringers. This deflection or deformation could result in damage to wire bundles and unintended inputs to the flight control cables which could affect airplane controllability. Multiple adjacent floor beams which are severed could result in rapid depressurization of the airplane and loss of structural integrity. The upper deck floor beams connect to the body frames in the flat sided areas of the upper body. Flight critical wire bundles and controls are routed through cutouts in the floor beams and frames. Initially, two operators told Boeing about cracks in the upper deck floor beams on four 747-200F airplanes. These airplanes had flown 11,586 - 19,488 fight-cycles. The 747-400F floor beams are similar to the 747-200F and can be expected to experience similar problems. The 747 and 747-400 Passenger airplanes floor beams are made from 2024 aluminum which has an improved fatigue durability over the 7075 aluminum floor beams used on the 747-200F and 747-400F. For additional data, refer to Paragraph 1.C., Reason. Service Bulletins 747-53A2420 and 747-53A2429 have been issued for inspection, modification and repair of the 747-200F airplane upper deck floor beams. Since the initial release of service bulletin 747-53A2420, operators of 747-200F airplanes have told Boeing about the upper deck floor beam inspections accomplished on approximately twenty airplanes. In virtually all of these inspections, crack indications were found at the upper deck floor beam to frame attachment points. Boeing Service Related Problem (SRP) 747-SRP-53-0102 and 747-SRP-53-0439 are related to this service bulletin. The upper deck floor beams have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to Boeing Service Letter 747-SL-53-088. 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: May 09, 2002 747-53A2443Revision 2: August 02, 2013 7 of 107 ### Page 8 ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Air- plane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 85900-235) Do an initial Detailed Inspection and open hole High Frequency Eddy Current (HFEC) Inspection at maximum of 15,000 total airplane flight-cycles followed by another Detailed inspection and open hole High Frequency Eddy Current (HFEC) Inspection and a Preventive Modification at a maximum of 20,000 total airplane flight-cycles, but not more than 5,000 flight-cycles after the initial inspection. Do follow up Detailed Inspections and open hole High Frequency Eddy Current (HFEC) or Surface HFEC Inspections that start at 15,000 flight-cycles after the Preventive Modification has been done. Do the Inspections: For Groups 1 and 2 airplanes gain access from below the upper deck floor beams by removing the ceiling liners from STA 340 to STA 520. Remove fasteners common to the floor beam straps as required to do the Inspections as given in the Logic Diagram for the inspections. Do the Detailed Inspection and High Frequency Eddy Current (HFEC) Inspections. Restore access and put the airplane back to a serviceable condition. Do the Preventive Modification (Primary and Alternative): For Group 2 airplanes remove the upper deck left and right partitions to gain access for the STA 380 floor beam modification. For Groups 1 and 2 airplanes gain access from below the upper deck floor beams by removing the ceiling liners from STA 340 to STA 520. Gain access to the Left side wall area above and below the upper deck floor from STA 420 to STA 440 and at STA 520. Gain access to the Right side wall area above and below the upper deck floor from STA 420 to STA 520. Remove the upper chord straps from the Left STA 340 to STA 480 and STA 520 upper deck floor beams and install new straps. Remove the upper chord straps from the Right STA 340 to STA 380 and STA 420 to STA 520 upper deck floor beams. Install new upper chord straps on the Right STA 340 to STA 520 upper deck floor beams. Restore access and put the airplane back to a serviceable condition. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 8 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 9 NOTE: At floor beam locations from STA 420 to STA 520 where fasteners are trapped against the frame and access is not available to remove them, an option is given to grind off the fastener shank after the strap is removed. New fastener holes will not be drilled in the new strap at these locations. At floor beam locations where trapped fastener shanks are ground off, the modification installed is the Alternative Preventive Modification. At locations where there are no trapped fasteners or the trapped fasteners were removed and new fasteners installed, the modification installed is the Primary Preventive Modification. Do the Floor Beam Hole Zero-Timing: At floor beam locations where the Primary Preventive Modification was installed: Get access to the STA 340 - 520 upper deck floor beams. Zero-time the specified fastener holes in the floor beam and install new fasteners. Restore access and put the airplane back to a serviceable condition. At floor beam locations where the Alternative Preventive Modification was installed: Get access to the STA 420 - 520 upper deck floor beams. Remove the strap and do a HFEC surface inspection of the upper chord around the trapped fasteners for cracks. Zero-time the specified fastener holes in the strap and floor beam. Do a HFEC open hole inspection of the fastener holes in the floor beam and strap that are not zero-timed for cracks. Install the strap. Restore access and put the airplane back to a serviceable condition. EFFECTIVITY 747-400F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives 2005-13-05 and 2004-07-22 R1 are related to this service bulletin. Boeing recommends that Inspections, Preventive Modification and Floor Beam Hole Zero-Timing be accomplished as given in Figure 1: LOGIC DIAGRAM . INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and configuration changes given in this service bulletin. MANPOWER Refer to Paragraph 1.G., Manpower. MATERIAL INFORMATION Boeing Supplied Kits/Parts and 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: May 09, 2002 747-53A2443Revision 2: August 02, 2013 9 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 10 (OCR) BOEING SERVICE BULLETIN 747-53A2443 STA 520 × STA 340 - STA BL 520 STA TYPICAL INSPECTION 500 AREA 480 STA STA 460 STA 440 STA 420 STA 400 STA 380 STA 360 STA 340 UP SEND DO VISUAL AND OPEN HOLE HFEC INSPECTIONS OF THE FLOOR BEAMS. • DO THE PREVENTIVE MODIFICATION (PRIMARY OR ALTERNATIVE) THAT REPLACES AND REMOVES THE STRAPS, DO VISUAL AND HFEC INSPECTIONS OF ALL HOLES COMMON TO STRAP AND INSTALL NEW STRAPS. DO REPEAT VISUAL AND HFEC INSPECTIONS AFTER COMPLETION OF THE PREVENTIVE MODIFICATION. AT LOCATIONS WHERE THE PRIMARY PREVENTIVE MODIFICATION WAS INSTALLED, DO THE LOOR BEAM HOLE ZERO-TIMING. AT LOCATIONS WHERE THE ALTERNATIVE PREVENTIVE MODIFICATION WAS INSTALLED, REMOVE THE STRAP, DO DETAILED AND HFEC INSPECTIONS OF THE UPPER CHORD AND DO THE FLOOR BEAM HOLE ZERO-TIMING. V61754 (LEFT SIDE SHOWN, RIGHT SIDE SIMILAR) Original Issue: May 09, 2002 Revision 2: August 02, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2443 Work - See page 1 for details. 10 of 107 ### Page 11 Commercial Airplanes 747 Service Bulletin Number: 747-53A2443 Original Issue: May 09, 2002 Revision 2: August 02, 2013 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Modification 1. PLANNING INFORMATION A. Effectivity 1. Airplanes This service bulletin is for the airplane(s) shown below. Refer to PRR 85900-235 for data about this change. Refer to Service Bulletin Index Document D6-30300, Part 3 for Airplane Variable Number, Line Number, and Serial Number data. DESCRIPTIONCONFIGURATIONGROUP 747-400F airplanes line number 1087 to 1267.-1 747-400F airplanes line number 968 to 1069.-2 Airplane Models: 747-400F GroupVariable Number 1RL401 1RL411 - RL415 1RL651 - RL653 1RM851 - RM853 1RM856 1RM861 1RM871 - RM873 1RM881 - RM885 1RM891 - RM899 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 11 of 107 ### Page 12 GroupVariable Number 1RM901 - RM903 1RM911 2RR701 2RR721 - RR722 1RR723 - RR724 2RR746 - RR747 1RR748 2RR851 - RR854 1RR855 - RR856 1RR861 - RR862 2RR951 - RR952 2. Spares Affected None. B. Concurrent Requirements None. C. Reason Accomplishment of the Inspections and the Preventive Modification shown in this service bulletin will ensure the structurally integrity of the STA 340 through 520 upper deck floor beams. Cracks in these floor beams that are not found and repaired could extend and fully sever the floor beam adjacent to the body frame. This can lead to large deflection or deformation of the floor and of the body skin, frames, and stringers. This deflection or deformation could result in damage to wire bundles and unintended inputs to the flight control cables which could affect airplane controllability. Multiple adjacent floor beams which are severed could result in rapid depressurization of the airplane and loss of structural integrity. The upper deck floor beams connect to the body frames in the flat sided areas of the upper body. Flight critical wire bundles and controls are routed through cutouts in the floor beams and frames. Initially, two operators told Boeing about cracks in the upper deck floor beams on four 747-200F airplanes. Cracks up to 4 inches long were found in the STA 380 floor web. Cracks up to 1.0 inch long were found in the upper chord of STA 380 floor beam. These airplanes had flown 11,586 - 19,488 fight-cycles. The 747-400F floor beams are similar to the 747-200F and can be expected to experience similar problems. The 747 and 747-400 Passenger airplanes floor beams are made from 2024 aluminum which has an improved fatigue durability over the 7075 aluminum floor beams used on the 747-200F and 747-400F. Details of the cracks found in STA 380 floor beam are shown in the table that follows. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 12 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 13 STA 380 Cracks Found (inches)Total Flight- Hours Total Flight- Cycles Model Right SideLeft Side Upper ChordWebUpper ChordWeb 1.02.5-0.569,79918,502747-200F -0.3--63,83911,586747-200F Approx. 1Approx. 4--73,77719,488747-200F On one of the 747-200F airplanes with 19,488 flight-cycles, a crack approximately 0.7 inch long was found on the right end of the STA 360 floor beam. Open hole HFEC inspection also found web and upper chord cracks in the right ends of the floor beams at STA 340, 400, and 420. Service Bulletins 747-53A2420 and 747-53A2429 have been issued for inspection, modification and repair of the 747-200F airplane upper deck floor beams. Since the initial release of service bulletin 747-53A2420, operators of 747-200F airplanes have told Boeing about the upper deck floor beam inspections accomplished on approximately twenty airplanes. In virtually all of these inspections, crack indications were found at the upper deck floor beam to frame attachment points. Boeing Service Related Problem (SRP) 747-SRP-53-0102 and 747-SRP-53-0439 are related to this service bulletin. The upper deck floor beams have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). For more information about WFD, refer to Boeing Service Letter 747-SL-53-088. See Service Bulletins 747-53A2420 and 747-53A2429 for 747-200F airplanes. Revision 1 is sent to clarify the options available in the event cracks are found during the initial 15,000 flight-cycle inspection. These sections were changed: 1. In Paragraph 1.D., Description, added Affected Maintenance Zones. 2. In Paragraph 1.E., Compliance, added Federal Aviation Administration (FAA) Airworthiness Directives 2005-13-05 and 2004-07-22 R1. 3. In Paragraph 1.F., Approval, added FAA Alternate Method of Compliance (AMOC) paragraphs for FAA Airworthiness Directives 2005-13-05 and 2004-07-22 R1. 4. In Paragraph 1.J., References, added FAA Airworthiness Directives 2005-13-05 and 2004-07-22 R1. 5. In Paragraph 2.A., Material - Price and Availability, changed Unit Prices and Reorder Lead Time to reflect current pricing policy. 6. In Paragraph 3.B.1., Work Instructions, added Option 1 and Option 2 to clarify the options available in the event cracks are found during the initial 15,000 flight-cycle inspection. Also clarified that it is Boeing's intent that the modification be done within 5,000 flight-cycles after the initial inspection. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 13 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 14 7. In Figure 1, added Option 1 and Option 2 to clarify the options available in the event cracks are found during the initial 15,000 flight-cycle inspection. Also changed the logic diagram to clarify that it is Boeing's intent that the modification be done within 5,000 flight-cycles after the initial inspection. 8. Throughout the bulletin: Replaced references to the "detailed visual inspection" with "detailed inspection". The data given in Information Notice 747-53-2443 IN 01 is included in this revision. IN 01 was issued to advise that in the Group Configuration Table the line number range specified for Group 1 is for Group 2 and the line number range specified for Group 2 is for Group 1. Revision 2 is sent to add a recommendation to not accomplish the preventive modification before 15,000 total flight cycles due to post modification requirements, to add a floor beam second modification (hole zero-timing) and to add an Alternative Preventive Modification at floor beam locations where access is not available to remove fasteners that are trapped by the frame. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. D. Description Do an initial Detailed Inspection and open hole High Frequency Eddy Current (HFEC) Inspection at maximum of 15,000 total airplane flight-cycles followed by another Detailed inspection and open hole High Frequency Eddy Current (HFEC) Inspection and a Preventive Modification at a maximum of 20,000 total airplane flight-cycles, but not more than 5,000 flight-cycles after the initial inspection. Do follow up Detailed Inspections and open hole High Frequency Eddy Current (HFEC) or Surface HFEC Inspections that start at 15,000 flight-cycles after the Preventive Modification has been done. Do the Inspections: For Groups 1 and 2 airplanes gain access from below the upper deck floor beams by removing the ceiling liners from STA 340 to STA 520. Remove fasteners common to the floor beam straps as required to do the Inspections as given in the Logic Diagram for the inspections. Do the Detailed Inspection and High Frequency Eddy Current (HFEC) Inspections. Restore access and put the airplane back to a serviceable condition. Do the Preventive Modification (Primary and Alternative): For Group 2 airplanes remove the upper deck left and right partitions to gain access for the STA 380 floor beam modification. For Groups 1 and 2 airplanes gain access from below the upper deck floor beams by removing the ceiling liners from STA 340 to STA 520. Gain access to the Left side wall area above and below the upper deck floor from STA 420 -STA 440 and at STA 520. Gain access to the Right side wall area above and below the upper deck floor from STA 420 to STA 520. Remove the upper chord straps from the Left STA 340 to STA 480 and STA 520 upper deck floor beams and install new straps. Remove the upper chord straps from the Right STA 340 to STA 380 and STA 420 to STA 520 upper deck floor beams. Install new upper chord straps on the Right STA 340 to STA 520 upper deck floor beams. Restore access and put the airplane back to a serviceable condition. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 14 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 15 NOTE: At floor beam locations from STA 420 to STA 520 where fasteners are trapped against the frame and access is not available to remove them, an option is given to grind off the fastener shank after the strap is removed. New fastener holes will not be drilled in the new strap at these locations. At floor beam locations where trapped fastener shanks are ground off, the modification installed is the Alternative Preventive Modification. At locations where there are no trapped fasteners or the trapped fasteners were removed and new fasteners installed, the modification installed is the Primary Preventive Modification. Do the Floor Beam Hole Zero-Timing: At floor beam locations where the Primary Preventive Modification was installed: Get access to the STA 340 - 520 upper deck floor beams. Zero-time the specified fastener holes in the floor beam and install new fasteners. Restore access and put the airplane back to a serviceable condition. At floor beam locations where the Alternative Preventive Modification was installed: Get access to the STA 420 - 520 upper deck floor beams. Remove the strap and do a HFEC surface inspection of the upper chord around the trapped fasteners for cracks. Zero-time the specified fastener holes in the strap and floor beam. Do a HFEC open hole inspection of the fastener holes in the floor beam and strap that are not zero-timed for cracks. Install the strap. Restore access and put the airplane back to a serviceable condition. The airplane effectivity has two groups. Group 1 airplanes are the same as Group 2 airplanes at all Floor Beam locations except for one Floor Beam location. For the Floor Beam at STA 380 Group 1 and Group 2 airplanes have different configurations. Revision 1 - No more work is necessary on airplanes modified as given in the original issue of this service bulletin. However, Boeing recommends that airplanes inspected prior to 15,000 total flight-cycles as given in the original issue of this service bulletin be inspected and modified within 5,000 flight-cycles after the initial inspection. Revision 2 - More work is necessary on airplanes changed as given in the Original Issue or Revision 1 of this service bulletin if the initial (preventive) modification was done before 15,000 total flight cycles. Airplanes that had the initial (preventive) modification done before 15,000 total flight cycles will require a second modification (fastener hole zero-timing) within 20,000 flight cycles after the initial (preventive) modification. Accomplishment of the second modification will allow continued operation to the Limit of Validity (LOV) of 35,000 total flight cycles. Revision 2 - No more work is necessary on airplanes changed as given in the Original Issue or Revision 1 of this service bulletin if the initial (preventive) modification was done at or after 15,000 total flight cycles. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 221, 222, 223, 224747-400F E. Compliance Federal Aviation Administration (FAA) Airworthiness Directives 2005-13-05 and 2004-07-22 R1 are related to this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 15 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 16 Boeing recommends that Inspections, Preventive Modification and Floor Beam Hole Zero-Timing be accomplished as given in Figure 1: LOGIC DIAGRAM. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the accomplishment of the applicable inspection, repair, modification, post modification inspections, and repair procedures of this service bulletin as an AMOC to the corresponding actions required by paragraphs (g), (h), (i), and (j) of AD 2005-13-05. This AMOC only applies to the areas inspected as given in this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with paragraph (k) of the AD. All provisions of AD 2005-13-05 that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. In addition, the Manager of the FAA Seattle ACO approves the accomplishment of the applicable inspection, repair, and modification procedures of this service bulletin as an AMOC to the corresponding actions for SSI F-19E, F-20F, and F-20G of Supplemental Structural Inspection Document (SSID) D6-35022, Revision G, dated December 2000, as required by paragraphs (h) and (i) of AD 2004-07-22 R1. This AMOC only applies to the areas inspected as given in this service bulletin. When this service bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by the FAA as required by paragraph (j) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly. G. Manpower The table below shows an estimate of the man-hours necessary to do this modification for each airplanes. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. GROUP 1 AIRPLANES - PREVENTIVE MODIFICATION (Includes hours for inspec- tions accomplished while doing the Preventive Modification.) Elapsed Time (Hours)Man-HoursNumber of PersonsTask Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 16 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 17 GROUP 1 AIRPLANES - PREVENTIVE MODIFICATION (Includes hours for inspec- tions accomplished while doing the Preventive Modification.) 10.5212Open Access 482Modify STA 340 Floor Beam 6.5132Modify STA 360 Floor Beam 2.755.52Modify STA 380 Floor Beam 2.254.52Modify STA 400 Floor Beam 24.5492Modify STA 420 Floor Beam 511021Modify STA 440 Floor Beam 25502Modify STA 460 Floor Beam 55.51112Modify STA 480 Floor Beam 9182Modify STA 500 Floor Beam 57.51152Modify STA 520 Floor Beam 11222Close Access 259.5519TOTAL FOR EACH AIRPLANE GROUP 2 AIRPLANES - PREVENTIVE MODIFICATION (Includes hours for inspec- tions accomplished while doing the Preventive Modification.) Elapsed Time (Hours)Man-HoursNumber of PersonsTask 10.5212Open Access 482Modify STA 340 Floor Beam 6.5132Modify STA 360 Floor Beam 5102Modify STA 380 Floor Beam 2.254.52Modify STA 400 Floor Beam 24.5492Modify STA 420 Floor Beam Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 17 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 18 GROUP 2 AIRPLANES - PREVENTIVE MODIFICATION (Includes hours for inspec- tions accomplished while doing the Preventive Modification.) 511022Modify STA 440 Floor Beam 25502Modify STA 460 Floor Beam 55.51112Modify STA 480 Floor Beam 9182Modify STA 500 Floor Beam 57.51152Modify STA 520 Floor Beam 11222Close Access 261.75523.5TOTAL FOR EACH AIRPLANE GROUP 1 AND 2 AIRPLANES - DETAILED AND OPEN HOLE HFEC INSPECTION Elapsed Time (Hours)Man-HoursNumber of PersonsTask 1.532Open Access 2.552Detail Inspection 7142Remove Fasten- ers 10202Open Hole HFEC Inspection 13.5272Install Fasteners 1.532Close Access 3672TOTAL FOR EACH AIRPLANE GROUP 1 AND 2 AIRPLANES - DETAILED AND SURFACE HFEC INSPECTION Elapsed Time (Hours)Man-HoursNumber of PersonsTask 1.532Open Access 2.552Detail Inspection 362Surface HFEC Inspection 1.532Close Access 8.517TOTAL FOR EACH AIRPLANE GROUP 1 AND 2 AIRPLANES - AFTER-MODIFICATION - FLOOR BEAM HOLE ZERO-TIMING (PRIMARY PREVENTIVE MODIFICATION INSTALLED) Elapsed Time (Hours)Man-HoursNumber of PersonsTask Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 18 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 19 GROUP 1 AND 2 AIRPLANES - AFTER-MODIFICATION - FLOOR BEAM HOLE ZERO-TIMING (PRIMARY PREVENTIVE MODIFICATION INSTALLED) 10.5212Open Access 1.51.51FIGURE 9 - STA 340 Left 1.51.51FIGURE 9 - STA 340 Right 1.51.51FIGURE 9 - STA 360 Left 1.51.51FIGURE 9 - STA 360 Right 1.51.51FIGURE 9 - STA 380 Left 1.51.51FIGURE 9 - STA 380 Right 1.51.51FIGURE 9 - STA 400 Left 1.51.51FIGURE 9 - STA 400 Right 1.51.51FIGURE 9 - STA 420 Left 1.51.51FIGURE 9 - STA 420 Right 1.51.51FIGURE 9 - STA 440 Left 1.51.51FIGURE 9 - STA 440 Right 1.51.51FIGURE 9 - STA 460 Left 1.51.51FIGURE 9 - STA 460 Right 1.51.51FIGURE 9 - STA 480 Left 1.51.51FIGURE 9 - STA 480 Right 1.51.51FIGURE 9 - STA 500 Right 1.51.51FIGURE 9 - STA 520 Left 1.51.51FIGURE 9 - STA 520 Right Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 19 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 20 GROUP 1 AND 2 AIRPLANES - AFTER-MODIFICATION - FLOOR BEAM HOLE ZERO-TIMING (PRIMARY PREVENTIVE MODIFICATION INSTALLED) 11222Close Access 5071.5TOTAL FOR EACH AIRPLANE (a) (a) The total hours given are for when the Primary Preventive Modification is installed at all STA 340 to STA 520 floor beam locations. GROUP 1 AND 2 AIRPLANES - AFTER-MODIFICATION - FLOOR BEAM HOLE ZERO-TIMING (ALTERNATIVE PREVENTIVE MODIFICATION INSTALLED) Elapsed Time (Hours)Man-HoursNumber of PersonsTask 10.5212Open Access 362FIGURE 10 - STA 420 Left 362FIGURE 10 - STA 420 Right 362FIGURE 10 - STA 440 Left 362FIGURE 10 - STA 440 Right 362FIGURE 10 - STA 460 Right 362FIGURE 10 - STA 480 Left 362FIGURE 10 - STA 480 Right 362FIGURE 10 - STA 500 Right 362FIGURE 10 - STA 520 Left 362FIGURE 10 - STA 520 Right 11222Close Access 51.5103TOTAL FOR EACH AIRPLANE (a) (a) The total hours given are for when the Alternative Preventive Modification is in- stalled at all applicable STA 420 to STA 520 floor beam locations. H. Weight and Balance Changes Change in Moment Pound-Inches Change in Weight Pounds SideSTAAirplane + 170+ 0.5Left340GROUPS 1 AND 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 20 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 21 Change in Moment Pound-Inches Change in Weight Pounds SideSTAAirplane + 170+ 0.5Right340GROUPS 1 AND 2 + 72+ 0.2Left360GROUPS 1 AND 2 +72+ 0.2Right360GROUPS 1 AND 2 + 76+ 0.2Left380GROUP 1 No ChangeNo ChangeRight380GROUP 1 + 190+ 0.5Left380GROUP 2 +114+ 0.3Right380GROUP 2 + 80+ 0.2Left400GROUPS 1 AND 2 + 80+ 0.2Right400GROUPS 1 AND 2 + 252+ 0.6Left420GROUPS 1 AND 2 - 84- 0.2Right420GROUPS 1 AND 2 + 88+ 0.2Left440GROUPS 1 AND 2 + 88+ 0.2Right440GROUPS 1 AND 2 + 92+ 0.2Left460GROUPS 1 AND 2 + 92+ 0.2Right460GROUPS 1 AND 2 + 144+ 0.3Left480GROUPS 1 AND 2 + 96+ 0.2Right480GROUPS 1 AND 2 + 100+ 0.2Right500GROUPS 1 AND 2 + 208+ 0.4Left520GROUPS 1 AND 2 + 260+ 0.5Right520GROUPS 1 AND 2 I. Electrical Load Data Not changed J. References 1. Existing Data: a. Engineering Change Memo PRR 85900-235. b. Service Related Problem (SRP) 747-SRP-53-0102, 747-SRP-53-0439. c. 747-400 Maintenance Manual (AMM) Subject 21-42-02, 25-21-02, 25-21-04, 25-24-18, 25-25-01, 25-32-01, 25-59-01. d. 747-400 Structural Repair Manual (SRM) Chapter 51. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 21 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 22 e. 747 Nondestructive Test (NDT) Manual D6-7170 , Part 6 , 51-00-00, Procedure 1, 4, 11, 16, 23. f. 747-400 Illustrated Parts Catalog Subject 21-22-51, 25-13-82, 25-14-00, 25-13-62, 25-13-64, 25-13-82, 25-15-55, 25-19-03, 52-51-00. g. 747 Structural Item Interim Advisory (SIIA) 747-175. h. Boeing Service Bulletin 747-53A2420 "FUSELAGE -Upper Deck Floor Beam Web and Chord Crack Inspection". i. Boeing Service Bulletin 747-53A2429 "FUSELAGE -Upper Deck Floor Beam Modification and Repair". j. FAA Airworthiness Directives (AD) 2005-13-05 and 2004-07-22 R1. k. Boeing Service Letter 747-SL-51-048, 747-SL-53-088 l. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-19 m. 747-400F Structural Repair Manual (SRM) 51-10-02 2. Data Supplied with this Service Bulletin: a. Drawings: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 22 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 23 ADCNDCN/REVSheetTitleDrawing No --1FLOOR BEAM INSTL - UPPER DECK, FREIGHTER, KIT 141U5600 --10 -A11 -A12 --13 -A14 -B15 -A16 --17 -A18 -A19 --2 -A20 -A3 --4 -A5 --6 -B7 -A8 -A9 -BPL --PSDLFLOOR BEAM INSTL - UPPER DECK, FREIGHTER, KIT 141U5600#DL 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. K. Publications Affected 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 23 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 24 Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS and new DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information. M. Software Accomplishment Summary Not affected. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 24 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 25 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 Unit Price as of the Revision 1 date of this Service Bulletin (US Dollars) NameKit Number $28,885.00Top Kit - Group 1015U1682-1 $29,738.00Top Kit - Group 2015U1682-2 The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. B. Industry Support Information Boeing warranty remedies are not available for the inspections, configuration changes and repair procedures given in this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. Kit 015U1682 NotesExisting Part Number NameQTYNew Part Number -1-2 Top Kit - Group 1-.015U1682-1 Top Kit - Group 2.-015U1682-2 Strap Instl11141U5600-1 Strap Instl11141U5600-10 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 25 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 26 Kit 015U1682 NotesExisting Part Number NameQTYNew Part Number -1-2 Angle Instl.1141U5600-11 Fastener Kit11141U5600-12 Strap Instl11141U5600-2 Strap Instl1.141U5600-3 Strap Instl11141U5600-4 Strap Instl11141U5600-5 Strap Instl11141U5600-6 Strap Instl11141U5600-7 Strap Instl11141U5600-8 Strap Instl11141U5600-9 Kit 141U5600 NotesExisting Part Number NameQTYNew Part Number -1-10-11-12-2-3 Strap Instl-.....141U5600-1 Strap Instl.-....141U5600-10 Angle Instl..-...141U5600-11 (e)Fastener Instl...-..141U5600-12 Strap Instl....-.141U5600-2 Strap Instl.....-141U5600-3 Roll Tape..1...140U5995-54 (a) (c) (d) 141U5466-27Angle - Upper Chord ..1...141U5104-25 (a) (c) (d) 141U5466-28Angle - Upper Chord ..1...141U5104-26 (a) (c) (d) 141U5466-5Strap - Upper Chord1.....141U5466-61 (a) (b) (d) 141U5466-66Strap - Upper Chord1.....141U5466-62 (a) (b) (d) 141U5466-58Strap - Upper Chord.....1141U5466-65 (a) (b) (d) 141U5466-59Strap - Upper Chord.....1141U5466-66 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 26 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 27 Kit 141U5600 NotesExisting Part Number NameQTYNew Part Number -1-10-11-12-2-3 (a) (b) (d) 141U5466-35Strap - Upper Chord.1....141U5466-80 (c)Plug..2...69B17956-18 Bolt...4..BACB30NW6K10X Bolt...4..BACB30NW6K7X Bolt...14..BACB30NX10K10X Bolt...6..BACB30NX10K11X Bolt...8..BACB30NX10K14X Bolt...4..BACB30NX10K15X Bolt...10..BACB30NX10K9X Bolt...4..BACB30NX6K10 Bolt...12..BACB30NX6K10X Bolt...8..BACB30NX6K11X Bolt...3..BACB30NX6K12X Bolt...17..BACB30NX6K3X Bolt...3..BACB30NX6K4 Bolt...46..BACB30NX6K4X Bolt...25..BACB30NX6K5 Bolt...97..BACB30NX6K5X Bolt...13..BACB30NX6K5Y Bolt...29..BACB30NX6K6 Bolt...215..BACB30NX6K6X Bolt...19..BACB30NX6K6Y Bolt...26..BACB30NX6K7 Bolt...164..BACB30NX6K7X Bolt...9..BACB30NX6K8 Bolt...94..BACB30NX6K8X Bolt...4..BACB30NX6K9 Bolt...22..BACB30NX6K9X Bolt...30..BACB30NX8K10X Bolt...19..BACB30NX8K11X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 27 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 28 Kit 141U5600 NotesExisting Part Number NameQTYNew Part Number -1-10-11-12-2-3 Bolt...7..BACB30NX8K12X Bolt...8..BACB30NX8K13X Bolt...6..BACB30NX8K14X Bolt...9..BACB30NX8K4X Bolt...44..BACB30NX8K5X Bolt...162..BACB30NX8K6X Bolt...247..BACB30NX8K7X Bolt...115..BACB30NX8K8X Bolt...6..BACB30NX8K8Y Bolt...50..BACB30NX8K9X Bolt...6..BACB30NX8K9Y Bolt...11..BACB30NY6K4 Bolt...4..BACB30NY6K8X Collar...10..BACC30AC8 Collar...10..BACC30BH10 Collar...4..BACC30BH10S Collar...438..BACC30BH6 Collar...37..BACC30BH6S Collar...503..BACC30BH8 Collar...6..BACC30BH8S Collar...4..BACC30M6 Filler..1...BACF3F011V067NN Filler..1...BACF3F011V073NN Radius Filler..16...BACF3H06DF006HN Nut Plate..5...BACN10JN3 Nut...342..BACN11E3 Nut...190..BACN11E4 Nut...26..BACN11E5 Clipnuts..5...BACN11K3 Rivet..10...BACR15BA3AD5C Rivet...4..BACR15BB8D11C Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 28 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 29 Kit 141U5600 NotesExisting Part Number NameQTYNew Part Number -1-10-11-12-2-3 Rivet...4..BACR15FT5D10 Rivet...3..BACR15FT5D12 Rivet...3..BACR15FT5D13 Rivet...92..BACR15FT5D6 Rivet...43..BACR15FT5D7 Rivet...3..BACR15FT5D8 Rivet...55..BACR15FT6D10 Rivet...36..BACR15FT6D11 Rivet...8..BACR15FT6D12 Rivet...6..BACR15FT6D13 Rivet...103..BACR15FT6D5 Rivet...505..BACR15FT6D6 Rivet..10426..BACR15FT6D7 Rivet...160..BACR15FT6D8 Rivet...85..BACR15FT6D9 Rivet...3..BACR15FT8D10 Rivet...11..BACR15FT8D8 Rivet...18..BACR15FT8D9 Rivet...3..BACR15GF5D5 Screw Assy..10...BACS12GR3L18 Filler..1..1BACS40R008C012F Washer...83..BACW10BP31NAPU Washer...24..BACW10BP32NAPU Washer...22..BACW10BP41NAPU Washer...6..BACW10BP51NAPU Panel Inserts..10...SL5107A3-410 (a) (c) (d) 141U5466-23Strap- Upper Chord....1.141U5466U63 (a) (c) (d) 141U5466-24Strap- Upper Chord....1.141U5466U64 (a) (c) (d) 141U5466-33Strap- Upper Chord.1....141U5466U79 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 29 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 30 Kit 141U5600 NotesExisting Part Number NameQTYNew Part Number -1-10-11-12-2-3 (a) Discard the existing part (b) This part is used in production. (c) This part is not used in production. (d) You cannot use the existing part to replace the new or changed part. (e) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 is used to determine the part numbers used as substitutes. Kit 141U5600 NotesExisting Part Number NameQTYNew Part Number -4-5-6-7-8-9 Strap Instl-.....141U5600-4 Strap Instl.-....141U5600-5 Strap Instl..-...141U5600-6 Strap Instl...-..141U5600-7 Strap Instl....-.141U5600-8 Strap Instl.....-141U5600-9 (a) (b)141U5466-3Strap - Upper Chord1.....141U5466-67 (a) (b)Strap - Upper Chord1.....141U5466-68 (a) (b)141U5466-16Strap - Upper Chord.1....141U5466-70 (a) (b)141U5466-19Strap - Upper Chord..1...141U5466-71 (a) (b)141U5466-20Strap - Upper Chord..1...141U5466-72 (a) (b)141U5466-9Strap - Upper Chord...1..141U5466-73 (a) (b)141U5466-10Strap - Upper Chord...1..141U5466-74 (a) (b)141U5466-38Strap - Upper Chord....1.141U5466-76 (a) (b)141U5466-43Strap - Upper Chord.....1141U5466-78 (a) (b)141U5466-15Strap- Upper Chord.1....141U5466U69 (a) (b)141U5466-39Strap- Upper Chord....1.141U5466U75 (a) Discard the existing part. (b) You cannot use the existing part to replace the new or changed part. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 30 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 31 2. Parts and Materials Supplied by the Operator: The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. Parts Necessary for After Modification Floor Beam Hole Zero-Timing (a) (b) NotesNameQTYPart Number / Specification (c)Sealant32 ozBMS5-95, Class B (c)Primer4 ozBMS10-11, Type 1 (d)Chemical Conversion Coating4 ozType 2, Class A (e) 1st OversizeBolt2BACB30ME8AK5 (e) 2nd OversizeBolt7BACB30ME8AK5 (e) 2nd OversizeBolt8BACB30ME8AK6 (e) 2nd OversizeBolt2BACB30ME8AK7 (e) 2nd OversizeBolt2BACB30ME8AK8 (e) 2nd OversizeBolt2BACB30ME8AK9 (e) 2nd OversizeBolt8BACB30ME8AK10 (e) 2nd OversizeBolt6BACB30ME8AK11 (e) 2nd OversizeBolt4BACB30ME10AK7 (e) 1st OversizeBolt4BACB30ME10AK8 (e) 1st OversizeBolt4BACB30ME10AK9 (e) 2nd OversizeBolt3BACB30ME10AK8 (e) 2nd OversizeBolt4BACB30ME10AK9 (e) 2nd OversizeBolt6BACB30ME10AK10 (e) 2nd OversizeBolt5BACB30ME10AK11 (e) 2nd OversizeBolt5BACB30ME10AK12 (e) 2nd OversizeBolt2BACB30ME10AK13 (e) 2nd OversizeBolt4BACB30ME10AK14 (e) 2nd OversizeBolt4BACB30ME12AK10 (e) 2nd OversizeBolt2BACB30ME12AK14 (e) 2nd OversizeBolt2BACB30ME12AK15 (e) Initial SizeBolt7BACB30NX8K5X (e) Initial SizeBolt8BACB30NX8K6X (e) Initial SizeBolt2BACB30NX8K7X (e) Initial SizeBolt2BACB30NX8K8X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 31 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 32 Parts Necessary for After Modification Floor Beam Hole Zero-Timing (a) (b) NotesNameQTYPart Number / Specification (e) Initial SizeBolt2BACB30NX8K9X (e) Initial SizeBolt8BACB30NX8K10X (e) Initial SizeBolt6BACB30NX8K11X (e) Initial SizeBolt2BACB30NX8K5Y (e) 1st OversizeBolt7BACB30NX8K5Y (e) 1st OversizeBolt8BACB30NX8K6Y (e) 1st OversizeBolt2BACB30NX8K7Y (e) 1st OversizeBolt2BACB30NX8K8Y (e) 1st OversizeBolt2BACB30NX8K9Y (e) 1st OversizeBolt6BACB30NX8K10Y (e) 1st OversizeBolt6BACB30NX8K11Y (e) 2nd OversizeBolt2BACB30NX10K5 (e) Initial SizeBolt4BACB30NX10K7X (e) Initial SizeBolt7BACB30NX10K8X (e) Initial SizeBolt4BACB30NX10K9X (e) Initial SizeBolt6BACB30NX10K10X (e) Initial SizeBolt5BACB30NX10K11X (e) Initial SizeBolt5BACB30NX10K12X (e) Initial SizeBolt2BACB30NX10K13X (e) Initial SizeBolt4BACB30NX10K14X (e) 1st OversizeBolt4BACB30NX10K7Y (e) Initial SizeBolt4BACB30NX10K8Y (e) Initial SizeBolt7BACB30NX10K9Y (e) 1st OversizeBolt7BACB30NX10K8Y (e) 1st OversizeBolt4BACB30NX10K9Y (e) 1st OversizeBolt6BACB30NX10K10Y (e) 1st OversizeBolt5BACB30NX10K11Y (e) 1st OversizeBolt5BACB30NX10K12Y (e) 1st OversizeBolt2BACB30NX10K13Y (e) 1st OversizeBolt4BACB30NX10K14Y (e) 2nd OversizeBolt4BACB30NX12K8 (e) 2nd OversizeBolt4BACB30NX12K9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 32 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 33 Parts Necessary for After Modification Floor Beam Hole Zero-Timing (a) (b) NotesNameQTYPart Number / Specification (e) Initial SizeBolt4BACB30NX12K10X (e) Initial SizeBolt2BACB30NX12K14X (e) Initial SizeBolt2BACB30NX12K15X (e) 1st OversizeBolt4BACB30NX12K10Y (e) 1st OversizeBolt2BACB30NX12K14Y (e) 1st OversizeBolt2BACB30NX12K15Y (e) 1st OversizeCollar7BACC30AC8 (e) 1st OversizeCollar2BACC30AC8S (e) Initial SizeCollar4BACC30AC10 (e) 1st OversizeCollar13BACC30AC10 (e) 1st OversizeCollar2BACC30AC10S (e) 1st OversizeCollar2BACC30AC12 (e) 1st OversizeCollar2BACC30AC12S (e) Initial SizeCollar7BACC30BH8 (e) Initial SizeCollar2BACC30BH8S (e) Initial SizeCollar16BACC30BH10 (e) Initial SizeCollar2BACC30BH10S (e) Initial SizeCollar2BACC30BH12 (e) 2nd OversizeCollar4BACC30BH12 (e) Initial SizeCollar2BACC30BH12S (e) 1st OversizeCollar1BACC30U8 (e) 2nd OversizeCollar31BACC30U8 (e) 1st OversizeCollar4BACC30U10 (e) 2nd OversizeCollar32BACC30U10 (e) 2nd OversizeCollar8BACC30U12 (e) Initial SizeNut23BACN11E4 (e) 1st OversizeNut22BACN11E4 (e) Initial SizeNut19BACN11E5 (e) 1st OversizeNut19BACN11E5 (e) 2nd OversizeNut2BACN11E5 (e) Initial SizeNut4BACN11E6 (e) 1st OversizeNut4BACN11E6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 33 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 34 Parts Necessary for After Modification Floor Beam Hole Zero-Timing (a) (b) NotesNameQTYPart Number / Specification (e) Initial SizeWasher6BACW10BP41NAPU (e) 1st OversizeWasher6BACW10BP42NAPU (e) 2nd OversizeWasher2BACW10BP5NAPU (e) 2nd OversizeWasher4BACW10BP51NAPU (e) 2nd OversizeWasher4BACW10BP52NAPU (e) 2nd OversizeWasher1BACW10BP6NAPU (e) 2nd OversizeWasher2BACW10BP61NAPU (e) 2nd OversizeWasher2BACW10BP62NAPU (a) A total of 81 fasteners are needed for holes that require zero-timing. Three different size options are listed as three different sizes are listed for each hole at the time of the preventive modification The size required depends on the starting size of the hole. (b) At locations where the Alternative Preventive Modification is accomplished, fasteners in kit 141U5600-12 are also required to re-install the strap. (c) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (d) Refer to SOPM 20-43-03 for material sources. (e) Refer to 747 Structural Repair Manual Chapter 51 for alternate fasteners. 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 34 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 35 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets are in 747-400F SRM, Chapter 51 – Torque limits to tighten nuts and bolts are in 747-400F SRM, Chapter 51 2. Use the approved fastener and process material substitutions in accordance with 747-400F SRM, Chapter 51. 3. If the length of any fastener specified in this service bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification,or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. 4. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 5. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "as given in" are included in the instruction, the procedure in the Boeing document must be used. 6. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 7. Obey all of the warnings and cautions given in the specified manual sections. 8. Unless otherwise specified in this service bulletin or associated installation drawings, it is acceptable to make fastener holes up to 1/32 inch oversize in diameter to remove crack indications, provided that a minimum edge margin of 1.7D is maintained on the floor beam and frame structure. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 35 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 36 9. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 10. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 11. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 12. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data. B. WORK INSTRUCTIONS PART 1 - INITIAL INSPECTION 1. Refer to Figure 1 - Logic Diagram. 2. Open access for the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 3. Do the Detailed Inspection of the web, upper chord and strap for any cracks as given in Figure 5. 4. Do the Floor Beam Upper Chord Open Hole High Frequency Eddy Current (HFEC) Inspection as given in Figure 8. 5. If cracks are found in the Floor Beam Web, Floor Beam Upper Chord or Upper Deck Floor Beam Straps repair as given in this service bulletin or contact Boeing for repair instructions. a. Option 1: (1) Repair the cracks by making fastener holes oversize as given in Figure 8. If cracks cannot be removed by making fastener holes oversize as given in Figure 8, contact Boeing for repair data. After repair, at the time given in Figure 1, do inspections and a preventive modification as given in PART 2 or PART 3 of the Work Instructions in this service bulletin. (2) Restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. b. Option 2: (1) Repair the cracks by making fastener holes oversize as given in Figure 6. If cracks cannot be removed by making fastener holes oversize as given in Figure 6, contact Boeing for repair data. As part of the repair, also install the preventive modification as given in Figure 4 of this service bulletin. In order to install the preventive modification concurrent with a repair or on a previously repaired floor beam where all of the service bulletin requirements cannot be met, contact Boeing with details of the damage found, so the preventative modification can be provided. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 36 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 37 (2) Restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. NOTE: Regardless of which of the above options is used, for repairs and modifications that comply with all of the service bulletin requirements, start to do after-modification inspections as given in PART 4 or PART 5 of the Work Instructions in this service bulletin at the time given in Figure 1. For repairs and modifications that do not comply with all of the service bulletin requirements, contact Boeing for an after-modification inspection plan. 6. If no cracks are found, restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 7. Put the airplane back to a serviceable condition. If the preventive modification was not installed at the initial time given in Figure 1, do inspections and a preventive modification as given in PART 2 or PART 3 of the Work Instructions in this service bulletin at the time given in Figure 1. If the preventive modification was installed, start to do after-modification inspections as given in PART 4 or PART 5 of the Work Instructions in this service bulletin at the time given in Figure 1. Group 1: PART 2 - INSPECTION AND PREVENTIVE MODIFICATION 1. Refer to Figure 1 - Logic Diagram. 2. Open access for the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 3. Remove the Upper Deck Floor Beam Straps as given in Figure 4. NOTE: At floor beam locations from Station 420 to Station 520 where fasteners are trapped against the frame and access is not available to remove them, an option is given within Figure 4 to grind off the fastener shank after the strap is removed. New fastener holes will not be drilled in the new strap at these locations. At floor beam locations where trapped fastener shanks are ground off, the modification installed is the Alternative Preventive Modification. At locations where there are no trapped fasteners or the trapped fasteners were removed and new fasteners installed, the modification installed is the Primary Preventive Modification. 4. Do the Detailed Inspection for cracks as given in Figure 5. 5. Do the Open Hole HFEC Inspection with the Straps removed as given in Figure 6. 6. If cracks are found in the Floor Beam Web or Floor Beam Upper Chord, repair by making fastener holes oversize as given in Figure 6 and install the Upper Deck Floor Beam Straps as given in Figure 4. If cracks cannot be removed by making fastener holes oversize as given in Figure 6, contact Boeing for repair instructions. 7. If no cracks are found, install the Upper Deck Floor Beam Straps as given in Figure 4. 8. Restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 37 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 38 9. Put the airplane back to a serviceable condition. At the time given in Figure 1, start to do after-modification inspections as given in PART 4 or PART 5 of the Work Instructions in this service bulletin. Group 2: PART 3 - INSPECTION AND PREVENTIVE MODIFICATION 1. Refer to Figure 1 - Logic Diagram. 2. Open access for the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 3. Gain access to the Station 380 Upper Deck Floor Beam as given in Figure 3. 4. Remove the Upper Deck Floor Beam Straps as given in Figure 4. NOTE: At floor beam locations from Station 420 to Station 520 where fasteners are trapped against the frame and access is not available to remove them, an option is given within Figure 4 to grind off the fastener shank after the strap is removed. New fastener holes will not be drilled in the new strap at these locations. At floor beam locations where trapped fastener shanks are ground off, the modification installed is the Alternative Preventive Modification. At locations where there are no trapped fasteners or the trapped fasteners were removed and new fasteners installed, the modification installed is the Primary Preventive Modification. 5. Do the Detailed Inspection for cracks as given in Figure 5. 6. Do the Open Hole HFEC Inspection with the Straps removed as given in Figure 6. 7. If cracks are found in the Floor Beam Web or Floor Beam Upper Chord repair by making fastener holes oversize as given in Figure 6 and install the Upper Deck Floor Beam Straps as given in Figure 4. If cracks cannot be removed by making fastener holes oversize as given in Figure 6, contact Boeing for repair instructions. 8. If no cracks are found, install the Upper Deck Floor Beam Straps as given in Figure 4. 9. Restore access to the Station 380 Upper Deck Floor Beam as given in Figure 3. 10. Restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 11. Put the airplane back to a serviceable condition. At the time given in Figure 1, start to do after-modification inspections as given in PART 4 or PART 5 of the Work Instructions in this service bulletin. PART 4 - AFTER-MODIFICATION REPEAT DETAILED AND SURFACE HFEC INSPECTIONS 1. Refer to Figure 1 - Logic Diagram. 2. Open access for the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 3. Do the Detailed Inspection for cracks as given in Figure 5. 4. Do the Floor Beam Upper Chord Surface HFEC Inspection as given in Figure 7. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 38 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 39 5. If cracks are found in the Floor Beam Web, Floor Beam Upper Chord or Upper Deck Floor Beam Straps, do the steps that follow: a. Repair as given in this service bulletin or contact Boeing for repair instructions. b. Restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 6. If no cracks are found, restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 7. Put the airplane back to a serviceable condition. Continue to do after-modification inspections as given in PART 4 or PART 5 and do the after-modification hole zero-timing as given in PART 6 of the Work Instructions in this service bulletin at the times given in Figure 1. PART 5 - AFTER-MODIFICATION REPEAT DETAILED AND OPEN-HOLE HFEC INSPECTIONS 1. Refer to Figure 1 - Logic Diagram. 2. Open access for the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 3. Do the Detailed Inspection for cracks as given in Figure 5. 4. Do the Floor Beam Upper Chord Open Hole HFEC Inspection as given in Figure 8. 5. If cracks are found in the Floor Beam Web, Floor Beam Upper Chord or Upper Deck Floor Beam Straps, do the steps that follow: a. Repair as given in this service bulletin or contact Boeing for repair instructions. b. Restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 6. If no cracks are found, restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 7. Put the airplane back to a serviceable condition. Continue to do after-modification inspections as given in PART 4 or PART 5 and do the after-modification hole zero-timing as given in PART 6 of the Work Instructions in this service bulletin at the times given in Figure 1. PART 6 - AFTER-MODIFICATION - FLOOR BEAM HOLE ZERO-TIMING 1. Refer to Figure 1 - Logic Diagram. 2. Open access for the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 3. Group 2: Get access to the Station 380 Upper Deck Floor Beam as given in Figure 3, as necessary. 4. At Floor Beam locations where the Primary Preventive Modification was accomplished, do the Floor Beam Hole Zero-Timing procedure as given in Figure 9. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 39 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 40 5. At Floor Beam locations where the Alternative Preventive Modification was accomplished, do the Floor Beam Hole Zero-Timing procedure as given in Figure 10. a. If any crack is found in the floor beam web or in an upper chord that cannot be removed within the oversizing and edge margin limits specified in this service bulletin, contact Boeing for repair information and do the work instructed by Boeing. 6. Group 2: Restore access to the Station 380 Upper Deck Floor Beam as given in Figure 3, as necessary. 7. Restore access to the Station 340 to Station 520 Upper Deck Floor beams as given in Figure 2. 8. Put the airplane back to a serviceable condition. Continue to do after-modification inspections as given in PART 4 or PART 5 of the Work Instructions in this service bulletin at the times given in Figure 1. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2: August 02, 2013 40 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 41 (OCR) BOEING SERVICE BULLETIN 747-53A2443 THE ACTIONS AND COMPLIANCE TIMES GIVEN BELOW APPLY TO EACH AFFECTED FLOOR BEAM INDEPENDENTLY BEFORE THE ACCUMULATION OF 15,000 TOTAL FLIGHT-CYCLES OR WITHIN 1,000 FLIGHT-CYCLES AFTER THE EFFECTIVE DATE OF AD 2005-13-05, WHICHEVER OCCURS LATER, DO ONE OF THE FOLLOWING DO AN INITIAL DETAILED INSPECTION OF FLOOR BEAM WEB, UPPER CHORD AND STRAPS. DO HFEC OPEN HOLE INSPECTIONS OF HOLES COMMON TO THE FLOOR BEAM STRAP AS GIVEN IN PART 1 CRACKS FOUND NO CRACKS FOUND BEFORE THE NEXT FLIGHT, REPAIR CRACKS AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTIONS. WITHIN 5,000 FLIGHT-CYCLES AFTER THE INITIAL INSPECTION, BUT PRIOR TO 20,000 TOTAL FLIGHT-CYCLES. DO A DETAILED INSPECTION OF FLOOR BEAM WEB, UPPER CHORD AND STRAPS. DO HFEC OPEN HOLE INSPECTIONS OF HOLES COMMON TO THE FLOOR BEAM STRAP AS GIVEN IN PART 2 OR PART 3. CRACKS FOUND NO CRACKS FOUND BEFORE THE NEXT FLIGHT, REPAIR AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTIONS. ACCOMPLISH THE FLOOR BEAM PREVENTIVE MODIFICATION BEFORE THE NEXT FLIGHT AS GIVEN IN PART 2 OR PART 3. BEGIN INSPECTIONS WITHIN 15,000 FLIGHT-CYCLES AFTER THE MODIFICATION IS ACCOMPLISHED. AT FLOOR BEAM LOCATIONS WHERE ALL AT FLOOR BEAM LOCATIONS WHERE FASTENERS WERE REMOVED DURING MODIFICATION (PRIMARY PREVENTIVE MODIFICATION). TRAPPED FASTENERS WERE NOT REMOVED DURING MODIFICATION (ALTERNATIVE PREVENTIVE MODIFICATION). FIGURE 1: LOGIC DIAGRAMS - GROUPS 1 AND 2 (SHEET 1 OF 4) Original Issue: May 09, 2002 Revision 2 August 02, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2443 Work - See page 1 for details. 41 of 107 ### Page 42 (OCR) BOEING SERVICE BULLETIN 747-53A2443 DO ONE OF THE FOLLOWING DO A DETAILED INSPECTION OF FLOOR BEAM WEB, UPPER CHORD AND STRAPS. DO HFEC SURFACE INSPECTIONS ALONG THE LOWER EDGE OF THE FLOOR BEAM UPPER CHORD AS GIVEN IN PART 4. DO A DETAILED INSPECTION OF FLOOR BEAM WEB, UPPER CHORD AND STRAPS. DO OPEN HOLE HFEC INSPECTIONS OF HOLES COMMON TO THE FLOOR BEAM STRAP AND BODY FRAME AS GIVEN IN PART 5 CRACKS FOUND NO CRACKS FOUND CRACKS FOUND NO CRACKS FOUND BEFORE THE NEXT FLIGHT, REPAIR AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTION. BEFORE THE NEXT FLIGHT, REPAIR AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTION. DO ONE OF THE FOLLOWING DO ONE OF THE FOLLOWING WITHIN 1,000 FLIGHT-CYCLES ACCOMPLISH THE FLOOR BEAM HOLE WITHIN 5,000 FLIGHT-CYCLES UNTIL THE FLOOR BEAM HOLE ZERO-TIMING WITHIN 20,000 FLIGHT UNTIL THE FLOOR BEAM HOLE ZERO-TIMING IS ACCOMPLISHED. CYCLES AFTER THE PRIMARY MODIFICATION ZERO-TIMING IS ACCOMPLISHED. IS ACCOMPLISHED OR WITHIN 1,000 FLIGHT CYCLES AFTER THE REVISION 2 DATE OF THIS SERVICE BULLETIN, WHICHEVER OCCURS LATER AS GIVEN IN PART 6. WITHIN 15,000 FLIGHT-CYCLES AFTER THE FLOOR BEAM HOLE ZERO-TIMING IS ACCOMPLISHED DO ONE OF THE FOLLOWING DO A DETAILED INSPECTION OF FLOOR BEAM SURFACE INSPECTIONS ALONG THE LONER UPPER CHORD AND STRAPS. DO HFEC EDGE OF THE FLOOR BEAM UPPER CHORD AS GIVEN IN PART 4. DO A DETAILED INSPECTION OF FLOOR BEAM WEB, UPPER CHORD AND STRAPS. DO OPEN HOLE HFEC INSPECTIONS OF HOLES COMMON TO THE FLOOR BEAM STRAP AND BODY FRAME AS GIVEN IN PART 5. CRACKS FOUND NO CRACKS FOUND CRACKS FOUND NO CRACKS FOUND BEFORE THE NEXT FLIGHT, REPAIR AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTION. BEFORE THE NEXT FLIGHT, REPAIR AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTION. WITHIN 1,000 FLIGHT-CYCLES WITHIN 5,000 FLIGHT-CYCLES FIGURE 1: LOGIC DIAGRAMS - GROUPS 1 AND 2 (SHEET 2 OF 4) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING 747-53A2443 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 107 ### Page 43 (OCR) BOEING SERVICE BULLETIN 747-53A2443 DO A DETAILED INSPECTION OF FLOOR BEAM WEB, UPPER CHORD AND STRAPS. DO HFEC SURFACE INSPECTIONS ALONG THE LOWER EDGE OF THE FLOOR BEAM UPPER CHORD AS GIVEN IN PART 4. CRACKS FOUND NO CRACKS FOUND BEFORE THE NEXT FLIGHT, REPAIR AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTION. DO ONE OF THE FOLLOWING ACCOMPLISH THE FLOOR BEAM HOLE ZERO-TIMING WITHIN 1,000 FLIGHT-CYCLES WITHIN 20,000 FLIGHT CYCLES AFTER THE UNTIL THE FLOOR BEAM HOLE ALTERNATIVE MODIFICATION IS ACCOMPLISHED ZERO-TIMING IS ACCOMPLISHED. OR WITHIN 1,000 FLIGHT CYCLES AFTER THE REVISION 2 DATE OF THIS SERVICE BULLETIN, WHICHEVER OCCURS LATER AS GIVEN IN PART 6 WITHIN 15,000 FLIGHT-CYCLES AFTER THE FLOOR BEAM HOLE ZERO-TIMING IS ACCOMPLISHED DO A DETAILED INSPECTION OF FLOOR BEAM WEB, UPPER CHORD AND STRAPS. DO HFEC SURFACE INSPECTIONS ALONG THE LOWER EDGE OF THE FLOOR BEAM UPPER CHORD AS GIVEN IN PART 4. CRACKS FOUND NO CRACKS FOUND BEFORE THE NEXT FLIGHT, REPAIR AS GIVEN IN THIS SERVICE BULLETIN OR CONTACT BOEING FOR REPAIR INSTRUCTION. WITHIN 1,000 FLIGHT-CYCLES. V68584 FIGURE 1: LOGIC DIAGRAMS - GROUPS 1 AND 2 (SHEET 3 OF 4) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING 747-53A2443 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 107 ### Page 44 (OCR) BOEING SERVICE BULLETIN 747-53A2443 BOEING RECOMMENDS THAT OPERATORS DO NOT ACCOMPLISH THE PREVENTIVE MODIFICATION PRIOR TO 15,000 TOTAL FLIGHT CYCLES. THEREFORE BOEING RECOMMENDS THAT OPERATORS SCHEDULE THE INITIAL INSPECTION ACCORDINGLY. DO NOT USE THIS INSPECTION FOR FLOOR BEAMS THAT WILL RESULT IN FLOOR BEAM OR FRAME STRUCTURE HAVING AN EDGE MARGIN LESS THAN 1.7D. INSTEAD, DO THE DETAILED VISUAL AND HFEC SURFACE INSPECTION AT 1,000 FLIGHT-CYCLE INTERVALS. THE FLOOR BEAM HOLE ZERO-TIMING MUST BE ACCOMPLISHED WITHIN 20,000 FLIGHT CYCLES AFTER THE PREVENTIVE MODIFICATION IS INSTALLED. BOEING RECOMMENDS THAT OPERATORS DO NOT ACCOMPLISH THE NEXT INSPECTION AND PREVENTIVE MODIFICATION PRIOR TO 15,000 TOTAL FLIGHT CYCLES. ACCOMPLISHING THE PREVENTIVE MODIFICATION BEFORE 15,000 TOTAL FLIGHT CYCLES COULD RESULT IN THE AIRPLANE REQUIRING A SECOND MODIFICATION (FASTENER HOLE ZERO-TIMING) PRIOR TO THE AIRPLANE REACHING THE LIMIT OF VALIDITY (LOV) OF 35,000 TOTAL FLIGHT CYCLES. 6 THE EFFECTIVE DATE OF AD 2005-13-05 IS JULY 27, 2005 2219716 FIGURE 1: LOGIC DIAGRAMS - GROUPS 1 AND 2 (SHEET 4 OF 4) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2443 Work - See page 1 for details. 44 of 107 ### Page 45 (OCR) BOEING SERVICE BULLETIN 747-53A2443 STA 520 9 10/16 UPPER _DECK STA FRAME 340 BODY SKIN MAIN INSULATION CAP STRIP (TYPICAL) DECK B-B 18) FORWARD ENTRY DOOR MAIN DECK CARGO COMPARTMENT A-A V61799 FIGURE 2: ACCESS AND RESTORATION - GROUPS 1 AND 2 (SHEET 1 OF 4) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING 747-53A2443 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 107 ### Page 46 (OCR) BOEING SERVICE BULLETIN 747-53A2443 (6) 13) C-C SIDEWALL PANELS 8)11 DADO PANELS 712 SIDEWALL PANELS (TYPICAL) D-D V61853 FIGURE 2: ACCESS AND RESTORATION - GROUPS 1 AND 2 (SHEET 2 OF 4) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2443 Work - See page 1 for details. 46 of 107 ### Page 47 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one airplane. NOTESQTYREFERENCESNAMETASKSTEP ACCESS Remove Ceiling Panels from Station 380 to Station 520. -AMM 25-59-01Ceiling PanelsRemove / Keep 1 Remove the upper portion of the Sidewall Panel just below the Floor Beams from STA 420 to STA 520. Remove the panels to allow access to the top 40 inches of the frames. -AMM 25-59-01Sidewall PanelsRemove / Keep 2 Remove the upper portion of the Frame Insulation Cap Strips just below the Floor Beams from STA 420 to STA 520. Remove the In- sulation Cap Strips to allow ac- cess to the top 40 inches of the frames. -AMM 25-21-04Insulation Cap StripsRemove / Keep 3 -AMM 25-25-01SeatsRemove / Keep 4 1AMM 25-24-18ClosetRemove / Keep 5 1AMM 25-32-01GalleyRemove / Keep 6 -Dado PanelsRemove / Keep 7 -AMM 25-21-02Sidewall PanelsRemove / Keep 8 Remove the lower portion of the Frame Insulation Cap Strips just above the Floor Beams on the Left Side from STA 420 to STA 440 and at STA 520. On the Right Side remove the Frame Insulation Cap Strips from STA 420 to STA 520. Remove the Insulation Blankets to allow access to the lower 50 inches of the frames. -AMM 25-21-04Insulation Cap StripsRemove / Keep 9 RESTORATION -AMM 25-21-04Insulation Cap StripsInstall / Kept 10 FIGURE 2: ACCESS AND RESTORATION - GROUPS 1 AND 2 (SHEET 3 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2 August 02, 2013 47 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 48 NOTESQTYREFERENCESNAMETASKSTEP -AMM 25-21-02Sidewall PanelsInstall / Kept 11 -Dado PanelsInstall / Kept 12 1AMM 25-32-01GalleyInstall / Kept 13 1AMM 25-24-18ClosetInstall / Kept 14 -AMM 25-25-01SeatsInstall / Kept 15 -AMM 25-21-04Insulation Cap StripsInstall / Kept 16 -AMM 25-59-01Sidewall PanelsInstall / Kept 17 -AMM 25-59-01Ceiling PanelsInstall / Kept 18 FIGURE 2: ACCESS AND RESTORATION - GROUPS 1 AND 2 (SHEET 4 OF 4) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2 August 02, 2013 48 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 49 (OCR) BOEING SERVICE BULLETIN 747-53A2443 This Figure applies only to: Group 2. STA 520 Y22 STA 340 SEE DOOO A-A V61869 FIGURE 3: ACCESS AND RESTORATION - STATION 380 FLOOR BEAM - GROUP 2 (SHEET 1 OF 5) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING 747-53A2443 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 107 ### Page 50 (OCR) BOEING SERVICE BULLETIN 747-53A2443 STA 520. 320 \18) STA 340 4x19 • V62072 FIGURE 3: ACCESS AND RESTORATION - STATION 380 FLOOR BEAM - GROUP 2 (SHEET 2 OF 5) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING 747-53A2443 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 107 ### Page 51 (OCR) BOEING SERVICE BULLETIN 747-53A2443 STA 520 STA 340_ STA .520 STA _340 1013) V62343 FIGURE 3: ACCESS AND RESTORATION - STATION 380 FLOOR BEAM - GROUP 2 (SHEET 3 OF 5) Original Issue: May 09, 2002 Revision 2 August 02, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2443 Work - See page 1 for details. 51 of 107 ### Page 52 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one airplane. NOTESQTYREFERENCESNAMETASKSTEP ACCESS -IPC 25-15-55 Fig. 1Accent StripeRemove / Keep 1 1IPC 25-13-82 Fig 2, IPC 52-51-00 Fig 1 Curtain TrackRemove / Keep 2 1IPC 25-14-00 Fig. 5Ceiling PanelRemove / Keep 3 1IPC 25-13-62 Fig. 1Right Side Stowage Unit Remove / Keep 4 1IPC 25-13-64 Fig. 5Left Side Stowage Unit Remove / Keep 5 1IPC 25-19-03 Fig. 17Left Side PartitionRemove / Keep 6 1IPC 25-19-03 Fig. 15Right Side PartitionRemove / Keep 7 1AMM 21-42-02 and IPC 21-22-51 Fig. 6A Left Side Shoulder Heater Remove / Keep 8 Remove ducts to allow access to floor panel above the STA 380 Floor Beam -IPC 21-22-51 Fig. 6ALeft Side Air Condi- tioning Ducts Remove / Keep 9 1AMM 21-42-02 and IPC 21-22-51 Fig. 10A Right Side Shoulder Heater Remove / Keep 10 Remove ducts to allow access to floor panel above the STA 380 Floor Beam -IPC 21-22-51 Fig. 10A Right Side Air Condi- tioning Ducts Remove / Keep 11 INSTALLATION Remove ducts to allow access to floor panel above the STA 380 Floor Beam -IPC 21-22-51 Fig. 10A Right Side Air Condi- tioning Ducts Install / Kept 12 1AMM 21-42-02 and IPC 21-22-51 Fig. 10A Right Side Shoulder Heater Install / Kept 13 Remove ducts to allow access to floor panel above the STA 380 Floor Beam -IPC 21-22-51 Fig. 6ALeft Side Air Condi- tioning Ducts Install / Kept 14 FIGURE 3: ACCESS AND RESTORATION - STATION 380 FLOOR BEAM - GROUP 2 (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2 August 02, 2013 52 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 53 NOTESQTYREFERENCESNAMETASKSTEP 1AMM 21-42-02 and IPC 21-22-51 Fig. 6A Left Side Shoulder Heater Install / Kept 15 1IPC 25-19-03 Fig. 15Right Side PartitionInstall / Kept 16 1IPC 25-19-03 Fig. 17Left Side PartitionInstall / Kept 17 1IPC 25-13-64 Fig. 5Left Side Stowage Unit Install / Kept 18 1IPC 25-13-62 Fig. 1Right Side Stowage Unit. Install / Kept 19 1IPC 25-14-00 Fig. 5Ceiling PanelInstall / Kept 20 1IPC 25-13-82 Fig 2, IPC 52-51-00 Fig 1 Curtain TrackInstall / Kept 21 -IPC 25-15-55 Fig. 1Accent StripeInstall / Kept 22 FIGURE 3: ACCESS AND RESTORATION - STATION 380 FLOOR BEAM - GROUP 2 (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2 August 02, 2013 53 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 54 (OCR) BOEING SERVICE BULLETIN 747-53A2443 STA 520 STA 340 > SEE D STA BL 520 STA 500 STA 480 STA STA STA 360 STA 340 > FWD SEE A-A THRU C-C V62352 FIGURE 4: FLOOR BEAM MODIFICATION (PRIMARY AND ALTERNATIVE) - GROUPS 1 AND 2 (SHEET 1 OF 5) Original Issue: May 09, 2002 Revision 2 August 02, 2013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-53A2443 Work - See page 1 for details. 54 of 107 ### Page 55 (OCR) BOEING SERVICE BULLETIN 747-53A2443 FRAME 230S FRAME INNER CHORD UPPER CHORD FASTENER TRAPPED BY FRAME UP FLOOR BEAM WEB → INBD A-A RIGHT SIDE SHOWN LEFT SIDE OPPOSITE STA 420 LEFT AND RIGHT SIDES (2)3 4)5 FRAME FRAME INNER CHORD UPPER CHORD FLOOR BEAM WEB UP FASTENERS TRAPPED BY FRAME - INBD B-B RIGHT SIDE SHOWN LEFT SIDE OPPOSITE TYPICAL STA 460 RIGHT SIDE STA 480 LEFT AND RIGHT SIDES STA 500 RIGHT SIDE STA 520 LEFT AND RIGHT SIDES 2219961 FIGURE 4: FLOOR BEAM MODIFICATION (PRIMARY AND ALTERNATIVE) - GROUPS 1 AND 2 (SHEET 2 OF 5) Original Issue: May 09, 2002 Revision 2 August 02, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2443 Work - See page 1 for details. 55 of 107 ### Page 56 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the numbers of parts necessary for one airplane. At floor beam locations from Station 420 to Station 520 where fasteners are trapped against the frame and access is not available to remove them, an option is given to grind off the fastener shank after the strap is removed. New fastener holes will not be drilled in the new strap at these locations. At floor beam locations where trapped fastener shanks are ground off, the modification installed is the Alternative Preventive Modification. At locations where there are no trapped fasteners or trapped fasteners were removed and new fasteners installed, the modification installed is the Primary Preventive Modification. In case the primary modification is accomplished, do not disassemble the Floor Beam to Frame connections of adjacent bays at the same time. NOTESQTYPART NUMBERNAMETASKSTEP Refer to Table 1-_Straps (a)Remove / Discard 1 CAUTION: WHEN CUTTING OR GRINDING FASTENER SHANKS, TAKE CARE NOT TO DAMAGE THE FLOOR BEAM UPPER CHORD. (c) (d)--Fastener ShankCut2 (c) (d)--Fastener ShankGrind FIGURE 4: FLOOR BEAM MODIFICATION (PRIMARY AND ALTERNATIVE) - GROUPS 1 AND 2 (SHEET 3 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2 August 02, 2013 56 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 57 NOTESQTYPART NUMBERNAMETASKSTEP (c) (e)-Type 2, Class AChemical Conversion Coating Apply3 (c) (f)-BMS10-11, Type 1PrimerApply4 (c) (g)--Upper ChordInspect5 The Detailed and HFEC inspections as given in PART 3 of the ACCOMPLISHMENT INSTRUCTIONS must be accomplished before the new Straps are installed. Refer to Table 1--Straps (b) (h)Install6 (a) There are no existing straps to be removed on the Floor Beams at STA 400 - Right Side and STA 500 Left Side. (b) Straps are not installed on Floor Beams at STA 500 Left Side. (c) This step applies to the Alternative Preventive modification only and is applicable at floor beam locations where a fastener is trapped between the upper chord and the fuselage frame and access to remove the fastener is not available. (d) Maintain a 63 AA or better surface finish. (e) Apply to bare metal surfaces. Refer to SOPM 20-43-03 as an accepted procedure. (f) Apply 1 layer to bare metal surfaces. Refer to SOPM 20-41-02 as an accepted procedure. (g) Do a surface High Frequency Eddy Current (HFEC) inspection of the upper chord around the holes where the fastener shanks have been ground down to make sure there are no cracks as given in 747 NDT Manual Part 6, 51-00-00, Procedure 4 or Procedure 23. (h) Do not drill fastener holes in the new straps at locations where the fastener shanks of trapped fasteners in the floor beam have been ground down. TABLE 1 Upper Deck Floor Beams - Location of Straps to Be Removed NotesUse Kit NumbersUse Drawing 141U5600 Sheet Number SideAirplane Groups STA 141U5600-1 and 141U5600-12 2Left1 and 2340 141U5600-1 and 141U5600-12 2Right1 and 2340 141U5600-2 and 141U5600-12 3Left1 and 2360 141U5600-2 and 141U5600-12 3Right1 and 2360 141U5600-3 and 141U5600-12 4Left1380 FIGURE 4: FLOOR BEAM MODIFICATION (PRIMARY AND ALTERNATIVE) - GROUPS 1 AND 2 (SHEET 4 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2 August 02, 2013 57 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 58 TABLE 1 Upper Deck Floor Beams - Location of Straps to Be Removed NotesUse Kit NumbersUse Drawing 141U5600 Sheet Number SideAirplane Groups STA 141U5600-3 and 141U5600-12 4Right1380 Modification of this Floor Beam also requires modification of the Floor Panel. 141U5600-11 and 141U5600-12 5Left2380 Modification of this Floor Beam also requires modification of the Floor Panel. 141U5600-11 and 141U5600-12 5Right2380 141U5600-4 and 141U5600-12 6Left1 and 2400 There is no existing strap to re- move on the Right Side of this Floor Beam. 141U5600-4 and 141U5600-12 6Right1 and 2400 141U5600-5 and 141U5600-12 7 and 8Left1 and 2420 141U5600-5 and 141U5600-12 7 and 9Right1 and 2420 141U5600-6 and 141U5600-12 10 and 11Left1 and 2440 141U5600-6 and 141U5600-12 10 and 12Right1 and 2440 141U5600-7 and 141U5600-12 13Left1 and 2460 141U5600-7 and 141U5600-12 13 and 14Right1 and 2460 141U5600-8 and 141U5600-12 15 and 16Left1 and 2480 141U5600-8 and 141U5600-12 15 and 16Right1 and 2480 141U5600-9 and 141U5600-12 17 and 18Right1 and 2500 141U5600-10 and 141U5600-12 19 and 20Left1 and 2520 141U5600-10 and 141U5600-12 19 and 20Right1 and 2520 FIGURE 4: FLOOR BEAM MODIFICATION (PRIMARY AND ALTERNATIVE) - GROUPS 1 AND 2 (SHEET 5 OF 5) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: May 09, 2002 747-53A2443Revision 2 August 02, 2013 58 of 107 BOEING SERVICE BULLETIN 747-53A2443 ### Page 59 (OCR) BOEING SERVICE BULLETIN 747-53A2443 STA 520× STA 340 • SEE Q 520 STA 500 480 STA 460 STA 440 STA 420 STA 400 STA STA TYPICAL INSPECTION AREA V68624 FIGURE 5: FLOOR BEAM - DETAILED INSPECTION (SHEET 1 OF 5) Original Issue: May 09, 2002 Revision 2 August 02, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2443 Work - See page 1 for details. 59 of 107 ### Page 60 (OCR) BOEING SERVICE BULLETIN 747-53A2443 FRAME INNER CHORD CHORD AND STRAP CRACK UP SEE (B INDO SO FOR RIGHT SIDE A-A LEFT SIDE STA 340 SHOWN OTHER AFFECTED FLOOR BEAMS SIMILAR 2 UPPER CHORD 3) STRAP UP > FWD O WEB B-B (TYPICAL, ALL AFFECTED FLOOR BEAMS) FIGURE 5: FLOOR BEAM - DETAILED INSPECTION (SHEET 2 OF 5) Original Issue: May 09, 2002 Revision 2 August 02, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2443 Work - See page 1 for details. 60 of 107 The text continues at https://openairdocs.org/service-documents/boeing/747-53a2443/file/37c9689b1d2e.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). 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