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### 1 of 173 ALERT ALERT 

### Commercial **Airplane Group**  

# 747

**ALERT ALERT**  

# Service Bulletin

**Number: 747-53A2500** Date: December 21, 2004 Revision 1: September 25, 2008 ATA System: 5311 5312 5321 5211 **SUBJECT:** FUSELAGE - Main Frame - Inspections Based on Fatigue Test Results 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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### 3 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT Table of Contents**  Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 32 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 32 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 32 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 33 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 33 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 2: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES . . . . . . . . . . . . 57 FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES . . . . . . . . . . . . 68 FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 FIGURE 7: INSPECTION OF AREA 7 - BODY STATION 260, 340, AND 400 BULKHEADS AND NOSE

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400 . . . . . . . . . . 90 FIGURE 8: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 1, 3, 5, 6, 7, 8, AND 10 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 FIGURE 9: INSPECTION OF AREA 9 - MAIN ELECTRONICS BAY ACCESS DOOR CUTOUT . . . 103 FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES 105 FIGURE 11: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES 110 FIGURE 12: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 4 AIRPLANES . 115 FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND 10 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 9 FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES 125 FIGURE 15: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 2, 4, AND 9 AIRPLANES 130 FIGURE 16: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 FIGURE 18: INSPECTION OF AREA 1 - FRAM E INSPECTION COMMON TO UPPER DECK FLOOR BEAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 FIGURE 19: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GR OUP 9 AIRPLANES 157 FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES 161 FIGURE 21: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 8 AIRPLANES . 168 APPENDIX A: LOGIC DIAGRAM - GROUP 1 AND 6 AIRPLANES . . . . . . . . . . . . . . . . . . 172 APPENDIX B: LOGIC DIAGRAM - GROUP 2, 3, 4, 5, 7, 9, AND 10 AIRPLANES. . . . . . . . . . . 173

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### 5 of 173 ALERT ALERT 

### Commercial **Airplane Group**  

# 747

**ALERT ALERT**  

# Service Bulletin

**Number: 747-53A2500** 

### Revision Transmittal Sheet Date: December 21, 2004 Revision 1: September 25, 2008 ATA System: 5311 5312 5321 5211 **SUBJECT:** FUSELAGE - Main Frame - Inspections Based on Fatigue Test Results
This Revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** More work is necessary on airplanes inspected as given in the original issue of this service bulletin. Operators should incorporate the additional inspection requirements for Area 1 and Area 6 during the next scheduled inspection. No airplanes have been added to the service bulletin effectivity. However, 747 Large Cargo Freighter (LCF) airplanes RT631-RT632, RT743, and RT876 were moved from Group 1 to new Group 8. 747-200F airplanes through line number 685 were moved from Group 2 to new Group 9. 747-200C airplanes through line number 685 were moved from Group 3 to new Group 10. Federal Aviation Administration (FAA) Airworthiness Directives 2006-05-02 and 2004-07-22 R1 are related to this service bulletin. **REASON FOR REVISION** This revision is sent to add new inspection requirements for Area 1, and to add to and to clarify some inspection requirements for Area 6. Inspection Area 1 (upper deck floor beams) has been changed to include inspections of the fuselage frames in the areas where the upper deck floor beams are attached. Inspection Area 6 has been changed to include inspection of more fuselage frames in the area above Main Entry Door 1 on 747-200C and 747-200F airplanes after line number 685, and on all 747-400, 747-400D, and 747-400F airplanes. For 747- 200C and 747-200F airplanes through line number 685, this inspection area is included in Boeing Service Bulletin 747-53A2732. In addition, Compliance information and inspection area requirements for 747 Large cargo Freighter (LCF) airplanes have been added. These sections were changed: 1. In Summary Background section and in Reason, Paragraph 1.C., referenced Boeing Service Related Problem (SRP) 747-SRP-53-0311. Also, updated Summary illustration. 2. In Description Paragraph 1.D., a description of the inspections required on Group 8 airplanes has been added.

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** 3. In Compliance, Paragraph 1.E., Compliance information for new Group 8 airplanes has been added. Related airworthiness directives have also been added. 4. In Approval, Paragraph 1.F., the approval statement has been updated and Alternative Method of Compliance information for related airworthiness directives has been added. 5. In Manpower, Paragraph 1.G., the estimate has been updated to include inspection of the frames in the upper deck floor beam attachment areas in Area 1. 6. In References, Paragraph 1.J., updated references list. 7. In Work Instructions, Paragraph 3.B., descriptions of the inspections required in the various Inspection Areas for Group 8 airplanes have been added. 8. In Work Instructions, Paragraph 3.B., Area 1 inspection, instructions were added for detailed inspection of the frame inner chord, the frame outer chord, and the frame web in the area between the upper and lower chords of the upper deck floor beams. Instructions were added to inspect Group 8 airplanes as given in Figure 21. 9. In Work Instructions, Paragraph 3.B., Area 5 inspection, step 5 has been revised to refer to Figure 17 (was Figure 19). 10. In Work Instructions, Paragraph 3.B., Area 6 inspection, instructions were added to inspect Group 9 airplanes as given in Figure 19. Instructions were added to inspect Group 10 airplanes as given in Figure 20. 11. Figures 6 and 14 (for Area 6) have been revised to clarify and add inspection requirements for the area above the Main Entry Door No. 1 cutout. On these airplanes, also do detailed inspections of the body frames at STA 400 through STA 500, from the top of the upper deck floor to Stringer 8. 12. Figure 18 (for Area 1) has been added for detailed inspection of the frame inner chord, the frame outer chord, and the frame web in the area between the upper and lower chords of the upper deck floor beams. This inspection is necessary on both sides of the airplane at each frame from body station 260 to body station 520. 13. Figure 19 (for Area 6 on Group 9 airplanes) has been added to show that on these airplanes it is not necessary to do inspections of the frames above the upper deck floor above Main Entry Door 1 left. 14. Figure 20 (for Area 6 on Group 10 airplanes) has been added to show that on these airplanes it is not necessary to do inspections of the frames above the upper deck floor above Main Entry Door 1 left and right. 15. Figure 21 (for Area 1 on Group 8 airplanes) has been added to show the detailed inspection requirements for the upper deck floor beams on Group 8 airplanes. Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes. 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.

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT REVISION HISTORY**  Original Issue: December 21, 2004 Revision 1: September 25, 2008

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

BLANK PAGE

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### 9 of 173 ALERT ALERT 

### Commercial **Airplane Group**  

# 747

**ALERT ALERT**  

# Service Bulletin

**Number: 747-53A2500** 

### Summary Date: December 21, 2004 Revision 1: September 25, 2008 ATA System: 5311 5312 5321 5211 **SUBJECT:** FUSELAGE - Main Frame - Inspections Based on Fatigue Test Results

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** This service bulletin gives data for the inspection and repair, if necessary, of certain fuselage structure. These inspections and repairs are necessary for safe operation of 747-400 airplanes and nose cargo door 747 airplanes past the design life goal. Tests by Boeing have determined that the structure shown in this service bulletin is subject to fatigue cracks. Boeing has completed extended pressure fatigue tests on a 747SR and a 747-400 fuselage test article. Boeing has also used updated analysis methods on the 747 fuselage structure. The tests and analysis have identified areas of the fuselage where fatigue cracks can occur. Inspection and repair of these areas is necessary for safe operation of 747 airplanes past the design life goal. The inspections in this service bulletin will make sure that fatigue cracks in the areas of fuselage internal structure shown do not become critical. Additional service bulletins will be required to be accomplished in certain specific areas, as a result of fatigue crack findings in the 747 fleet. Also, Supplemental Structural Inspection Document (SSID), D6-35022 Revision G and Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 require inspections to be accomplished, starting at 20,000 total flight-cycles. Boeing Service Related Problem (SRP) 747-SRP-53-0211 is related to this service bulletin. Boeing Service Related Problem (SRP) 747-SRP-53-0311 is related to this service bulletin. **ACTION** (PRR 85901-44RS) Do internal detailed inspections for cracks in these areas of internal fuselage structure:

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** 1. Upper deck floor beams. 2. Section 42 frames. 3. Section 46 frames. 4. Nose wheel well bulkheads, sidewall panels, and the STA 360 and 380 main deck floor beams. 5. Section 41 frame structure in the area between the upper deck floor beam chords, from STA 260 to 520. Do internal and external detailed inspections of the main entry doors and door cutouts for cracks. Do internal and external detailed inspections of the fuselage skin for cracks at all four corners of the main electronics bay access door cutout. If cracks are found, refer to the structural repair manual for repair instructions. If the damage is beyond the limits shown in the structural repair manual, ask Boeing for repair data. Also, ask Boeing for repair data if an applicable repair is not included in the structural repair manual. **EFFECTIVITY** All 747-200C, 747-200F, 747-400, 747-400D, and 747-400F series airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Airworthiness Directives 2006-05-02 and 2004-07-22 R1 are related to this service bulletin. Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection or repair procedures given in this service bulletin. **MANPOWER**

**MATERIAL INFORMATION** None. **Airplanes Total Task Hours Elapsed Hours** All 1990 322

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

FRAMES LOWER LOBE SECTION 42 INSPECT THE 1000 STA

520 STA

260 BULKHEAD 140 STA

INSPECT THE BODY STATION INSPECT THE BODY

WHEEL WELL STRUCTURE BULKHEADS AND NOSE STATION 340 AND 400 ENTRY DOORS AND DOOR CUTOUTS INSPECT THE MAIN INSPECT THE UPPER DECK FLOOR BEAMS AND INSPECT THE FRAMES IN THE AREA COMMON TO THE UPPER DECK FLOOR BEAMS 520 STA

UPPER DECK FLOOR BEAMS INSPECT THE INSPECT THE UPPER LOBE FRAMES SECTION 42

ACCESS DOOR CUTOUT ELECTRONICS BAY AT THE MAIN INSPECT THE SKIN DECK FLOOR BEAMS 360 AND 380 MAIN INSPECT THE STA DOORS AND DOOR INSPECT THE MAIN ENTRY CUTOUTS

DOORS AND DOOR CUTOUTS MAIN ENTRY INSPECT THE

1000 STA 1480 STA

1480 STA 2360 STA

DOORS AND DOOR

SECTION 46 SECTION 46

FRAMES LOWER LOBE CUTOUTS MAIN ENTRY INSPECT THE

UPPER LOBE FRAMES INSPECT THE

INSPECT THE DECK FLOOR BEAMS INSPECT THE UPPER RIGHT SIDE OPPOSITE LEFT SIDE SHOWN



### SECTION 42
RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN



### SECTION 41

RIGHT SIDE OPPOSITE LEFT SIDE SHOWN



### SECTION 46
RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN



### SECTION 44 FWD

FWD

FWD FWDW59427

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

BLANK PAGE

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### 13 of 173 ALERT ALERT 

### Commercial **Airplane Group**  

# 747

**ALERT ALERT**  

# Service Bulletin

**Number: 747-53A2500** Date: December 21, 2004 Revision 1: September 25, 2008 ATA System: 5311 5312 5321 5211 **SUBJECT:** FUSELAGE - Main Frame - Inspections Based on Fatigue Test Results

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. Refer to PRR 85901-44RS for data about this change. **NOTE:** This service bulletin is for the airplanes identified below. The effectivity list shown below is complete for airplanes through line number 1413. However, airplanes after line number 1413 are also affected by this service bulletin.

**GROUP CONFIGURATION DESCRIPTION** 1 - All 747-400 airplanes line number 758 and on, except Combi and 747-400F airplanes and airplanes modified by Boeing to the Large Cargo Freighter (LCF) configuration. 2 - All 747-200F airplanes line number 686 and on. 3 - All 747-200C airplanes line number 686 and on. 4 - All 747-400F airplanes. 5 - All 747-400 airplanes through line number 757, except Combi and 747-400F airplanes.

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

Airplane models: 747-200C 747-200F 747-400 747-400D 747-400F IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AEROLINEAS ARGENTINAS (ARG) 1 RT701–RT702 RT704 AIR ATLANTA ICELANDIC (AID) 1 RT515 RT751 2 RR206 9 RR204 RR332 AIR CHINA (BEJ) 1 RM341 RT878–RT880 2 RR451 6 RM811–RM813 RT032–RT035 7 RT031 AIR CHINA CARGO (CGC) 4 RL501–RL502 6 RT101 RT103 AIR FRANCE (AFA) 1 RM401–RM403 RT711–RT716 2 RR308–RR309 4 RL671–RL675 5 RT591 6 RT071–RT075 RT121 9 RR306 AIR INDIA (AIN) 1 RT749 RU001–RU006 6 - All 747-400 Combi airplanes line number 758 and on. 7 - All 747-400 Combi airplanes through line number 757. 8 - All 747-400 airplanes line number 758 and on, modified by Boeing to the Large Cargo Freighter (LCF) configuration. 9 - All 747-200F airplanes through line number 685. 10 - All 747-200C airplanes through line number 685. **GROUP CONFIGURATION DESCRIPTION**

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** AIR NEW ZEALAND (ANZ) 1 RM082 RM191–RM192 RT672–RT673 RT703 RT932 5 RT671 AIR PACIFIC (APC) 5 RT502 RT504 AIR PULLMANTUR (PUL) 1 RT525 AIRBRIDGE CARGO (ABM) 2 RR556 4 RL576–RL577 RL579 9 RR552 ALL NIPPON AIRWAYS (ANA) 1 RM231 RM233 RT753–RT756 RT776–RT777 RU831–RU841 AMIRI FLIGHT (ABD) 1 RM084 6 RT137 ASIANA AIRLINES (AAR) 1 RM071 RU032 4 RM861–RM863 RR746–RR747 6 RT131–RT136 ATLAS AIR (TLS) 1 RT752 10 RJ333 4 RM891–RM899 RM901–RM906 RR748 9 RR301 AVION AIRCRAFT TRADING H.F. (VNG) 1 RT633–RT634 AWAS (AWW) 10 RJ321 3 RJ322 BAHRAIN ROYAL FLIGHT (BHR) 1 RM426 BOEING (TBC) 9 RR222–RR223 BOEING AIRCRAFT HOLDING CO. (BHC) 10 RJ132

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** BRITISH AIRWAYS (BAB) 1 RM096–RM097 RM136–RM145 RM261–RM264 RT476–RT499 RU121–RU132 5 RT471–RT475 C.A.L. CARGO AIR LINES (CRG) 10 RJ331–RJ332 CARGO 360, INC. (CGN) 2 RR024–RR025 CARGO B AIRLINES (CBO) 2 RR307 9 RR561 CARGOLUX AIRLINES (CLX) 4 RL551 RM881–RM890 RR701 RR721–RR724 CATHAY PACIFIC AIRWAYS (CAT) 1 RT453–RT469 RT508 RT511–RT512 RT514 RT517–RT518 RT522 RT528–RT529 RT781–RT782 2 RR441–RR442 4 RL581–RL583 RM856–RM859 RR951–RR952 5 RT451–RT452 CHINA AIRLINES (CHI) 1 RM021–RM024 RM441–RM443 RM445 RT636–RT640 4 RL411–RL430 RL481 CHINA CARGO (CIQ) 4 RL521–RL522 CHINA SOUTHERN AIRLINES (GUN) 4 RL751–RL752 CORSAIR (COR) 1 RT613–RT614 RT616 RT618–RT619 RT621 DRAGONAIR (DRG) 1 RT510 RT513 RT516 RT524 2 RR522 DUBAI AIR WING (DAW) 1 RM167–RM168 6 RT102 EL AL ISRAEL AIRLINES (ELA) 1 RM091 RU081–RU083 10 RJ152 9 RR225–RR226 EMIRATES (EAD) 4 RL533–RL534

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** EVA AIR (EVA) 1 RM116–RM117 RT951–RT952 RT955 4 RL401–RL403 6 RT162–RT163 RT165–RT168 RT953–RT954 EVERGREEN INTERNATIONAL A/L (EVR) 10 RJ131 RJ133 8 RT631–RT632 RT743 RT876 EXPORT RESTRICTED AIRPLANES (YWV) 1 RT412 RT606 RT615 RT620 RT622 5 RT602 9 RR001–RR004 GARUDA INDONESIA (GIA) 1 RT931 RU061–RU062 GENERIC CUSTOMER/SUPPLIER (XXX) 2 RR310 9 RR202–RR203 GOVERNMENT OF JAPAN (JAG) 1 RT681–RT682 GRAND STAR (GCG) 4 RR861 GREAT WALL AIRLINES (GWL) 1 RT520 IRAQI AIRWAYS (IRQ) 10 RJ301–RJ303 JADE CARGO INTERNATIONAL (JDE) 4 RL511–RL516 JAL INTERNATIONAL (JAL) 1 RM126–RM132 RM316–RM318 RT641–RT657 RT861–RT864 RT966–RT967 RU801–RU809 4 RL461–RL462 9 RR265–RR266 KALITTA AIR (KAC) 7 RT021–RT022 9 RR261–RR262 RR361–RR362 RR501 RR521 KINGDOM HOLDING COMPANY (KBA) 1 RT877

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** KLM - ROYAL DUTCH AIRLINES (KLM) 1 RT533–RT535 4 RL681–RL684 5 RT531–RT532 6 RM801–RM803 RT003–RT014 7 RT001–RT002 KOREAN AIR (KAL) 1 RM011–RM013 RT574–RT588 RT590 RT811–RT814 4 RL451–RL456 RM871–RM880 RR862 5 RT571–RT573 6 RT061 KUWAIT AIRWAYS (KUW) 6 RT151 LUFTHANSA GERMAN AIRLINES (DLH) 1 RM001–RM007 RT434–RT439 RT441–RT447 5 RT431–RT433 6 RT044–RT047 7 RT041–RT043 MALAYSIA AIRLINES (MAS) 1 RM036–RM040 RM366–RM367 RT744 RT746 RT748 RT750 RU016–RU017 4 RL491–RL492 MARTINAIR HOLLAND (MTH) 1 RT506–RT507 RT509 5 RT501 MK AIRLINES (MKA) 9 RR022–RR023 RR224 RR336 RR421 NIPPON CARGO AIRLINES (NCA) 2 RR555 4 RL471–RL479 9 RR553 NORTHWEST AIRLINES (NWA) 1 RM241–RM246 RT407–RT410 2 RR566 5 RT401–RT406 9 RR005 RR341–RR342 RR344–RR345 RR431–RR432 RR503 OASIS HONG KONG AIRLINES (OHK) 1 RM232 RT505 5 RT503 OMAN ROYAL FLIGHT (RFO) 1 RM010

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** ORIENT THAI AIRLINES (OTH) 9 RR264 PHILIPPINE AIRLINES (PAL) 1 RU059 6 RT152 POLAR AIR CARGO (PAO) 4 RL651–RL655 9 RR504 PRONAIR (TXI) 9 RR221 QANTAS (QAN) 1 RF001–RF006 RM331–RM333 RT554–RT568 RT741–RT742 RU031 5 RT551–RT553 ROYAL AIR MAROC (RAM) 1 RT717 SAUDI ARABIAN AIRLINES (SVA) 1 RM156–RM157 RU101–RU102 2 RR526 SAUDI ROYAL FLIGHT (SRF) 1 RM158 SIACARGO (SIT) 4 RL431–RL436 RM851–RM855 RR851–RR856 SINGAPORE AIRLINES (SIA) 1 RM041–RM045 RT519 RT521 RT523 RT526–RT527 RT530 RT747 RT831–RT835 RT837 SOUTH AFRICAN AIRWAYS (SAA) 1 RM081 RM083 RM146–RM147 RT784 SOUTHERN AIR (SOF) 2 RR554 9 RR267 RR302–RR305 RR551 THAI AIRWAYS INTERNATIONAL (TII) 1 RM026–RM030 RM431 RT691–RT699 RT801–RT803 THE SULTAN'S FLIGHT (BWN) 1 RT440 TNT AIRWAYS (TNB) 4 RL531–RL532

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** TRANSAERO AIRLINES (TRX) 1 RT783 UNITED AIR LINES (UAL) 1 RM166 RM169–RM177 RT411 RT603–RT605 RT607–RT612 RT617 RT623–RT630 5 RT601 UPS (UPS) 4 RL561–RL568 6 RT161 RT164 US AIR FORCE (USF) 4 RM911 VIRGIN ATLANTIC AIRWAYS (VAA) 1 RM051–RM053 RM351–RM355 RT945–RT949 WILMINGTON TRUST COMPANY (WBT) 1 RU051–RU052 RU060 WORLD AIRWAYS, INC. (WLD) 1 RT745 YANGTZE RIVER EXPRESS (YTH) 1 RT757 IDENTIFICATION BY VARIABLE NUMBER **Variable Group** RF001–RF006 1 RJ131–RJ133 10 RJ151–RJ152 10 RJ301–RJ303 10 RJ321 10 RJ322 3 RJ331–RJ333 10 RL401–RL403 4 RL411–RL436 4 RL451–RL456 4 RL461–RL462 4 RL471–RL479 4 RL481 4 RL491–RL492 4 RL501–RL502 4 RL511–RL516 4 RL521–RL522 4

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RL531–RL534 4 RL551 4 RL561–RL568 4 RL576–RL577 4 RL579 4 RL581–RL583 4 RL651–RL655 4 RL671–RL675 4 RL681–RL684 4 RL751–RL752 4 RM001–RM007 1 RM010–RM013 1 RM021–RM024 1 RM026–RM030 1 RM036–RM045 1 RM051–RM053 1 RM071 1 RM081–RM084 1 RM091 1 RM096–RM097 1 RM116–RM117 1 RM126–RM132 1 RM136–RM147 1 RM156–RM158 1 RM166–RM177 1 RM191–RM192 1 RM231–RM233 1 RM241–RM246 1 RM261–RM264 1 RM316–RM318 1 RM331–RM333 1 RM341 1 RM351–RM355 1 RM366–RM367 1 RM401–RM403 1 RM426 1 RM431 1 RM441–RM443 1 RM445 1 **Variable Group**

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RM801–RM803 6 RM811–RM813 6 RM851–RM859 4 RM861–RM863 4 RM871–RM899 4 RM901–RM906 4 RM911 4 RR001–RR005 9 RR021–RR023 9 RR024–RR025 2 RR031 9 RR201–RR205 9 RR206 2 RR221–RR226 9 RR261–RR267 9 RR301–RR306 9 RR307–RR310 2 RR331–RR332 9 RR336 9 RR341–RR345 9 RR361–RR362 9 RR421–RR422 9 RR431–RR432 9 RR441–RR442 2 RR451 2 RR501–RR504 9 RR521 9 RR522 2 RR526 2 RR531 9 RR551–RR553 9 RR554–RR556 2 RR561 9 RR566 2 RR701 4 RR721–RR724 4 RR746–RR748 4 RR851–RR856 4 RR861–RR862 4 **Variable Group**

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RR951–RR952 4 RT001–RT002 7 RT003–RT014 6 RT021–RT022 7 RT031 7 RT032–RT035 6 RT041–RT043 7 RT044–RT047 6 RT061 6 RT071–RT075 6 RT101–RT103 6 RT121 6 RT131–RT137 6 RT151–RT152 6 RT161–RT168 6 RT401–RT406 5 RT407–RT412 1 RT431–RT433 5 RT434–RT447 1 RT451–RT452 5 RT453–RT469 1 RT471–RT475 5 RT476–RT499 1 RT501–RT504 5 RT505–RT530 1 RT531–RT532 5 RT533–RT535 1 RT551–RT553 5 RT554–RT568 1 RT571–RT573 5 RT574–RT590 1 RT591 5 RT601–RT602 5 RT603–RT630 1 RT631–RT632 8 RT633–RT657 1 RT671 5 RT672–RT673 1 RT681–RT682 1 **Variable Group**

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2. Spares Affected None. **B. Concurrent Requirements** None. RT691–RT699 1 RT701–RT704 1 RT711–RT717 1 RT741–RT742 1 RT743 8 RT744–RT757 1 RT776–RT777 1 RT781–RT784 1 RT801–RT803 1 RT811–RT814 1 RT831–RT837 1 RT861–RT864 1 RT876 8 RT877–RT880 1 RT931–RT932 1 RT945–RT949 1 RT951–RT952 1 RT953–RT954 6 RT955 1 RT966–RT967 1 RU001–RU006 1 RU016–RU017 1 RU031–RU032 1 RU051–RU052 1 RU059–RU062 1 RU081–RU083 1 RU101–RU102 1 RU121–RU132 1 RU801–RU809 1 RU831–RU841 1 **Variable Group**

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT C. Reason**  This service bulletin gives data for the inspection and repair, if necessary, of certain fuselage structure. These inspections and repairs are necessary for safe operation of 747-400 airplanes and nose cargo door 747 airplanes past the design life goal. Tests by Boeing have determined that the structure shown in this service bulletin is subject to fatigue cracks. Boeing has completed extended pressure fatigue tests on a 747SR and a 747-400 fuselage test article. Boeing has also used updated analysis methods on the 747 fuselage structure. The tests and analysis have identified areas of the fuselage where fatigue cracks can occur. Inspection and repair of these areas is necessary for safe operation of 747 airplanes past the design life goal. The inspections in this service bulletin will make sure that fatigue cracks in the areas of fuselage internal structure shown do not become critical. Additional service bulletins will be required to be accomplished in certain specific areas, as a result of fatigue crack findings in the 747 fleet. Also, Supplemental Structural Inspection Document (SSID), D6-35022 Revision G and Federal Aviation Administration (FAA) Airworthiness Directive 2004-07-22 R1 require inspections to be accomplished, starting at 20,000 total flight-cycles. Boeing Service Related Problem (SRP) 747-SRP-53-0211 is related to this service bulletin. Boeing Service Related Problem (SRP) 747-SRP-53-0311 is related to this service bulletin. Revision 1 is sent to add new inspection requirements for Area 1, and to add to and to clarify some inspection requirements for Area 6. Inspection Area 1 (upper deck floor beams) has been changed to include inspections of the fuselage frames in the areas where the upper deck floor beams are attached. Inspection Area 6 has been changed to include inspection of more fuselage frames in the area above Main Entry Door 1 on 747-200C and 747-200F airplanes after line number 685, and on all 747-400, 747-400D, and 747-400F airplanes. For 747-200C and 747-200F airplanes through line number 685, this inspection area is included in Boeing Service Bulletin 747-53A2732. In addition, Compliance information and inspection area requirements for 747 Large cargo Freighter (LCF) airplanes have been added. These sections were changed as part of Revision 1: 1. In Summary Background section and in Reason, Paragraph 1.C., referenced Boeing Service Related Problem (SRP) 747-SRP-53-0311. Also, updated Summary illustration. 2. In Description Paragraph 1.D., a description of the inspections required on Group 8 airplanes has been added. 3. In Compliance, Paragraph 1.E., Compliance information for new Group 8 airplanes has been added. Related airworthiness directives have also been added. 4. In Approval, Paragraph 1.F., the approval statement has been updated and Alternative Method of Compliance information for related airworthiness directives has been added. 5. In Manpower, Paragraph 1.G., the estimate has been updated to include inspection of the frames in the upper deck floor beam attachment areas in Area 1. 6. In References, Paragraph 1.J., updated references list.

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7. In Work Instructions, Paragraph 3.B., descriptions of the inspections required in the various Inspection Areas for Group 8 airplanes have been added. 8. In Work Instructions, Paragraph 3.B., Area 1 inspection, instructions were added for detailed inspection of the frame inner chord, the frame outer chord, and the frame web in the area between the upper and lower chords of the upper deck floor beams. Instructions were added to inspect Group 8 airplanes as given in Figure 21. 9. In Work Instructions, Paragraph 3.B., Area 5 inspection, step 5 has been revised to refer to Figure 17 (was Figure 19). 10. In Work Instructions, Paragraph 3.B., Area 6 inspection, instructions were added to inspect Group 9 airplanes as given in Figure 19. Instructions were added to inspect Group 10 airplanes as given in Figure 20. 11. Figures 6 and 14 (for Area 6) have been revised to clarify and add inspection requirements for the area above the Main Entry Door No. 1 cutout. On these airplanes, also do detailed inspections of the body frames at STA 400 through STA 500, from the top of the upper deck floor to Stringer 8. 12. Figure 18 (for Area 1) has been added for detailed inspection of the frame inner chord, the frame outer chord, and the frame web in the area between the upper and lower chords of the upper deck floor beams. This inspection is necessary on both sides of the airplane at each frame from body station 260 to body station 520. 13. Figure 19 (for Area 6 on Group 9 airplanes) has been added to show that on these airplanes it is not necessary to do inspections of the frames above the upper deck floor above Main Entry Door 1 left. 14. Figure 20 (for Area 6 on Group 10 airplanes) has been added to show that on these airplanes it is not necessary to do inspections of the frames above the upper deck floor above Main Entry Door 1 left and right. 15. Figure 21 (for Area 1 on Group 8 airplanes) has been added to show the detailed inspection requirements for the upper deck floor beams on Group 8 airplanes. **D. Description** Group 1-7, 9-10: 1. Do internal detailed inspections for cracks in these areas of internal fuselage structure: a. Upper deck floor beams. b. Section 42 frames. c. Section 46 frames. d. Nose wheel well bulkheads, sidewall panels, and the STA 360 and 380 main deck floor beams. e. Section 41 frame structure in the area between the upper deck floor beam chords, from STA 260 to 520.

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2. Do internal and external detailed inspections of the main entry doors and door cutouts for cracks. 3. Do internal and external detailed inspections of the fuselage skin for cracks at all four corners of the main electronics bay access door cutout. Group 8: 1. Do internal detailed inspections for cracks in these areas of internal fuselage structure: a. Upper deck floor beams. b. Section 42 lower lobe frames. c. Section 46 lower lobe frames. d. Nose wheel well bulkheads, sidewall panels, and the STA 360 and 380 main deck floor beams. e. Section 41 frame structure in the area between the upper deck floor beam chords, from STA 260 to 520. 2. Do internal and external detailed inspections of Main Entry Door 1 left and right and the Main Entry Door 1 cutouts for cracks. 3. Do internal and external detailed inspections of the fuselage skin for cracks at all four corners of the main electronics bay access door cutout. If cracks are found, refer to the structural repair manual for repair instructions. If the damage is beyond the limits shown in the structural repair manual, ask Boeing for repair data. Also, ask Boeing for repair data if an applicable repair is not included in the structural repair manual. The airplane effectivity is divided in ten groups. Revision 1 - More work is necessary on airplanes inspected as given in the original issue of this service bulletin. Operators should incorporate the additional inspection requirements for Area 1 and Area 6 during the next scheduled inspection. **E. Compliance** The Federal Aviation Administration (FAA) will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

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On Groups 1 - 7 and 9 - 10 airplanes, for inspections that were added to this service bulletin in Revision 1 (i.e., in Areas 1 and 6), start the new inspections at 22,000 total flight-cycles or within 1,000 flight-cycles after the date on Revision 1 of this service bulletin, whichever is later. On Groups 1 - 7 and 9 - 10 airplanes, these inspections include the frame inspections in Figure 18 from body station 260 to 520, between the upper and lower chords of the upper deck floor beams. On Groups 1 - 7 airplanes, these inspections also include the frame inspections in Figures 6 and 14 from body station 400 to 500, from the upper chord of the upper deck floor beams to Stringer 8. For all the existing inspections, refer to TABLE 1 for compliance times.

**NOTE:** On Group 8 airplanes, this service bulletin does not include Area 2 and Area 5 inspections. Federal Aviation Administration (FAA) Airworthiness Directives 2006-05-02 and 2004-07-22 R1 are related to this service bulletin. Group 1-7, 9-10: TABLE 1: **Group Area Action Compliance Time (Whichever is later) Repeat Interval** 1 and 6 1, 3, 4, 6, 7, 8, and 9 Inspect 22,000 total flight-cycles 1,000 flight-cycles after the date on the original issue of this service bulletin. 3,000 flight-cycles

2 and 5 Inspect 25,000 total flight-cycles 1,000 flight-cycles after the date on the original issue of this service bulletin. 3,000 flight-cycles

2, 3, 4, 5, 7, 9, and 10 1, 2, 3, 4, 6, 7, 8, and 9 Inspect 22,000 total flight-cycles 1,000 flight-cycles after the date on the original issue of this service bulletin. 3,000 flight-cycles

5 Inspect 25,000 total flight-cycles 1,000 flight-cycles after the date on the original issue of this service bulletin. 3,000 flight-cycles

Group 8: TABLE 2:

**Condition Action Compliance Time (Whichever**  **occurs later) Repeat Interval**  **(Not to Exceed)** All Group 8 airplanes Inspect Area 1 as given in Paragraph 3.B. 20,000 total flight-cycles 1,000 flight-cycles after the date on Revision 1 of this service bulletin. 2,500 flight-cycles

All Group 8 airplanes Inspect Area 3, Area 4, and Area 8 as given in Paragraph 3.B. 22,000 total flight-cycles 1,000 flight-cycles after the date on Revision 1 of this service bulletin. 3,000 flight-cycles

All Group 8 airplanes Inspect Area 6 and Area 9 as given in Paragraph 3.B. 15,000 total flight-cycles 1,000 flight-cycles after the date on Revision 1 of this service bulletin. 1,500 flight-cycles

All Group 8 airplanes Inspect Area 7 as given in Paragraph 3.B. 18,000 total flight-cycles 1,000 flight-cycles after the date on Revision 1 of this service bulletin. 2,500 flight-cycles

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT 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 approves the accomplishment of the applicable inspection and repair procedures of this service bulletin as an AMOC to the corresponding inspection and repair requirements of paragraph (f) of AD 2006-05-02. 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 in accordance with FAA-approved procedures as required by paragraph (g) of the AD. All provisions of AD 2006-05-02 that are not specifically referenced in the preceding statement remain fully applicable and must be complied with. The Manager of the FAA Seattle ACO also approves the accomplishment of the applicable inspection and repair procedures of this service bulletin as an AMOC to the corresponding inspection and repair requirements of paragraphs (h), (i), and (j) of FAA AD 2004-07-22 R1 for SSI F-21A, F-21B, F-24A, F-24C, F-41A, and F-41B of Supplemental Structural Inspection Document (SSID) D6-35022, Revision G. 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 in accordance with FAA-approved procedures as required by paragraph (j) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically referenced in the preceding statement, including the initial inspection threshold per paragraph (i) of AD 2004-07-22 R1, remain fully applicable and must be complied with. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this inspection for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-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

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— Time to find the tools. Group 1-7, 9-10: TABLE 1:
**Area Task Number of**  **Persons Task-Hours Elapsed Hours** 1 Open Access 8 120 15 Inspect Floor Beams 4 132 33 Inspect Frames at Upper Deck Floor Beams 26 3
Close Access 8 160 20 Test 3 18 6 TOTAL FOR AREA 1 436 77 2 Open Access 8 176 22 Examine 6 72 12 Close Access 8 240 30 Test 4 28 7 TOTAL FOR AREA 2 516 71 3 Open Access 8 96 12 Examine 4 16 4 Close Access 8 144 18 Test 4 20 5 TOTAL FOR AREA 3 276 39 4 Open Access 4 28 7 Examine 2 8 4 Close Access 4 40 10 Test 1 1 1 TOTAL FOR AREA 4 77 22 5 Open Access 6 66 11 Examine 2 8 4 Close Access 6 96 16 Test 2 8 4 TOTAL FOR AREA 5 178 35 6 Open Access 2 10 5 Examine 1 2 2 Close Access 2 14 7 Test 1 2 2 TOTAL FOR EACH DOOR 28 16 TOTAL FOR AREA 6 280 28

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**NOTE:** More time will be necessary for repairs if cracks are found. **H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Engineering Change Memo PRR85901-44RS b. Service Related Problem (SRP) 747-SRP-53-0211 c. Service Related Problem (SRP) 747-SRP-53-0311 d. 747 Maintenance Manual (AMM) Subject 25-21-02, 25-21-03, 25-21-04, 25-22-01, 25-22-03, 25-25-01, 25-28-01, 25-28-02, 25-52-01, 25-52-04, 25-53-15, 25-55-02, 25-55-03, 25-59-01, 25-59-05, 52-11-02, 53-21-02 e. 747-400 Maintenance Manual (AMM) Subject 25-21-02, 25-21-03, 25-21-04, 25-22-01, 25-22-03, 25-25-01, 25-28-01, 25-28-02, 25-52-01, 25-52-04, 25-53-15, 25-55-02, 25-55-03, 25-59-01, 25-59-05, 52-11-02, 53-21-02 f. 747 Structural Repair Manual (SRM) Subject 52-00-03, 52-10-02, 53-00-01, 53-10-03, 53- 10-04, 53-10-04, 53-10-07, 53-30-03 7 Open Access 4 50 12.5 Examine 2 20 10 Close Access 4 62 15.5 Test 2 4 2 TOTAL FOR AREA 7 136 40 8 Open Access 1 3 3 Examine 1 1 1 Close Access 1 4 4 Test 1 1 1 TOTAL FOR EACH DOOR 9 9 TOTAL FOR AREA 8 90 9 9 Examine 1 1 1 TOTAL FOR AREA 9 1 1 TOTAL FOR EACH AIRPLANE 1990 322 Group 1-7, 9-10: TABLE 1:
**Area Task Number of**  **Persons Task-Hours Elapsed Hours**

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** g. 747-400 Structural Repair Manual (SRM) Subject 52-10-01, 52-10-02, 53-00-01, 53-00-03, 53-00-51, 53-10-07, 53-10-08, 53-10-51, 53-20-07, 53-20-51, 53-60-07, 53-60-15 h. 747-400F Structural Repair Manual (SRM) Subject 52-10-01, 52-10-02, 53-00-01, 53-00- 03, 53-10-07, 53-10-08, 53-20-07, 53-60-07, 53-60-15 i. Boeing Service Bulletins 747-53-2358, "Fuselage - Main Entry Doors Number 1, 2, 3, and 4 - Forward Edge Stop Support Fitting Inspection and Replacement,"; 747-53A2396, "Fuselage - Skins - Skin and Internal Doubler Inspection, Repair, and Modification Above Main Entry Door 1 at Station 460,"; 747-53A2414, "Fuselage - Main Entry Door 1 Cutout - Door Frame Aft Edge at Station 488 - Inspection and Repair,"; 747-53A2416, "Fuselage - Center Section - Body Station 1265 Frame Inspection, Repair, and Modification,"’ 747- 53A2417, "Fuselage - Main Entry Door Number 1 Cutout - Door Frame Forward Edge at Station 434 - Inspection and Repair,"; 747-53A2450, "Fuselage - Section 46 - Body Station 2231 Frame Inspection - Stringers 23 through 31"; 747-53A2451, "Fuselage - Section 42 - Door Number 2 Forward Edge Frame at Body Station 800 - Inspection and Repair"; and 747-53A2512, Fuselage - Main Entry Door Number 3 Cutout - Lower Forward Corner and Upper Aft Corner - Inspection and Repair at Left and Right Side Skin and Bearstrap. j. Boeing Service Letter 747-SL-53-088-A k. 747 Supplemental Structural Inspection Document (SSID) D6-35022, Items F-21A, F-21B, F-24A, F-24B, F-24C, F-41A and F-41B l. FAA Airworthiness Directives 2004-07-22 R1 and 2006-05-02 m. Boeing Parts Standards Document D-590 n. Boeing Drawing 012W6100 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. **K. Publications Affected** None. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** None. **B. Industry Support Information** Boeing warranty remedies are not available for the inspections or repair procedures given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator: None. 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, may be necessary. Examine operator tool supply to make sure all necessary tools are available.

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BLANK PAGE

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches — Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. — Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch — Angular tolerance is plus or minus 2 degrees — Hole dimensions for standard solid rivets are given in 747, 747-400, or 747-400F Structural Repair Manual, Chapter 51 — Torque limits to tighten nuts and bolts are given in 747, 747-400, or 747-400F Structural Repair Manual, Chapter 51. 4. For approved fastener and process material substitutions, refer to 747, 747-400, or 747- 400F Structural Repair Manual, Chapter 51. Alternate fasteners are given in 747, 747- 400, or 747-400F Structural Repair Manual Chapter 51 and Boeing Drawing 012W6100. 5. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 6. Start to do inspections at the time shown in Paragraph 1.E., Compliance. 7. 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 a mirror, magnifying lenses, etc., may be necessary. Surface cleaning procedures may be required. Inspection aids such as 10X magnifying lenses may be required. 8. Figures 1 - 18 show Group 1, 2, 3, 4, 5, 6, 7, 9, and 10 airplanes. Group 8 airplanes are similar, except as described below in each affected inspection area. **B. WORK INSTRUCTIONS AREA 1 - UPPER DECK FLOOR BEAMS**  1. Remove the equipment that follows from the main deck passenger cabin for access from below

### December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** to the upper deck floor beams. Use the AMM subjects that follow:

**NOTE:** All upper deck floor beam inspections are to be performed from below. Group 1, 5-7: The upper deck floor beams to be inspected are from STA 260 to STA 1100. Group 2, 9: The upper deck floor beams to be inspected are from STA 260 to STA 740. Group 3, 10: The upper deck floor beams to be inspected are from STA 260 to STA 780. Group 4: The upper deck floor beams to be inspected are from STA 260 to STA 700. Group 8: The upper deck floor beams to be inspected are from STA 260 to STA 500. 2. If necessary, loosen and remove air conditioning ducts for access to the inspection area. 3. Group 1, 5-7: Do inspections of the upper deck floor beams for cracks as shown in Figure 1. 4. Group 2, 9: Do inspections of the upper deck floor beams for cracks as shown in Figure 10. 5. Group 3, 10: Do inspections of the upper deck floor beams for cracks as shown in Figure 11. 6. Group 4: Do inspections of the upper deck floor beams for cracks as shown in Figure 12. 7. Group 8: Do inspections of the upper deck floor beams for cracks as shown in Figure 21. 8. For each frame from body station 260 to body station 520, do a detailed inspection for cracks in the frame inner chord, the frame outer chord, and the frame web in the area between the upper and lower chords of the upper deck floor beam as shown in Figure 18. Do these detailed inspections on both the left side and right side of the airplane. 9. If floor beam web cracks are found, repair before any more flights. Repair as shown in 747-400 SRM 53-00-51, Figure 201, 747-400 SRM 53-10-51, Figure 201, 747 SRM 53-10-07, Figure 11, or ask Boeing for repair data.

**Equipment AMM Subject** Ceiling Insulation 747-100/200/300 AMM 25-21-04/401 747-400 AMM 25-21-04/401 Main Passenger Cabin Ceiling Panels 747-100/200/300 AMM 25-22-01/401 747-400 AMM 25-22-01/401 Main Deck Track Mounted Passenger Seats 747-100/200/300 AMM 25-25-01/401 747-400 AMM 25-25-01/401 Center Overhead Stowage Compartments 747-100/200/300 AMM 25-28-01/201 747-400 AMM 25-28-02/401 Side Overhead Stowage Compartments 747-100/200/300 AMM 25-28-01/201 747-400 AMM 25-28-01/201 Main Deck Cargo Compartment Ceiling Lining 747-100/200/300 AMM 25-59-01/401 747-400 AMM 25-59-01/401 Main Deck Cargo Compartment Ceiling Insulation 747-100/200/300 AMM 25-59-05/405 747-400 AMM 25-59-05/401

### December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

10. If any other floor beam cracks are found, repair before any more flights. Repair as shown in 747-100/200/300 SRM 53-10-07 Figure 21 or 23, 747-400 SRM 53-10-51 Figure 205, 747-400 SRM 53-20-51 Figure 204, or ask Boeing for repair data. 11. If frame inner chord, frame outer chord, or frame web cracks are found, repair them as given in the structural repair manual, or contact Boeing for repair instructions. 12. After repair, install all equipment that was removed for access. 13. If no cracks are found, install all equipment that was removed for access. 14. Put the airplane back to a serviceable condition. Do the Area 1 inspection again at the time shown in Paragraph 1.E., Compliance. **Group 1-7, 9-10: AREA 2 - SECTION 42 UPPER LOBE FRAMES** 1. Remove the equipment that follows from the main deck passenger cabin and the upper deck passenger cabin for access to the Section 42 upper lobe frames, from the main deck floor to the top of the crown. Use the AMM subjects that follow:

2. If necessary, loosen and remove air conditioning ducts for access to the inspection area. 3. Group 1, 5-7: Do inspections of Area 2 for cracks as shown in Figure 2. 4. Group 2-4, 9-10: Do inspections of Area 2 for cracks as shown in Figure 13. 5. If cracks are found, repair before any more flights as follows: a. Remove and replace cracked stringer clips before any more flights. Use 747-100/200/300 SRM 53-10-03, or 747-400 SRM 53-00-03, or 747-400 SRM 53-00-03. **Equipment AMM Subject** Sidewall and Ceiling Insulation 747-100/200/300 AMM 25-21-04/401 747-400 AMM 25-21-04/401 Main Deck Track Mounted Passenger Seats 747-100/200/300 AMM 25-25-01/401 747-400 AMM 25-25-01/401 Side Overhead Stowage Compartments 747-100/200/300 AMM 25-28-01/401 747-400 AMM 25-28-01/201 Upper Deck Ceiling Panel 747-100/200/300 AMM 25-22-03/401 747-400 AMM 25-22-03/401 Upper Deck Window Reveal Panel 747-100/200/300 AMM 25-21-02/401 747-400 AMM 25-21-02/401 Main Deck Sidewall Lining Doorway Panels 747-100/200/300 AMM 25-21-03/401 747-400 AMM 25-21-03/401 Main Deck Cargo Compartment Sidewall Lining 747-100/200/300 AMM 25-59-01/401 747-400 AMM 25-59-01/401 Main Deck Cargo Compartment Sidewall Insulation 747-100/200/300 AMM 25-59-05/401 747-400 AMM 25-59-05/401

### December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** b. Repair frame cracks before any more flights. Repair as shown in 747-100/200/300 SRM 53-10-04, 747-400 SRM 53-20-07, 747-400F SRM 53-20-07, or ask Boeing for repair data. c. If any other cracks are found, repair before any more flights. Repair as shown in the SRM, or ask Boeing for repair data. d. After repair, install all equipment that was removed for access. 6. If no cracks are found, install all equipment that was removed for access. 7. Put the airplane back to a serviceable condition. Do the Area 2 inspection again at the time given in Paragraph 1.E., Compliance. **AREA 3 - SECTION 46 LOWER LOBE FRAMES** 1. Remove the equipment that follows for access to the Section 46 lower lobe frames, from the main deck floor down. Use the AMM subjects that follow: **NOTE:** On Group 8 airplanes, it is not necessary to inspect the Section 46 lower lobe frames aft of STA 1940. On the left side of the airplane, it is not necessary to inspect the Section 46 lower lobe frames above Stringer 34. On the right side of the airplane, it is not necessary to inspect the Section 46 lower lobe frames above Stringer 34, except at STA 1810 and STA 1920. At STA 1810 and STA 1920 on the right side of the airplane, the inspection area is from the main deck floor down.

**Equipment AMM Subject** Sidewall Insulation 747-100/200/300 AMM 25-21-04/401 747-400 AMM 25-21-04/401 Main Deck Track Mounted Passenger Seats 747-100/200/300 AMM 25-25-01/401 747-400 AMM 25-25-01/401 Main Deck Sidewall Lining Doorway Panels 747-100/200/300 AMM 25-21-03/401 747-400 AMM 25-21-03/401 Cargo Compartment Lining Panels 747-100/200/300 AMM 25-52-01/401 747-400 AMM 25-52-01/401 Cargo Compartment Insulation 747-100/200/300 AMM 25-52-04/401 747-400 AMM 25-52-04/401 Ball Transfer Panels 747-100/200/300 AMM 25-53-15/401 747-400 AMM 25-53-15/401 Main Deck Floor Panels (a) 747-100/200/300 AMM 53-21-02/401 747-400 AMM 53-21-02/401 Bulk Cargo Compartment Lining 747-100/200/300 AMM 25-55-02/401 747-400 AMM 25-55-02/401 Main Deck Cargo Compartment Sidewall Lining 747-100/200/300 AMM 25-59-01/401 747-400 AMM 25-59-01/401 Main Deck Cargo Compartment Sidewall Insulation 747-100/200/300 AMM 25-59-05/401 747-400 AMM 25-59-05/401 Bulk Cargo Compartment Insulation 747-100/200/300 AMM 25-55-03/401 747-400 AMM 25-55-03/401 Bulk Cargo Compartment Floor Panels - - (a) From STA 2180 to STA 2360 for access to the lower lobe frames aft of the bulk cargo compartment.

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

2. If necessary, loosen and remove air conditioning ducts for access to the inspection area. 3. Do inspections of Area 3 for cracks as shown in Figure 3. 4. If cracks are found, repair before any more flights as follows: a. Remove and replace cracked stringer clips before any more flights. Use 747-100/200/300 SRM 53-10-03, or 747-400 SRM 53-00-03, or 747-400 SRM 53-00-03. b. Repair frame cracks before any more flights. Repair as shown in 747-100/200/300 SRM 53-10-04, 747-400 SRM 53-60-07, 747-400F SRM 53-60-07, or ask Boeing for repair data. c. If any other cracks are found, repair before any more flights. Repair as shown in the SRM, or ask Boeing for repair data. d. After repair, install all equipment that was removed for access. 5. If no cracks are found, install all equipment that was removed for access. 6. Put the airplane back to a serviceable condition. Do the Area 3 inspection again at the time given in Paragraph 1.E., Compliance. **AREA 4 - SECTION 42 LOWER LOBE FRAMES** 1. Remove the equipment that follows for access to the Section 42 lower lobe frames, from the main deck floor down. Use the AMM subjects that follow: **NOTE:** On Group 8 airplanes, it is not necessary to inspect the STA 540 lower lobe frame from S-26L to S-39R. On the left side of the airplane, it is not necessary to inspect the Section 42 lower lobe frames above Stringer 34. On the right side of the airplane, it is not necessary to inspect the Section 42 lower lobe frames above Stringer 28 from STA 580 to STA 660, or above Stringer 34 from STA 680 to STA 980.

2. If necessary, loosen and remove air conditioning ducts for access to the inspection area. 3. Do inspections of Area 4 for cracks as shown in Figure 4. 4. If cracks are found, repair before any more flights as follows: a. Remove and replace cracked stringer clips before any more flights. Use 747-100/200/300 SRM 53-10-03, or 747-400 SRM 53-00-03, or 747-400 SRM 53-00-03. b. Repair frame cracks before any more flights. Repair as shown in 747-100/200/300 SRM 53-10-04, 747-400 SRM 53-20-07, 747-400F SRM 53-20-07, or ask Boeing for repair data. c. If any other cracks are found, repair before any more flights. Repair as shown in the SRM, or ask Boeing for repair data. **Equipment AMM Subject** Cargo Compartment Lining Panels 747-100/200/300 AMM 25-52-01/401 747-400 AMM 25-52-01/401 Cargo Compartment Insulation 747-100/200/300 AMM 25-52-04/401 747-400 AMM 25-52-04/401 Ball Transfer Panels 747-100/200/300 AMM 25-53-15/401 747-400 AMM 25-53-15/401

### December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** d. After repair, install all equipment that was removed for access. 5. If no cracks are found, install all equipment that was removed for access. 6. Put the airplane back to a serviceable condition. Do the Area 4 inspection again at the time given in Paragraph 1.E., Compliance. **Group 1-7, 9-10: AREA 5 - SECTION 46 UPPER LOBE FRAMES** 1. Remove the equipment that follows for access to the Section 46 upper lobe frames, from the main deck floor to Stringer 20. Use the AMM subjects that follow:

2. If necessary, loosen and remove air conditioning ducts for access to the inspection area. 3. Group 1, 5: Do inspections of Area 5 for cracks as shown in Figure 5. 4. Group 2, 4, 9: Do inspections of Area 5 for cracks as shown in Figure 16. 5. Group 3, 6-7, 10: Do inspections of Area 5 for cracks as shown in Figure 17. 6. If cracks are found, repair before any more flights as follows: a. Remove and replace cracked stringer clips before any more flights. Use 747-100/200/300 SRM 53-10-03, or 747-400 SRM 53-00-03, or 747-400 SRM 53-00-03. b. Repair frame cracks before any more flights. Repair as shown in 747-100/200/300 SRM 53-10-04, 747-400 SRM 53-60-07, 747-400F SRM 53-60-07, or ask Boeing for repair data. c. If any other cracks are found, repair before any more flights. Repair as shown in the SRM, or ask Boeing for repair data. d. After repair, install all equipment that was removed for access. 7. If no cracks are found, install all equipment that was removed for access. 8. Put the airplane back to a serviceable condition. Do the Area 5 inspection again at the time given in Paragraph 1.E., Compliance. **Equipment AMM Subject** Sidewall Insulation 747-100/200/300 AMM 25-21-04/401 747-400 AMM 25-21-04/401 Main Deck Track Mounted Passenger Seats 747-100/200/300 AMM 25-25-01/401 747-400 AMM 25-25-01/401 Side Overhead Stowage Compartments 747-100/200/300 AMM 25-28-01/401 747-400 AMM 25-28-01/201 Main Deck Sidewall Lining Doorway Panels 747-100/200/300 AMM 25-21-03/401 747-400 AMM 25-21-03/401 Main Deck Cargo Compartment Sidewall Lining 747-100/200/300 AMM 25-59-01/401 747-400 AMM 25-59-01/401 Main Deck Cargo Compartment Sidewall Insulation 747-100/200/300 AMM 25-59-05/401 747-400 AMM 25-59-05/401

### December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

**AREA 6 - MAIN ENTRY DOOR CUTOUTS** 1. Open each Main Entry Door. At each Main Entry Door, remove the equipment that follows for access to the door cutout. Also remove and keep the threshold and scuff plate at each Main Entry Door. **NOTE:** Do inspections of the cutouts of all of the main entry doors. This includes any door that may have been deactivated.

2. Group 1, 3, 5-8: Do inspections of Area 6 for cracks as shown in Figure 6. **NOTE:** On Group 8 airplanes, only the cutouts for Main Entry Door 1 left and right are affected. 3. Group 2, 4: Do inspections of Area 6 for cracks as shown in Figure 14. 4. Group 9: Do inspections of Area 6 for cracks as shown in Figure 19. 5. Group 10: Do inspections of Area 6 for cracks as shown in Figure 20. 6. If cracks are found, repair before any more flights as follows: a. Repair frame cracks before any more flights. Repair as shown in 747-100/200/300 SRM 53-10-04, 747-400 SRM 53-10-07, 747-400 SRM 53-20-07747-400 SRM 53-60-07, 747- 400F SRM 53-10-07, or 747-400F SRM 53-60-07, or ask Boeing for repair data. b. Repair other door surround structure cracks before any more flights. Repair as shown in 747-100/200/300 SRM 53-30-03, 747-400 SRM 53-60-15 or 747-400F SRM 53-60-15, or ask Boeing for repair data. c. If any other cracks are found, repair before any more flights. Repair as shown in the SRM, or ask Boeing for repair data. d. After repair, install all equipment that was removed for access. 7. If no cracks are found, install all equipment that was removed for access. 8. Put the airplane back to a serviceable condition. Do the Area 6 inspection again at the time shown in Paragraph 1.E., Compliance. **Equipment AMM Subject** Sidewall Insulation 747-100/200/300 AMM 25-21-04/401 747-400 AMM 25-21-04/401 Main Deck Sidewall Lining Doorway Panels 747-100/200/300 AMM 25-21-03/401 747-400 AMM 25-21-03/401 Cargo Compartment Ceiling and Sidewall Lining 747-100/200/300 AMM 25-52-01/401 747-400 AMM 25-52-01/401 Cargo Compartment Insulation 747-100/200/300 AMM 25-52-04/401 747-400 AMM 25-52-04/401 Main Deck Cargo Compartment Sidewall Lining 747-100/200/300 AMM 25-59-01/401 747-400 AMM 25-59-01/401 Main Deck Cargo Compartment Sidewall Insulation 747-100/200/300 AMM 25-59-05/401 747-400 AMM 25-59-05/401

### December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

**AREA 7 - SECTION 41 STA 260, 340, AND 400 BULKHEADS, AND NOSE WHEEL WELL SIDEWALL FROM STA 340 TO STA 400**  1. Remove the insulation blankets from the STA 260, 340, and 400 bulkheads and the sidewall panels from STA 340 to STA 400. Also remove the insulation blankets from the nose wheel well top panel in the area of the STA 360 and 380 floor beams. Keep the insulation blankets for later installation. 2. Do inspections of Area 7 for cracks as shown in Figure 7. 3. If cracks are found, repair before any more flights. Repair as shown in 747-100/200/300 SRM 53-10-04747-400 SRM 53-10-08, or 747-400F SRM 53-10-08, or ask Boeing for repair data. After repair, install all equipment that was removed for access. 4. If no cracks are found, install all equipment that was removed for access. 5. Put the airplane back to a serviceable condition. Do the Area 7 inspection again at the time given in Paragraph 1.E., Compliance. **AREA 8 - MAIN ENTRY DOORS** 1. Remove the lining and insulation from all Main Entry Doors. Use 747 AMM 52-11-02/401. **NOTE:** On Group 8 airplanes, only Main Entry Door 1 left and right is affected. **CAUTION:** Group 1, 3, 5-8, 10: DO STRUCTURAL INSPECTIONS OF ALL MAIN ENTRY DOORS AS SHOWN IN THIS SERVICE BULLETIN, INCLUDING DOORS THAT HAVE BEEN DEACTIVATED. DEACTIVATED MAIN ENTRY DOORS ARE SUBJECT TO THE TYPES OF FATIGUE CRACKS SHOWN IN THIS SERVICE BULLETIN. 2. Group 1, 3, 5-8, 10: Do inspections of Area 8 for cracks as shown in Figure 8. **CAUTION:** Group 2, 4, 9: DO STRUCTURAL INSPECTIONS OF ALL MAIN ENTRY DOORS AS SHOWN IN THIS SERVICE BULLETIN, INCLUDING DOORS THAT HAVE BEEN DEACTIVATED. DEACTIVATED MAIN ENTRY DOORS ARE SUBJECT TO THE TYPES OF FATIGUE CRACKS SHOWN IN THIS SERVICE BULLETIN. 3. Group 2, 4, 9: Do inspections of Area 8 for cracks as shown in Figure 15. 4. If cracks are found, repair before any more flights. Repair as shown in 747-100/200/300 SRM 52-00-03, 747-100/200/300 SRM 52-10-02, 747-400 SRM 52-10-01, 747-400 SRM 52-10-02, 747-400F SRM 52-10-01, or 747-400F SRM 52-10-02, or ask Boeing for repair data. After repair, install all equipment that was removed for access. 5. If no cracks are found, install all equipment that was removed for access. 6. Put the airplane back to a serviceable condition. Do the Area 8 inspection again at the time given in Paragraph 1.E., Compliance. **AREA 9 - MAIN ELECTRONICS BAY ACCESS DOOR CUTOUT** 1. Open the Main Electronics Bay access door, just aft of the nose wheel well.

### December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

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### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

2. Do internal and external detailed inspections of Area 9 for cracks as shown in Figure 9. 3. If cracks are found, repair before any more flights. Repair skin cracks as shown in 747-100/200/ 300 SRM 53-00-01, 747-400 SRM 53-00-01, or 747-400F SRM 53-00-01, or ask Boeing for repair data. 4. If no cracks are found, close the Main Electronics Bay access door. 5. Put the airplane back to a serviceable condition. Do the Area 9 inspection again at the time given in Paragraph 1.E., Compliance.

### FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 44 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIRPLANES** 



### (TYPICAL) FLOOR BEAMS ALL UPPER DECK

F A SEE THROUGH 1W59452



### (SHEET 1 OF 5)

### FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 45 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE)

(RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN BL 0 LBL 24.17 LBL 46.83

LBL 60 LBL 80 520 STA

500 STA STA 480 460 STA

440 STA

420 STA BL 0 LBL 20 LBL 40 LBL 60 LBL 80 STA 340 STA 330 STA 320 STA 302 STA 287 STA 270 STA 360 STA 380 STA 400



### A

B FWD UP

FWD UPW59472



### (SHEET 2 OF 5)

### FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 46 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE) LBL 100 80 LBL 60 LBL 40 LBL 20 LBL 0 BL STA 720 STA 700 STA 680 STA 660 STA 640 STA 620 STA 600 STA 580 STA 560 STA 540



### C FWD UPW59530



### (SHEET 3 OF 5)

### FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 47 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

CARTLIFT ACCESS

880 STA
860 STA
840 STA

820 STA
800 STA

780 STA
760 STA
740 STA 900 STA 920 STA 940 STA 960 STA 980 STA BL 80 BL 60 BL 40 BL 20 BL 0

RIGHT SIDE LEFT SIDE 920 STA 940 STA 960 STA 980 STA

880 STA
860 STA

840 STA
820 STA
800 STA
780 STA

760 STA
740 STA LBL 100 LBL 80 LBL 60 LBL 40 LBL 20 900 STA ACCESS STAIRWAY

FWD UP FWD UP



### E D480179



### (SHEET 4 OF 5)

### FIGURE 1: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 1, 5, 6, AND 7 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 48 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 1, 5-7: The step number shown below agrees with the number shown in the circle symbol in the figure. **NOTE:** If necessary, loosen and remove air conditioning ducts for access to the inspection area.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Chord Detailed - From below the floor beams (a) Floor Beam Web Lower Chord Cab Floor Web (a) The inspection area is from STA 260 to STA 1100. Pay particular attention to all nutplate locations, cutout locations, and to the floor beam connections to the frames. Also inspect the cab floor web (in the plane of the floor) from STA 260 to STA 330. Pay particular attention to all cutouts and nutplate locations. **NOTE:** At STA 260, inspect the chord that is common to the cab floor web. Also inspect the adjacent 2 inches of the vertical web. STA 1100 STA 1080 STA 1060 STA 1040 STA 1020
1000 STA

LBL 80.56 LBL 54.00 24.17 LBL 7.50 LBL

(RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN INBD



### F FWD UPW59575



### (SHEET 5 OF 5)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 49 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 2: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7**  **AIRPLANES**

540 STA STA 720 STA 980
S-0

S-39 S-22 S-10A SEE A

F SEE

SEE C B SEE SEE E D SEEW59603



### (SHEET 1 OF 8)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION **42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 AIRPLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 50 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

(RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN STA 720 STA 700 STA 680 STA 660 STA 540 STA 560 STA 580 STA 600 STA 620 STA 640 S-2A S-2 S-1 S-0

S-3 S-4

S-5

S-6

S-7

S-8

S-9

S-10 S-10A

FWD 1



### AW59621



### (SHEET 2 OF 8)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 51 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE) STA STA STA STA STA STA STA STA STA STA

720 700 680 660 620 640 600 580 560 540 S-11 S-12 S-13

S-14 S-15
S-16 S-17 S-18 S-19 S-20 S-21 S-22



### B 1W59638 FWD



### (SHEET 3 OF 8)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION **42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 AIRPLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 52 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN DOOR CUTOUT IS BELOW S-26) (RIGHT SIDE OPPOSITE, EXCEPT THE CARGO S-27 S-26

S-28 S-29 S-23 S-24 S-25 720 STA
700 STA

680 660 STA STA

640
620 STA
STA

600 580 STA STA

560 540 STA STA



### C 1W59639 FWD



### (SHEET 4 OF 8)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 53 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**LEFT SIDE SHOWN(RIGHT SIDE OPPOSITE)S-10AS-10S-9S-8S-7S-6S-5S-4S-3AS-3S-2AS-2S-0S-1STASTASTASTA980960920900940STA780STASTASTASTASTASTA860840820800880STASTA760740FWD1DW59645



### (SHEET 5 OF 8)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION **42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 AIRPLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 54 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN

SHOWN FOR CLARITY UPPER DECK FLOOR BEAMS NOT (RIGHT SIDE OPPOSITE) STA 980 960 STA STA 940 STA 900 STA 920 STA 880 STA 860 STA 820 STA 840 STA 800 STA 780 STA 760 STA 740

S-22 S-21 S-20 S-18 S-17 S-16 S-15 S-14 S-13 S-12 S-11

S-19

FWD 1



### EW59651



### (SHEET 6 OF 8)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 55 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-27 S-26

LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE) S-23 S-24 S-25

S-28 S-29

S-30

S-31

S-32

S-33

S-34 840 STA STA 820

STA 980 960 STA 940 STA STA 920 STA 900 STA 880 860 STA STA 800 STA 780 STA 760 STA 740

FWD 1



### FW59666



### (SHEET 7 OF 8)

### FIGURE 2: INSPECTION OF AREA 2 - SECTION **42 UPPER LOBE FRAMES - GROUP 1, 5, 6, AND 7 AIRPLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 56 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** This Figure applies to Group 1, 5-7: The step number shown below agrees with the number shown in the circle symbols in the figure. **STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Lobe Frames Detailed - (a) (b) (a) The inspection area is from STA 520 to STA 1000, from the main deck floor to the top of the crown. (b) Pay particular attention to frame inner chords at the last fastener in a reinforcing strap, frame webs, fail-safe chords, and stringer cutouts.

**(SHEET 8 OF 8)**

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 57 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES** 

S-39R

S-39L STA 1500

S-0 2160

STA 1720 STA 1980 STA 2360 STA

INSTALLED ON SOME AIRPLANES.

MAIN DECK SIDE CARGO DOOR

TYPICAL AIRPLANE SHOWN, G D SEE B SEE A SEE

F SEE H

C SEE E IW59671



### (SHEET 1 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 58 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-24 S-23 S-22

S-39

S-38

S-37

S-36

S-35

S-34

S-33

S-31

S-29 S-28

S-32

S-30

S-27 STA

S-16

S-25

S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-17 S-18 S-19 S-20 S-2 S-1 S-3 S-4

S-5

S-6

S-7 STA 1520 STA 1560 STA 1600 1580 STA 1540 STA 1500 STA 1640 STA 1680 STA 1620 STA 1660 STA 1700 STA 1720

LEFT SIDE SHOWN

POSTS NOT SHOWN FOR CLARITY

MAINDECK FLOOR BEAMS AND

(RIGHT SIDE OPPOSITE) 1



### A FWDW59676



### (SHEET 2 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 59 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S I D E S H O W N

L E F T A N D R I G H TS-42RS-40RS-44RS-46RS-48RS-50RS-51RS-51LS-48LS-46LS-44LS-42LS-40LS-50L1580STASTA1540STA1500STA1600STA15601520STASTA1620STA17001720STASTA1660STA1640STA1680FWD

B1W59699



### (SHEET 3 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 60 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S22 S21 S23 S25 S26 S27 S28

S34 S32

POSTS NOT SHOWN FOR CLARITY

MAIN DECK FLOOR BEAMS AND LEFT SIDE SHOWN S2 S4 S6 S8 S10 S12 S9

S7 S5 S3 S1

S11 S13

S15 S17 S19

S30

S36 S38 S20

S29 S31 S33
S37 S39 STA 1840 STA 1800 STA 1760 1860 STA 1820 STA 1780 STA 1740 STA 1880 1960 STA 1920 STA STA

1940 STA 1900 STA 1980 STA

S35 S18 S16 S14

FWD



### C 1W59850



### (SHEET 4 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 61 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**LEFT AND RIGHT SIDE SHOWNS-44RS-46RS-48RS-50RS-51LS-41LS-43LS-45LS-47LS-49L1800STASTA1760STA1820STA1780STA1740STA1860STA1900STA18401880STASTA1940STA1920STA1980STA1960D1W59892FWD



### (SHEET 5 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 62 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-26R

CLARITY POSTS NOT SHOWN FOR MAIN DECK FLOOR BEAMS AND RIGHT SIDE SHOWN, S-22R S-23R S-24R S-25R S-27R S-28R S-29R S-30R S-31R S-32R S-33R S-34R S-35R S-36R S-37R S-39R S-38R 1860 STA 1880 STA 1900 STA 1920 STA 1940 STA STA 1960 1980 STA

1840 STA 1820 STA 1800 STA STA 1780 1760 STA 1740 STA

1



### EW59982 FWD



### (SHEET 6 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 63 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

POSTS NOT SHOWN FOR CLARITY

MAIN DECK FLOOR BEAMS AND LEFT SIDE SHOWN, S-2 S-4 S-6 S-8 S-10 S-12 S-1 S-3

S-7

S-11 S-5

S-9

S-13 S-14

S-25 S-20 S-22 S-15

S-17 S-19 S-16

S-18

S-23 S-24

S-31

S-29 S-27 S-26 S-28 S-30 S-32 S-34 S-35 S-36 S-38 S-37 S-33

S-39 STA 2000 STA 2020 STA 2060 STA 2040 STA 2080 STA 2120 STA 2100 STA 2140 STA 2160

FWD 1



### FW59991



### (SHEET 7 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 64 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**LEFT AND RIGHT SIDE SHOWNS51LS49LS47LS45LS43LS41LS50RS44RS43RS46RS48RS42RSTA2000STA2020STA2040STA20602080STASTA2100STA2120STA21402160STAS41R S 4 0 L

S 4 2 L

S 4 4 L

S 4 6 L

S 4 8 L

S 5 0 L

S 5 1 R

S 4 9 R
S 4 7 R

S 4 5 RFWDG1W60000



### (SHEET 8 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 65 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-22 S-23 S-24 S-25 S-26 S-27 S-28 S-29 S-30 S-31 S-32 S-33 S-34 S-35 S-36

S-39 S-37 S-38 2160 STA 2140 STA 2120 STA 2100 STA 2080 STA 2060 STA 2040 STA 2020 STA 2000 STA

POSTS NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS AND RIGHT SIDE SHOWN, FWD

1



### HW60023



### (SHEET 9 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 66 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**STA2180STA2200STA2220STA2240STA2260STA2280STA2360STA2340STA2320STA2300S49S47S44S50S48(RIGHT SIDE OPPOSITE)LEFT SIDE SHOWNS28S29S30S31S32S33S34S35S36S37S38S51S42S40S461IW60070FWD



### (SHEET 10 OF 11)

### FIGURE 3: INSPECTION OF AREA 3 - SECTION 46 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 67 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** The step number shown below agrees with the number shown in the circle symbols in the figure. **NOTE:** The STA 1480 bulkhead is not shown. **STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Lower Lobe Frames Detailed - (a) (b) (a) The inspection area is from STA 1480 to STA 2360, from the main deck floor down. (b) Pay particular attention to frame inner chords at the last fastener in a reinforcing strap, frame webs, fail-safe chords, and stringer cutouts.

**(SHEET 11 OF 11)**

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 68 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES** 

S-39R

S-39L S-10A S-0

S-22
S-39 STA 980

STA 720

STA 540

F D C SEE SEE E

B SEE AW60099



### (SHEET 1 OF 8)

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 69 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-39 STA STA STA STA STA
STA STA STA STA STA 720

SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS NOT LEFT SIDE SHOWN, S-25 S-23 S-24 700 680 660 640
620 600 580 560 540

S-26 S-27 S-28 S-29 S-30 S-31 S-32 S-33 S-34 S-35 S-36 S-37 S-38 FWD 1



### AW60118



### (SHEET 2 OF 8)

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 70 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-22 S-23 S-24 S-25 S-26

S-27 S-28 S-29

S-32 S-30 S-31

S-34 S-33
S-35

S-36

S-37

S-38

S-39

SHOWN FOR CLARITY MAIN DECK FLOOR BEANS NOT RIGHT SIDE ONLY, STA 720 STA STA 700 STA 680 660 STA STA 640 620 STA STA 600 580 STA STA 560 540 1



### BW60126 FWD



### (SHEET 3 OF 8)

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 71 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**LEFT AND RIGHT SIDE SHOWNSTA620STA540STA560STA580STA600S-41RS-47LS-47RS-46RS-45RS-44RS-42RS-40LS-41LS-42LS-43LS-44LS-45LS-46LS-43RS-40RFWD1CW60167



### (SHEET 4 OF 8)

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 72 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**S-40RS-41RS-43RS-42RS-44RS-45RS-46RS-40LS-41LS-42LS-43LS-44LS-45LS-46LS-47LS-47RSTA640STA660STA680STA700STA720LEFT AND RIGHT SIDE SHOWNFWD1DW60178



### (SHEET 5 OF 8)

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 73 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS AND POSTS (RIGHT SIDE OPPOSITE EXCEPT AS NOTED) LEFT SIDE SHOWN S-39

S-38

S-37

S-36

S-35

S-34

S-33

S-32

S-31 S-30 S-25 S-26 S-27 S-28

S-23 S-24

STA 840 STA 820 STA 920 STA 940 STA 960 STA 980

STA 860

STA 740 STA 760 STA 780 STA 800 STA STA 900 880

(LEFT SIDE ONLY) OUTFLOW VALVE

FWD



### E 1W60185



### (SHEET 6 OF 8)

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 74 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**LEFT AND RIGHT SIDE SHOWN880900940920960980STASTASTASTASTASTASTA860STA840STA820STA800780STASTA760STA740FWDF1W60194



### (SHEET 7 OF 8)

### FIGURE 4: INSPECTION OF AREA 4 - SECTION 42 LOWER LOBE FRAMES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 75 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** The step number shown below agrees with the number shown in the circle symbols in the figure. **NOTE:** The STA 520 frame and the STA 1000 bulkhead are not shown. **STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Lower Lobe Frames Detailed - (a) (b) (a) The inspection area is from STA 520 to STA 1000, from the main deck floor down. (b) Pay particular attention to frame inner chords at the last fastener in a reinforcing strap, frame webs, fail-safe chords, and stringer cutouts.

**(SHEET 8 OF 8)**

### FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 76 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5**  **AIRPLANES**

STA 2360 STA 2160
STA 1980
STA 1720

STA 1500

S-0 D SEE

C SEE

B SEE

SEE AW60199



### (SHEET 1 OF 6)

### FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 77 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

(RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-26 S-24 S-23

S-27 S-28

S-32 S-33 S-34 S-35 S-36 S-37 S-38 S-39 1700 STA 1660 STA 1620 STA 1580 STA 1540 STA 1500 STA

1520 STA 1560 STA 1600 STA 1640 STA 1680 STA 1720 STA

S-11 S-12 S-13 S-14 S-15 S-16 S-17 S-18 S-19

S-25 S-1

S-2

S-3

S-4

S-5

S-6

S-7 S-8 S-9 S-10

S-20 S-22

S-29 S-30 S-31

POSTS NOT SHOWN FOR CLARITY

MAIN DECK FLOOR BEAMS AND 1



### A FWDW60201



### (SHEET 2 OF 6)

### FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 78 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS AND POSTS (RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S38 S36 S31 S24 S23

S16 S18 S20 S17 S15 S6 S8 S10
S14 S12 S4 S2

S39 S37

S35 S33 S32 S30 S29 S28

S27 S19

S13 S11 S9 S7 S5 S3 S1 STA 1940 1900 STA 1860 STA 1820 STA 1780 STA STA 1740 1920 STA 1880 STA 1840 STA 1800 STA 1760 STA 1980 STA 1960 STA



### B FWD 1W60221



### (SHEET 3 OF 6)

### FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 79 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS AND POSTS (RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-8 S-6 S-4 S-2 S-1 S-3 S-5 S-7 S-9 S-10

S-20

S-11

S-12 S-13

S-14

S-15 S-16

S-18 S-19

S-22 S-23 S-24 S-25 S-26 S-27 S-28 S-29 S-30 S-31 S-32 S-33 S-34 S-35 S-36 S-38 S-39

S-37 STA 2040 STA 2000 STA 2020 STA 2060

2140 STA STA 2100

STA 2120 STA 2080

STA 2160

S-17

FWD 1



### CW60290



### (SHEET 4 OF 6)

### FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 80 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

(RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-25 S-24

S-23 S-22

S-20

S-19 S-18 S-17 S-16 S-15 S-14 S-13 S-12 S-11 S-10 S-9 S-4

S-5

S-6 S-3 S-2

S-7 S-8 S-1 STA 2180 STA 2200 STA 2220 STA 2240 STA 2260 STA 2280 STA 2300 STA 2320 2340 STA 2360 STA

S-26

FWD



### D 1W60305



### (SHEET 5 OF 6)

### FIGURE 5: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 1 AND 5 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 81 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** This Figure applies to Group 1, 5: The step number shown below agrees with the number shown in the circle symbols in the figure. **NOTE:** The STA 1480 bulkhead is not shown.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Lobe Frames Detailed - (a) (b) (a) The inspection area is from STA 1480 to STA 2360, from the main deck floor to the top of the crown. (b) Pay particular attention to frame inner chords at the last fastener in a reinforcing strap, frame webs, fail-safe chords, and stringer cutouts.

**(SHEET 6 OF 6)**

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 82 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY**  **DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIRPLANES** 

ENTRY DOOR NO. 1 MAIN NO. 2 MAIN ENTRY DOOR

NO. 3 MAIN ENTRY DOOR ENTRY DOOR NO. 4 MAIN ENTRY DOOR NO. 5 MAIN C SEE

SEE D E SEE SEE F

SEE A SEE BW60324



### (SHEET 1 OF 8)

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 83 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

STA 520 STA 500 420 STA 400 STA

(RIGHT SIDE OPPOSITE) MAIN ENTRY DOOR NO. 1 LEFT SIDE SHOWN LOWER MAIN SILL UPPER MAIN SILL

FORWARD FRAME S-22 S-23 S-24 S-26 S-27 S-28 S-30 S-20 S-19 S-18 S-17 S-16 S-15 S-14 S-13

AFT FRAME REVEAL ASSEMBLY

STA 480 STA 460 STA 440 LOWER AUXILLIARY SILL UPPER DECK FLOOR BEAM LOWER CHORDS

FWD 1



### AW60427



### (SHEET 2 OF 8)

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 84 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-3 S-3A S-4

S-6 S-5

S-8 S-9

S-10

S-10A S-11 S-12 S-7A S-7 STA 400 STA 420 STA 440 STA 460 STA 480 STA 500 STA 520

FWD 2



### B LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE1559279



### (SHEET 3 OF 8)

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 85 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

FORWARD FRAME STOP INTERCOSTAL (9 LOCATIONS)

UPPER SILL

AFT FRAME

LOWER AUXILIARY SILL LOWER SILL

854 STA 860 STA STA 780 800 STA
820 STA
840 STA

STA 880 UPPER AUXILIARY SILL

S-29 S-28 S-27

S-24 S-23 S-22 S-16 S-15

S-20 S-18 S-17

S-19

S-30 S-14 S-13

MAIN ENTRY DOOR NO. 2 LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE) FWD 3

3



### CW60430



### (SHEET 4 OF 8)

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 86 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

MAIN ENTRY DOOR NO. 3 (RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-13 S-14

S-15

S-22 S-18

S-20 S-19

S-26 S-25 S-24 S-23 S-16

S-17 STA 1241

STA 1350 STA 1335 STA 1319 STA 1301 STA 1283 STA 1265

UPPER SILL

INTERCOSTAL AFT STOP (9 LOCATIONS)

AFT FRAME LOWER SILL FORWARD FRAME

INTERCOSTAL FORWARD STOP (9 LOCATIONS) UPPER AUXILIARY SILL

FWD



### D 3

3W60763



### (SHEET 5 OF 8)

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 87 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

MAIN ENTRY DOOR NO. 4 LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE) THRESHOLD AFT FRAME UPPER MAIN SILL S-15

FORWARD STOP ASSEMBLY S-19

FORWARD FRAME

S-24 S-22

ASSEMBLY FORWARD STOP

LOWER AUXILIARY SILL LOWER MAIN SILL STA 1640 UPPER AUXILIARY SILL
STA 1680

STA 1700 S-17 S-13

FWD



### E 3

3W60798



### (SHEET 6 OF 8)

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 88 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 1, 3, 5-8: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. 2220 STA

S-20

S-22

FORWARD ASSEMBLY STOP UPPER SILL AUXILIARY SILL UPPER

FRAME

2280 STA

LOWER AUXILIARY SILL THRESHOLD S-27 S-24 S-19 FRAME

S-17 S-14 S-13

2240 STA

2260 STA

2280 STA

2200 STA
2220 STA
2240 STA
2260 STA MAIN ENTRY DOOR NO. 5 (RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN LOWER SILL

STA 2300 FWD 3



### F 3W60812



### (SHEET 7 OF 8)

### FIGURE 6: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 1, 3, 5, 6, 7, and 8 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 89 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT NOTE:**  On Group 8 airplanes, only the cutouts for Main Entry Door 1 left and right are affected.

**NOTE:** Inspection of the skin will require removal of the scuff plates and thresholds.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Main Entry Door No. 1 Cutout Area Detailed - (a) 2 Inspect Main Entry Door No. 1 Cutout Area Detailed - (b) 3 Inspect Main Entry Door Cutouts (except Main Entry Door No. 1) Detailed - (c)

(a) Do internal and external detailed inspection of the main entry door No. 1 cutout area below the upper deck. The inspection area is from the lower chord of the upper deck floor beam to the lower auxiliary sill, and between STA 400 and STA 500. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames. (b) Do internal and external detailed inspection of the main entry door No. 1 cutout area above the upper deck. The inspection area is from the upper chords of the upper deck floor beams to Stringer 8, between STA 400 and STA 500. Inspect both sides of the frames in this area. Pay special attention to the stringer cutouts and the inner chords of the frames. (c) Do internal and external detailed inspections of the main entry door cutouts. The inspection area is from the upper auxiliary sill to the lower auxiliary sill, one frame forward and aft of the door edge frames. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames.

**Related Service Bulletins Door Service Bulletin Subject**  1, 2, 3, and 4 747-53-2358 Fuselage - Main Entry Doors Number 1, 2, 3, and 4 - Forward Edge Stop Support Fitting Inspection and Replacement 1 747-53A2396 Fuselage - Skins - Skin and Internal Doubler Inspection, Repair, and Modification Above Main Entry Door 1 at Station 460 1 747-53A2414 Fuselage - Main Entry Door 1 Cutout - Door Frame Aft Edge at Station 488 - Inspection and Repair 4 747-53A2416 Fuselage - Center Section - Body Station 1265 Frame Inspection, Repair, and Modification 1 747-53A2417 Fuselage - Main Entry Door Number 1 Cutout - Door Frame Forward Edge at Station 434 - Inspection and Repair 5 747-53A2450 Fuselage - Section 46 - Body Station 2231 Frame Inspection - Stringers 23 through 31 2 747-53A2451 Fuselage - Section 42 - Door Number 2 Forward Edge Frame at Body Station 800 - Inspection and Repair 3 747-53A2512 Fuselage - Main Entry Door Number 3 Cutout - Lower Forward Corner and Upper Aft Corner - Inspection and Repair at Left and Right Side Skin and Bearstrap.

**(SHEET 8 OF 8)**

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 90 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 7: INSPECTION OF AREA 7 - BODY**  **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400** 

400 CANTED

260
STA 340 STA STA 140 STA
520 STA

340 STA

400 STA

BL 0 A C

C B B A

4 FWD SEE A SEE BW60833



### (SHEET 1 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 91 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

TYPICAL CRACK CRACK TYPICAL LEFT SIDE

FLOOR BEAM BEAM WEB VERTICAL FLOOR BEAM

BEAM WEB VERTICAL FLOOR BEAM STA 380 OR 360 BL 0

STA 380 OR 360

STA 380 OR 360

RIGHT SIDE SHOWN LEFT SIDE OPPOSITE LEFT SIDE SHOWN RIGHT SIDE OPPOSITE 5 5

INBD FWD UP 

### A INBD UP
FWD

INBD FWD UP C SEE



### C BW60840



### (SHEET 2 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 92 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

CHORD CRACKS BEAM FLOOR

CRACKS WEB INNER CHORD CRACK

TYPICAL CRACK LOCATIONS STA 260 FORWARD CANTED BULKHEAD


### A-A MAIN DECK FLOOR S-22R S-22L

WEB CRACKS WEB AND DOUBLER CRACKS INTERSECTION SIDEWALL BULKHEAD/ WEB CRACKS WEB CRACKS WEB CRACKS RBL 30.00 30.00

LBL

LOWER CHORD CRACKS E SEE

D SEE 1W60861



### (SHEET 3 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 93 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

WEB CRACKS

BROKEN STRAP

TYPICAL WEB AND INNER

CHORD STRAP CRACKS S-36 S-34 S-32A S-31A

S-39 S-38

INBD UP



### DW60866



### (SHEET 4 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 94 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

WEB CRACKS TYPICAL

(LEFT SIDE OPPOSITE) RIGHT SIDE SHOWN RBL RBL 30.00 40.00



### EW60869



### (SHEET 5 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 95 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

B-B TYPICAL STA 340 BULKHEAD CRACK LOCATIONS S-22R S-22L

CRACKS DOUBLER WEB AND WEB CRACK WEB

FLOOR DECK MAIN FLOOR BEAM CHORD CRACK BL 0 CHORD CRACK FLOOR BEAM CRACKS

CLIP CRACK F

2 SEEW60879



### (SHEET 6 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 96 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

CRACKS STRINGER CUTOUT

CHORD CRACKS FLOOR BEAM MAIN DECK CRACKS WEB

S-23

WEB CRACKS

SHEAR TIE CRACKS S-24A

INBD UP



### FW60891



### (SHEET 7 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 97 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

CHORD CRACKS STIFFENER CRACKS

BULKHEAD CRACKS TYPICAL STA 400


### C-C IN THIS AREA, IT IS ACCEPTABLE FORWARD SIDE ONLY. TO DO THE INSPECTION FROM THE

S-22R S-22L

CRACKS MAIN DECK FLOOR 0 BL WEB CRACK

STIFFENER WEB AND WEB CRACKS

3 G SEEW60893



### (SHEET 8 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 98 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

WEB CRACKS S-23L

TYPICAL STA 400 BULKHEAD STRINGER CUTOUT CRACK UP
INBD



### GW60930



### (SHEET 9 OF 10)

### FIGURE 7: INSPECTION OF AREA 7 - BODY **STATION 260, 340, AND 400 BULKHEADS AND NOSE WHEEL WELL SIDEWALLS FROM STATION 340 TO STATION 400**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 99 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect STA 260 Bulkhead Detailed - (a) 2 Inspect STA 340 Bulkhead Detailed - (a) 3 Inspect STA 400 Bulkhead Detailed - (a) 4 Inspect Sidewall Panel Web and Stiffeners Detailed - -
**NOTE:** 1. From STA 340 to STA 400, from the intersection with the top panel to the intersection with the body skin, on both the left and right sides. 2. In the area of the torque box, do the inspection from inside the wheel well. 3. Also inspect the intersection of the sidewall panel with the STA 340 and STA 400 bulkheads. 5 Inspect Floor Beam Lower Chord Detailed - (b) Floor Beam Web Vertical Beam Web (a) Inspect both the forward and aft sides of the entire bulkhead, from S-22L to S-22R, from both inside the airplane and inside the wheel well. Be sure to inspect the intersections between the bulkhead and nose wheel well sidewall panels. (b) Do detailed inspections of the STA 360 and STA 380 main deck floor beam lower chords, floor beam webs, and vertical beam webs within 12 inches of each intersection of the floor beam and vertical beam, on both the left and right sides. If cracks are found, repair before any more flights. Ask Boeing for repair data.

**(SHEET 10 OF 10)**

### FIGURE 8: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 1, 3, 5, 6, 7, 8, AND 10 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 100 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 8: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 1, 3, 5, 6, 7, 8, AND 10 AIRPLANES** 

ENTRY DOOR NO. 3 MAIN

(RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN ENTRY DOOR NO. 1 MAIN ENTRY DOOR NO. 2 MAIN ENTRY DOOR NO. 5 MAIN

ENTRY DOOR NO. 4 MAIN

1

A SEE 1

A SEE 1

A SEE 1

A SEE 1
SEE AW60934



### (SHEET 1 OF 3)

### FIGURE 8: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 1, 3, 5, 6, 7, 8, AND 10 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 101 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

(TYPICAL) DOOR STOP

(OTHER DOORS SIMILAR) NO. 2 AND NO. 4 MAIN ENTRY DOOR SHOWN

UPPER GATE ASSEMBLY

(TYPICAL) FRAME

LOWER GATE ASSEMBLY (TYPICAL) BUILT-UP BEAM

DOOR SKIN (TYPICAL) FRAME (CLOSURE BEAM)

B SEE

INBD FWD



### A 1W60946



### (SHEET 2 OF 3)

### FIGURE 8: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 1, 3, 5, 6, 7, 8, AND 10 AIR**PLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 102 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 1, 3, 5-8, 10: The step number shown below agrees with the number shown in the circle symbols in the figure. **NOTE:** On Group 8 airplanes, only Main Entry Door 1 left and right are affected.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Main Entry Door Structure Detailed - (a) (a) Do internal and external inspections of the door structure. FILLET CRACK

FLANGE CRACK CRACK PIN HOLE

TYPICAL DOOR STOP CRACKS 

### BW60955



### (SHEET 3 OF 3)

### FIGURE 9: INSPECTION OF AREA 9 - MAIN ELECTRONICS BAY ACCESS DOOR CUTOUT December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 103 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 9: INSPECTION OF AREA 9 - MAIN ELECTRONICS BAY ACCESS DOOR CUTOUT** 

TYPICAL 400 STA BAY ACCESS DOOR MAIN ELECTRONICS

FUSELAGE SKIN

INSPECTION AREA (TYPICAL 4 LOCATIONS) 440 STA

CRACK BAY ACCESS DOOR MAIN ELECTRONICS

420 STA

1 UP

FWDW60958



### (SHEET 1 OF 2)

### FIGURE 9: INSPECTION OF AREA 9 - MAIN ELECTRONICS BAY ACCESS DOOR CUTOUT December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 104 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** The step number shown below agrees with the number shown in the circle symbol in the figure. **NOTE:** The Main Electronics Bay Access Door should be open for the inspection.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Fuselage Skin Detailed - (a) (a) Internal and external, at all four corners of the door cutout, for cracks.

**(SHEET 2 OF 2)**

### FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 105 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES** 

270 (TYPICAL) FLOOR BEAMS ALL UPPER DECK

740 STA
540 STA

287 STA STA

300 STA 320 STA 330 STA 340 STA 360 STA 380 STA 400 STA

STA 240 TO STA 400 FWD UP A SEE C B D SEE



### A 1382860



### (SHEET 1 OF 5)

### FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 106 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

520 STA

500 STA

480 STA

460 STA

440 STA

420 STA
400 STA

LEFT SIDE - STA 400 TO STA 520 

### B FWD UP383134



### (SHEET 2 OF 5)

### FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 107 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

400 STA 520 STA

420 STA 440 STA 460 STA 480 STA 500 STA 0 BL

RIGHT SIDE - STA 400 TO STA 520 FWD UP



### C383395



### (SHEET 3 OF 5)

### FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 108 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

720 STA
700 STA
680 STA

640 STA

580 STA
560 STA 540 STA 0 BL 740 STA

660 STA

620 STA
600 STA



### D FWD UP384088 LEFT SIDE SHOWN RIGHT SIDE OPPOSITE



### (SHEET 4 OF 5)

### FIGURE 10: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 2 AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 109 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** This Figure applies to Group 2, 9: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NOTE:** 1. Boeing Service Bulletins 747-53A2420, 747-53A2429, and 747-53A2439 give instructions for NDT inspections of the upper deck floor beams on Group 2 and 9 airplanes. 2. If necessary, loosen and remove air conditioning ducts for access to the inspection area. **STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Chord Detailed - From below the floor beams (a) Web Lower Chord (a) The inspection area is from STA 260 to STA 740. Pay particular attention to all nutplate locations, cutout locations, and to the floor beam connections to the frames. Also inspect the cab floor web (in the plane of the floor) from STA 260 to STA 330. Pay particular attention to all cutouts and nutplate locations. **NOTE:** At STA 260, inspect the chord that is common to the cab floor web. Also inspect the adjacent 2 inches of the vertical web.

**(SHEET 5 OF 5)**

### FIGURE 11: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 110 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 11: INSPECTION OF AREA 1 - UPPER**  **DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES**

270 STA 780 STA

540

287 STA STA

300 STA 320 STA 330 STA 340 STA 360 STA 380 STA 400 STA (TYPICAL) FLOOR BEAMS ALL UPPER DECK

STA 240 TO STA 400 UP
FWD A SEE C B D SEE



### A 1384097



### (SHEET 1 OF 5)

### FIGURE 11: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 111 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

520 STA

500 STA

480 STA

460 STA

440 STA

420 STA
400 STA

LEFT SIDE - STA 400 TO STA 520 

### B FWD UP384158



### (SHEET 2 OF 5)

### FIGURE 11: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 112 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

400 STA 520 STA

420 STA 440 STA 460 STA 480 STA 500 STA 0 BL

RIGHT SIDE - STA 400 TO STA 520 FWD UP



### C385297



### (SHEET 3 OF 5)

### FIGURE 11: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 113 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

720 STA
700 STA
680 STA

640 STA

580 STA
560 STA 540 STA 0 BL 740 STA

660 STA

620 STA
600 STA 780 STA



### D FWD UP384368 LEFT SIDE SHOWN RIGHT SIDE OPPOSITE



### (SHEET 4 OF 5)

### FIGURE 11: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 3 AND 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 114 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** This Figure applies to Group 3, 10: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NOTE:** 1. Boeing Service Bulletins 747-53A2420, 747-53A2429, and 747-53A2439 give instructions for NDT inspections of the upper deck floor beams on Group 3 and 10 airplanes. 2. If necessary, loosen and remove air conditioning ducts for access to the inspection area. **STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Chord Detailed - From below the floor beams (a) Web Lower Chord (a) The inspection area is from STA 260 to STA 780. Pay particular attention to all nutplate locations, cutout locations, and to the floor beam connections to the frames. Also inspect the cab floor web (in the plane of the floor) from STA 260 to STA 330. Pay particular attention to all cutouts and nutplate locations. **NOTE:** At STA 260, inspect the chord that is common to the cab floor web. Also inspect the adjacent 2 inches of the vertical web.

**(SHEET 5 OF 5)**

### FIGURE 12: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 115 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 12: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 4 AIRPLANES** 



### (TYPICAL) FLOOR BEAMS ALL UPPER DECK 1

SEE E
A SEE C B D STA 140 STA 520384396



### (SHEET 1 OF 4)

### FIGURE 12: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 116 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

400 80 LBL 60 LBL 40 LBL 20 LBL 0 BL 400 STA

380 STA

360 STA

340 STA 330 STA
320 STA

302 STA

287 STA

270 STA

LEFT SIDE FLOOR BEAMS

BL STA
0 380 STA

360 STA

340 STA 330 STA
320 STA
STA 302
287 STA

270 STA

RIGHT SIDE FLOOR BEAMS 30 RBL

50 RBL

70 RBL

90 RBL

FWD UP 

### A

B FWD UP384408



### (SHEET 2 OF 4)

### FIGURE 12: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 117 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

FWD UP LBL 46.83

60 LBL

LBL 100 80 LBL LBL

LBL 86 28 24.17

LBL BL 0 520 STA

500 STA

STA 480
460 STA

440 STA

420 STA



### C

D FWD UP384939 RIGHT SIDE FLOOR BEAMS LEFT SIDE FLOOR BEAMS

STA 500

480 STA

460 STA

440 STA

420 STA

RBL 12.49

54.0 RBL 48.83 RBL 520 STA



### (SHEET 3 OF 4)

### FIGURE 12: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 118 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 4: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **NOTE:** If necessary, loosen and remove air conditioning ducts for access to the inspection area.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Chord Detailed - From below the floor beams (a) Web Lower Chord (a) The inspection area is from STA 260 to STA 700. Pay particular attention to all nutplate locations, cutout locations, and to the floor beam connections to the frames. Also inspect the cab floor web (in the plane of the floor) from STA 260 to STA 330. Pay particular attention to all cutouts and nutplate locations. **NOTE:** At STA 260, inspect the chord that is common to the cab floor web. Also inspect the adjacent 2 inches of the vertical web. 

### E FWD UP384946 LBL 20

BL 0

LBL 40 LBL 60

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN, LBL 80
LBL 100 540 STA 560 STA 580 STA 600 STA 620 STA 640 STA 700 STA

680 STA

660 STA



### (SHEET 4 OF 4)

### FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND **10 AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 119 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND 10**  **AIRPLANES**

540 STA 720 STA S-0 980 STA

S-12A

S-26
S-40 SEE A

B SEE D SEE SEE C384047



### (SHEET 1 OF 6)

### FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND **10 AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 120 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-0L

720 STA 700 STA 680 STA 660 STA 640 STA 620 STA 600 STA 580 STA 560 STA 540 STA S-1L S-2L S-2AL

S-3L S-3AL

S-4L

S-5L

S-6L

S-7L

S-8L

S-9L S-10L S-10AL S-11L S-12L

LEFT SIDE SHOWN

TIES NOT SHOWN FOR CLARITY UPPER DECK FOOR BEAMS AND TENSION RIGHT SIDE OPPOSITE FWD 1



### A384082



### (SHEET 2 OF 6)

### FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND **10 AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 121 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

CLARITY FLOOR BEAMS NOT SHOWN FOR RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN 540 STA

560 STA

580 STA

600 STA

640 STA

660 STA

680 STA

700 STA 620 STA

720 STA S-20 S-19 S-18 S-17 S-16 S-15 S-14 S-13

S-26

S-25 S-24 S-23 S-22

FWD 1



### B384170



### (SHEET 3 OF 6)

### FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND **10 AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 122 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S H O W N F O R C L A R I T Y

A N D T E N S I O N T I E S N O T

U P P E R D E C K F L O O R B E A M S

R I G H T S I D E O P P O S I T E

L E F T S I D E S H O W N740STA760STA780STA800STA820STA840STA860STA880STA900STA920STA940STA960STA980STAS-0S-1S-2S-2AS-3S-3AS-4S-6S-5S-7S-8S-9S-10S-10AS-11S-12

C1384324FWD



### (SHEET 4 OF 6)

### FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND **10 AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 123 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY UPPER DECK FLOOR BEAMS

RIGHT SIDE OPPOSITE LEFT SIDE SHOWN S-25 S-24 S-26

S-23 S-22

S-17 S-18 S-19 S-20 S-13 S-14 S-15 S-16 800 STA 780 STA 760 STA 740 STA

920 STA 900 STA 880 STA 860 STA 840 STA 820 STA

980 STA 960 STA 940 STA



### D384339 FWD



### (SHEET 5 OF 6)

### FIGURE 13: INSPECTION OF AREA 2 - SECTION 42 UPPER LOBE FRAMES - GROUP 2, 3, 4, 9, AND **10 AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 124 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** This Figure applies to Group 2-4, 9-10: The step number shown below agrees with the number shown in the circle symbols in the figure. **NOTE:** The STA 520 frame and the STA 1000 bulkhead are not shown.

**NOTE:** If necessary, loosen and remove air conditioning ducts for access to the area to be inspected. **STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Lobe Frames Detailed - (a) (a) The inspection area is from STA 520 to STA 1000, from the main deck floor to the top of the crown.

**(SHEET 6 OF 6)**

### FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 125 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES** 

ENTRY DOOR NO. 1 MAIN C SEE

SEE A SEE B NO. 5 MAIN ENTRY DOOR STA 2360

STA 1961.10

STA 1000 STA 1480

STA 520384963



### (SHEET 1 OF 5)

### FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 126 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

MAIN ENTRY DOOR NO. 1 LEFT SIDE ONLY STA 520 STA 500 420 STA 400 STA LOWER MAIN SILL UPPER MAIN SILL

FORWARD FRAME S-22 S-23 S-24 S-26 S-27 S-28 S-30 S-20 S-19 S-18 S-17 S-16 S-15 S-14 S-13

AFT FRAME REVEAL ASSEMBLY

STA 480 STA 460 STA 440 LOWER AUXILLIARY SILL UPPER DECK FLOOR BEAM LOWER CHORDS

FWD



### A 1384983



### (SHEET 2 OF 5)

### FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 127 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-3 S-3A S-4

S-6 S-5

S-8 S-9

S-10

S-10A S-11 S-12 S-7A S-7 STA 400 STA 420 STA 440 STA 460 STA 480 STA 500 STA 520

FWD 2



### B LEFT SIDE ONLY1559250



### (SHEET 3 OF 5)

### FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 128 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 2, 4: MAIN ENTRY DOOR NO. 5 LEFT SIDE ONLY S-20

S-22

2280 STA S-27 S-24 S-19 S-17 S-14 S-13

2240 STA

2260 STA

2280 STA

2200 STA
2220 STA
2240 STA
2260 STA
STA 2300 2220 STA

UPPER SILL

LOWER AUXILIARY SILL LOWER

SILL UPPER AUXILIARY SILL

THRESHOLD FWD



### C 3 3384996



### (SHEET 4 OF 5)

### FIGURE 14: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 2 and 4 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 129 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** The step number shown below agrees with the number shown in the circle symbols in the figure.

**NOTE:** Inspection of the skin will require removal of the scuff plates and thresholds.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Main Entry Door No. 1 Cutout Area Detailed - (a) 2 Inspect Main Entry Door No. 1 Cutout Area Detailed - (b) 3 Inspect Main Entry Door Cutouts (except Main Entry Door No. 1) Detailed - (c)

(a) Do internal and external detailed inspection of the main entry door No. 1 cutout area below the upper deck. The inspection area is from the lower chord of the upper deck floor beam to the lower auxiliary sill, and between STA 400 and STA 500. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames. (b) Do internal and external detailed inspection of the main entry door No. 1 cutout area above the upper deck. The inspection area is from the upper chords of the upper deck floor beams to Stringer 8, between STA 400 and STA 500. Inspect both sides of the frames in this area. Pay special attention to the stringer cutouts and the inner chords of the frames. (c) Do internal and external detailed inspections of the main entry door cutouts. The inspection area is from the upper auxiliary sill to the lower auxiliary sill, one frame forward and aft of the door edge frames. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames.

**(SHEET 5 OF 5)**

### FIGURE 15: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 2, 4, AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 130 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 15: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 2, 4, AND 9 AIRPLANES** 

SEE A A SEE385013 NO. 1 MAIN ENTRY DOOR NO. 5 MAIN ENTRY DOOR 2360 STA

1961.10 STA

1000 STA 1480 STA

520 STA



### (SHEET 1 OF 3)

### FIGURE 15: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 2, 4, AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 131 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

(TYPICAL) DOOR STOP

TYPICAL MAIN ENTRY DOOR UPPER GATE ASSEMBLY

(TYPICAL) FRAME

LOWER GATE ASSEMBLY (TYPICAL) BUILT-UP BEAM

DOOR SKIN (TYPICAL) FRAME (CLOSURE BEAM)

B SEE

INBD FWD



### A 1385016



### (SHEET 2 OF 3)

### FIGURE 15: INSPECTION OF AREA 8 - MAIN ENTRY DOORS - GROUP 2, 4, AND 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 132 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 2, 4, 9: The step number shown below agrees with the number shown in the circle symbols in the figure.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Main Entry Door Structure Detailed - (a) (a) Do internal and external inspections of the door structure. FILLET CRACK

FLANGE CRACK CRACK PIN HOLE

TYPICAL DOOR STOP CRACKS 

### B385019



### (SHEET 3 OF 3)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 133 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 16: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9**  **AIRPLANES**

STA

STA 2160

1500 STA STA 1720 STA 1980

S-0 2360

J I K AND SEE

E D C SEE F AND H AND G SEE

AND B SEE AW60030



### (SHEET 1 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 134 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-12 STA 1640 1660 STA
1680 STA STA 1700 1720 STA STA S-5
S-7 1560 STA 1580 1600 STA STA 1620 S-6 1500 STA
1520 STA
1540 STA

S-11 S-10 S-9 S-4

S-8 S-3 S-2 S-1

LEFT SIDE SHOWN RIGHT SIDE OPPOSITE FWD 1



### A423887



### (SHEET 2 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 135 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

STA STA

LEFT SIDE SHOWN

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS

RIGHT SIDE OPPOSITE 1560 STA 1500 1520 STA 1540

1620 STA 1640 STA

STA 1720 STA 1700 STA 1680 1660 STA 1580 STA STA 1600

FWD



### B 1423892 S-26

S-25 S-13

S-14

S-15

S-16 S-17 S-18 S-19 S-20 S-21 S-22 S-23 S-24



### (SHEET 3 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 136 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE STA 1960 1880 STA

1980 STA 1800 STA 1920 STA
1940 STA S-7 S-6 S-5 S-2

S-3 S-1

S-4

S-8 S-9

S-10

S-11

S-12 1860 STA 1800 STA 1760 STA STA 1740

1840 STA 1820 STA STA 1780

FWD



### C 1423898



### (SHEET 4 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 137 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

STA 1740 1780 STA 1820 STA 1860 STA STA 1900 1940 STA 1980 STA

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS LEFT SIDE S-34 S-29 S-27 S-20 S-17 S-15 S-13 S-11 S-7 S-5

S-9

S-22 S-25

FWD 1



### D423906



### (SHEET 5 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 138 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

STA 1780

S-12

RIGHT SIDE STA 1980 S-10 S-1 S-2

S-9

S-8

S-7

S-6 S-4 S-5 S-3 1740 STA 1760
1800 STA STA 1820 1840 STA
1860 STA
1880 STA STA 1900
1940 STA STA 1920 S-11 STA

STA 1960

1 FWD



### E423949



### (SHEET 6 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 139 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

1740 STA

1940 STA STA 1960 STA 1980 S-15

S-26 S-25 S-20 S-19 S-18 S-17

S-16 S-14

S-13 1760 STA
1780 STA
1800 STA
1820 STA
1840 STA
1860 STA
1880 STA 1900 STA STA

S-24 S-23 S-22 S-21 1920

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS RIGHT SIDE 1 FWD



### F423953



### (SHEET 7 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 140 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

S-2

2160 STA 2120 STA STA 2080 2040 STA

S-12 S-11 S-10 S-9 S-8 S-7 S-6 S-5 S-4 S-3 2000 STA
S-1

LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE FWD
1



### G423978



### (SHEET 8 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 141 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS

RIGHT SIDE OPPOSITE S-26 S-17
S-18 S-19
S-20 S-21
S-22
S-23 S-24 S-25 S-13

S-14

S-15

S-16

STA 2160 STA 2140 STA 2120 2100 STA 2080 STA 2060 STA 2040 STA STA 2020 STA 2000

1

FWD



### H423996



### (SHEET 9 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 142 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN RIGHT SIDE OPPOSITE STA 2320 2300 STA

STA 2360 2340 STA S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 S-9

S-10

S-11 STA 2260 STA 2240 2220 STA 2200 STA STA 2180

STA 2280

FWD



### I 1424019



### (SHEET 10 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 143 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

2340 STA STA 2360

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS LEFT SIDE STA 2300 STA 2320 S-13 S-14

S-15 S-16

S-17

S-18 S-19 S-20

S-21

S-22
S-23 S-24 S-25 S-26 2260 STA 2240 STA 2200 STA

2220 STA STA 2180

STA 2280

FWD

1



### J424021



### (SHEET 11 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 144 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS RIGHT SIDE S-13 S-14 S-15
S-16
S-17
S-18 S-19 S-20 S-21 S-22 S-23 S-24 S-25 S-26 STA 2180 STA 2200 STA 2240 STA 2220 STA 2260 STA 2280 STA 2300 STA 2320 STA 2340 STA 2360

FWD



### K 1424029



### (SHEET 12 OF 13)

### FIGURE 16: INSPECTION OF AREA 5 - SECTION **46 UPPER LOBE FRAMES - GROUP 2, 4, AND 9 AIR PLANES**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 145 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** This Figure applies to Group 2, 4, 9: The step number shown below agrees with the number shown in the circle symbols in the figure. **NOTE:** The STA 1480 bulkhead is not shown.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Lobe Frames Detailed - (a) (b) (a) The inspection area is from STA 1480 to STA 2360, from the main deck floor to the top of the crown. (b) Pay particular attention to frame inner chords at the last fastener in a reinforcing strap, frame webs, fail-safe chords, and stringer cutouts.

**(SHEET 13 OF 13)**

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 146 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 17: INSPECTION OF AREA**  **5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 AIRPLANES** 

STA

STA 2160

1500 STA STA 1720 STA 1980

S-0 2360

F SEE

C B SEE D AND E SEE

SEE A480379



### (SHEET 1 OF 8)

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 147 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

(RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-26 S-24 S-23

S-27 S-28

S-32 S-33 S-34 S-35 S-36 S-37 S-38 S-39 1700 STA 1660 STA 1620 STA 1580 STA 1540 STA 1500 STA

1520 STA 1560 STA 1600 STA 1640 STA 1680 STA 1720 STA

S-11 S-12 S-13 S-14 S-15 S-16 S-17 S-18 S-19

S-25 S-1

S-2

S-3

S-4

S-5

S-6

S-7 S-8 S-9 S-10

S-20 S-22

S-29 S-30 S-31

POSTS NOT SHOWN FOR CLARITY

MAIN DECK FLOOR BEAMS AND 1



### A FWD480380



### (SHEET 2 OF 8)

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 148 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE STA 1960 1880 STA

1980 STA 1800 STA 1920 STA
1940 STA S-7 S-6 S-5 S-2

S-3 S-1

S-4

S-8 S-9

S-10

S-11

S-12 1860 STA 1800 STA 1760 STA STA 1740

1840 STA 1820 STA STA 1780

FWD



### B 1480383



### (SHEET 3 OF 8)

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 149 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

STA 1740 1780 STA 1820 STA 1860 STA STA 1900 1940 STA 1980 STA

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS LEFT SIDE S-34 S-29 S-27 S-20 S-17 S-15 S-13 S-11 S-7 S-5

S-9

S-22 S-25

FWD 1



### C480394



### (SHEET 4 OF 8)

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 150 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS AND POSTS RIGHT SIDE S38 S36 S31 S24 S23 S16 S18 S20 S17 S15 S6 S8 S10
S14

S12 S4 S2

S39 S37 S35 S33 S32 S30 S29 S28 S27 S19

S13

S11 S9 S7 S5 S3 S1 STA 1940 1900 STA 1860 STA 1820 STA 1780 STA STA 1740 1920 STA 1880 STA 1840 STA 1800 STA 1760 STA 1980 STA 1960 STA



### D FWD 1480398



### (SHEET 5 OF 8)

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 151 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS AND POSTS (RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-8 S-6 S-4 S-2 S-1 S-3 S-5 S-7 S-9 S-10

S-20

S-11

S-12 S-13

S-14

S-15 S-16

S-18 S-19

S-22 S-23 S-24 S-25 S-26 S-27 S-28 S-29 S-30 S-31 S-32 S-33 S-34 S-35 S-36 S-38 S-39

S-37 STA 2040 STA 2000 STA 2020 STA 2060

2140 STA STA 2100

STA 2120 STA 2080

STA 2160

S-17

FWD 1



### E480410



### (SHEET 6 OF 8)

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 152 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

NOT SHOWN FOR CLARITY MAIN DECK FLOOR BEAMS (RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-25 S-24

S-23 S-22

S-20

S-19 S-18 S-17 S-16 S-15 S-14 S-13 S-12 S-11 S-10 S-9 S-4

S-5

S-6 S-3 S-2

S-7 S-8 S-1 STA 2180 STA 2200 STA 2220 STA 2240 STA 2260 STA 2280 STA 2300 STA 2320 2340 STA 2360 STA

S-26

FWD



### F 1480412



### (SHEET 7 OF 8)

### FIGURE 17: INSPECTION OF AREA 5 - SECTION 46 UPPER LOBE FRAMES - GROUP 3, 6, 7, AND 10 **AIRPLANES** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 153 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** This Figure applies to Group 3, 6-7, 10: The step number shown below agrees with the number shown in the circle symbols in the figure. **NOTE:** The STA 1480 bulkhead is not shown.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Lobe Frames Detailed - (a) (b) (a) The inspection area is from STA 1480 to STA 2360, from the main deck floor to the top of the crown. (b) Pay particular attention to frame inner chords at the last fastener in a reinforcing strap, frame webs, fail-safe chords, and stringer cutouts.

**(SHEET 8 OF 8)**

### FIGURE 18: INSPECTION OF AREA 1 - F **RAME INSPECTION COMMON TO UPPER DECK FLOOR BEAMS**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 154 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 18: INSPECTION OF AREA 1 - FRAM**  **E INSPECTION COMMON TO UPPER DECK FLOOR BEAMS** 

STA 260

UPPER DECK FLOOR BEAM AREA (STA. 260 - STA. 520) STA 520

STA 340

A A1556269



### (SHEET 1 OF 3)

### FIGURE 18: INSPECTION OF AREA 1 - FRAME INSPECTION COMMON TO UPPER DECK FLOOR **BEAMS** December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 155 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

UPPER DECK FLOOR BEAM UPPER CHORD S-11

S-13A FRAME INNER CHORD FRAME OUTER CHORD

LEFT SIDE SHOWN, RIGHT SIDE SIMILAR UPPER DECK FLOOR BEAM WEB

UPPER DECK FLOOR BEAM LOWER CHORD STA 340 INSPECTION AREA SHOWN, ALL OTHER INSPECTION AREAS (STA 260 - STA 520) SIMILAR FRAME WEB

UP
INBD



### A-A 11556271



### (SHEET 2 OF 3)

### FIGURE 18: INSPECTION OF AREA 1 - F **RAME INSPECTION COMMON TO UPPER DECK FLOOR BEAMS**  December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 156 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **STEP TASK NAME IDENTIFICATION QTY MORE DATA** 1 Inspect Detailed - - (a) (b) (c) (a) Do a detailed inspection for cracks in the frame inner chord, the frame outer chord, frame web, and any angles, straps, or doublers in the area shown. Do this detailed inspection on both sides of the frame (forward and aft). Do this detailed inspection on all frames from STA 260 to STA 520, and on both the right side and left side of the airplane. (b) If there is a repair in the frame inspection area, it is acceptable to inspect the repaired area. However, at least one side of the frame chords must be fully visible. (c) It is optional to do a borescope inspection in areas where access is limited.

**(SHEET 3 OF 3)**

### FIGURE 19: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 157 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 19: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 9 AIRPLANES** 

SEE A B SEE

NO. 1 MAIN ENTRY DOOR NO. 5 MAIN ENTRY DOOR STA 2360

STA 1961.10

STA 1000 STA 1480

STA 5201572878



### (SHEET 1 OF 4)

### FIGURE 19: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 158 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

STA 520 STA 500 420 STA 400 STA

(RIGHT SIDE OPPOSITE) MAIN ENTRY DOOR NO. 1 LEFT SIDE SHOWN LOWER MAIN SILL UPPER MAIN SILL

FORWARD FRAME S-22 S-23 S-24 S-26 S-27 S-28 S-30 S-20 S-19 S-18 S-17 S-16 S-15 S-14 S-13

AFT FRAME REVEAL ASSEMBLY

STA 480 STA 460 STA 440 LOWER AUXILLIARY SILL UPPER DECK FLOOR BEAM LOWER CHORDS

FWD 1



### A1572885



### (SHEET 2 OF 4)

### FIGURE 19: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 159 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 9: MAIN ENTRY DOOR NO. 5 LEFT SIDE ONLY S-20

S-22

2280 STA S-27 S-24 S-19 S-17 S-14 S-13

2240 STA

2260 STA

2280 STA

2200 STA
2220 STA
2240 STA
2260 STA
STA 2300 2220 STA

UPPER SILL

LOWER AUXILIARY SILL LOWER

SILL UPPER AUXILIARY SILL

THRESHOLD FWD



### B 2 21572886



### (SHEET 3 OF 4)

### FIGURE 19: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 9 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 160 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT** The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

**NOTE:** Inspection of the skin will require removal of the scuff plates and thresholds.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Main Entry Door No. 1 Cutout Area Detailed - (a) 2 Inspect Main Entry Door Cutouts (except Main Entry Door No. 1) Detailed - (b)

(a) Do internal and external detailed inspection of the main entry door No. 1 cutout area below the upper deck. The inspection area is from the lower chord of the upper deck floor beam to the lower auxiliary sill, and between STA 400 and STA 500. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames. (b) Do internal and external detailed inspections of the main entry door cutouts. The inspection area is from the upper auxiliary sill to the lower auxiliary sill, one frame forward and aft of the door edge frames. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames.

**(SHEET 4 OF 4)**

### FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 161 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES** 

ENTRY DOOR NO. 1 MAIN
NO. 2 MAIN ENTRY DOOR NO. 3 MAIN ENTRY DOOR ENTRY DOOR NO. 4 MAIN ENTRY DOOR NO. 5 MAIN

SEE A
B SEE SEE C D SEE SEE E1572888



### (SHEET 1 OF 7)

### FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 162 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

STA 520 STA 500 420 STA 400 STA

(RIGHT SIDE OPPOSITE) MAIN ENTRY DOOR NO. 1 LEFT SIDE SHOWN LOWER MAIN SILL UPPER MAIN SILL

FORWARD FRAME S-22 S-23 S-24 S-26 S-27 S-28 S-30 S-20 S-19 S-18 S-17 S-16 S-15 S-14 S-13

AFT FRAME REVEAL ASSEMBLY

STA 480 STA 460 STA 440 LOWER AUXILLIARY SILL UPPER DECK FLOOR BEAM LOWER CHORDS

FWD 1



### A1572889



### (SHEET 2 OF 7)

### FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 163 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

FORWARD FRAME STOP INTERCOSTAL (9 LOCATIONS)

UPPER SILL

AFT FRAME

LOWER AUXILIARY SILL LOWER SILL

854 STA 860 STA STA 780 800 STA
820 STA
840 STA

STA 880 UPPER AUXILIARY SILL

S-29 S-28 S-27

S-24 S-23 S-22 S-16 S-15

S-20 S-18 S-17

S-19

S-30 S-14 S-13

MAIN ENTRY DOOR NO. 2 LEFT SIDE SHOWN (RIGHT SIDE OPPOSITE) FWD 2

2



### B1572891



### (SHEET 3 OF 7)

### FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 164 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

MAIN ENTRY DOOR NO. 3 (RIGHT SIDE OPPOSITE) LEFT SIDE SHOWN S-13 S-14

S-15

S-22 S-18

S-20 S-19

S-26 S-25 S-24 S-23 S-16

S-17 STA 1241

STA 1350 STA 1335 STA 1319 STA 1301 STA 1283 STA 1265

UPPER SILL

INTERCOSTAL AFT STOP (9 LOCATIONS)

AFT FRAME LOWER SILL FORWARD FRAME

INTERCOSTAL FORWARD STOP (9 LOCATIONS) UPPER AUXILIARY SILL

FWD



### C 2

21572892



### (SHEET 4 OF 7)

### FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 165 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

LEFT SIDE SHOWN MAIN ENTRY DOOR NO. 4 (RIGHT SIDE OPPOSITE) THRESHOLD AFT FRAME UPPER MAIN SILL S-15

FORWARD STOP ASSEMBLY S-19

FORWARD FRAME

S-24 S-22

ASSEMBLY FORWARD STOP

LOWER AUXILIARY SILL LOWER MAIN SILL STA 1640 UPPER AUXILIARY SILL
STA 1680

STA 1700 S-17 S-13

FWD



### D 2

21572893



### (SHEET 5 OF 7)

### FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 166 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 10: The step numbers shown below agree with the numbers shown in the circle symbols in the figure. 2220 STA

S-20

S-22

FORWARD ASSEMBLY STOP UPPER SILL AUXILIARY SILL UPPER

FRAME

2280 STA

LOWER AUXILIARY SILL THRESHOLD S-27 S-24 S-19 FRAME

S-17 S-14 S-13

2240 STA

2260 STA

2280 STA

2200 STA
2220 STA
2240 STA
2260 STA LOWER SILL

STA 2300 LEFT SIDE SHOWN MAIN ENTRY DOOR NO. 5 (RIGHT SIDE OPPOSITE) FWD 2



### E 21572894



### (SHEET 6 OF 7)

### FIGURE 20: INSPECTION OF AREA 6 - MAIN ENTRY DOOR CUTOUTS - GROUP 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 167 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT NOTE:**  On Group 8 airplanes, only the cutouts for Main Entry Door 1 left and right are affected.

**NOTE:** Inspection of the skin will require removal of the scuff plates and thresholds.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Main Entry Door No. 1 Cutout Area Detailed - (a) 2 Inspect Main Entry Door Cutouts (except Main Entry Door No. 1) Detailed - (b)

(a) Do internal and external detailed inspection of the main entry door No. 1 cutout area below the upper deck. The inspection area is from the lower chord of the upper deck floor beam to the lower auxiliary sill, and between STA 400 and STA 500. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames. (b) Do internal and external detailed inspections of the main entry door cutouts. The inspection area is from the upper auxiliary sill to the lower auxiliary sill, one frame forward and aft of the door edge frames. Inspect both sides of the frames in this area. Inspect the upper main sill outer chord, web and inner chord. Pay special attention to the stringer cutouts and the inner chords of the frames.

**Related Service Bulletins Door Service Bulletin Subject**  1, 2, 3, and 4 747-53-2358 Fuselage - Main Entry Doors Number 1, 2, 3, and 4 - Forward Edge Stop Support Fitting Inspection and Replacement 1 747-53A2396 Fuselage - Skins - Skin and Internal Doubler Inspection, Repair, and Modification Above Main Entry Door 1 at Station 460 1 747-53A2414 Fuselage - Main Entry Door 1 Cutout - Door Frame Aft Edge at Station 488 - Inspection and Repair 4 747-53A2416 Fuselage - Center Section - Body Station 1265 Frame Inspection, Repair, and Modification 1 747-53A2417 Fuselage - Main Entry Door Number 1 Cutout - Door Frame Forward Edge at Station 434 - Inspection and Repair 5 747-53A2450 Fuselage - Section 46 - Body Station 2231 Frame Inspection - Stringers 23 through 31 2 747-53A2451 Fuselage - Section 42 - Door Number 2 Forward Edge Frame at Body Station 800 - Inspection and Repair 3 747-53A2512 Fuselage - Main Entry Door Number 3 Cutout - Lower Forward Corner and Upper Aft Corner - Inspection and Repair at Left and Right Side Skin and Bearstrap.

**(SHEET 7 OF 7)**

### FIGURE 21: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 8 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 168 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT FIGURE 21: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 8 AIRPLANES** 

340 STA 520 STA A SEE D THROUGH 1 ALL UPPER DECK FLOOR BEAMS1572899



### (SHEET 1 OF 4)

### FIGURE 21: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 8 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 169 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

400

RIGHT SIDE FLOOR BEAMS STA 270 STA 287 STA 302 STA 320 STA 330 STA 340 STA 360 STA 380 STA BL 0 RBL 30 RBL 50 RBL 70 RBL 90

STA 270 STA 287 STA 302 STA 320 STA 330 STA 340 STA 360 STA 380 STA 400 BL 0 LBL 20

LEFT SIDE FLOOR BEAMS LBL 40 LBL 60 LBL 80



### A

B1572901



### (SHEET 2 OF 4)

### FIGURE 21: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 8 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 170 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT**

This Figure applies to Group 8: The step number shown below agrees with the number shown in the circle symbol in the figure. INBD

FWD

FWD OUTBD 

### C

D RIGHT SIDE ONLY

BL 0.00

LBL 10.00 STA 420 LBL 24.17

LBL 46.83 LBL 58.88 LBL 65.96 STA 500

480 STA
STA 460 STA 440 STA 480 STA 460 STA 440 STA 420 BL 0.00 RBL 6.49 RBL 10.00

RBL 78.00 RBL 46.83

RBL 59.69 500 STA

LEFT SIDE ONLY1572905



### (SHEET 3 OF 4)

### FIGURE 21: INSPECTION OF AREA 1 - UPPER DECK FLOOR BEAMS - GROUP 8 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 171 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT NOTE:**  If necessary, loosen and remove air conditioning ducts for access to the inspection area.

**STEP TASK NAME PROCEDURE REFERENCES NOTES** 1 Inspect Upper Chord Detailed - From below the floor beams (a) Floor Beam Web Lower Chord Cab Floor Web (a) The inspection area is from STA 260 to STA 500. Pay particular attention to all nutplate locations, cutout locations, and to the floor beam connections to the frames. Also inspect the cab floor web (in the plane of the floor) from STA 260 to STA 330. Pay particular attention to all cutouts and nutplate locations. **NOTE:** At STA 260, inspect the chord that is common to the cab floor web. Also inspect the adjacent 2 inches of the vertical web.

**(SHEET 4 OF 4)**

### APPENDIX A: LOGIC DIAGRAM - GROUP 1 AND 6 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 172 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT APPENDIX A: LOGIC DIAGRAM - GROUP 1 AND 6 AIRPLANES** 

WHICHEVER IS LATER, DO AFTER THE DATE ON THE SERVICE BULLETIN, OR 1,000 FLIGHT-CYCLES 22,000 TOTALFLIGHT-CYCLES,

WHEN THE AIRPLANE HAS

INSPECTIONS AND EXTERNAL DETAILED 3, 4 AND 7. DO INTERNAL INSPECTIONS OF AREAS 1, INTERNAL DETAILED

OF AREAS 6, 8, AND 9. WHICHEVER IS LATER, OR 1,000 FLIGHT-CYCLES 25,000 TOTAL FLIGHT-CYCLES,

SERVICE BULLETIN, DO AN INTERNAL DETAILED AREAS 2 AND 5. INSPECTION OF WHEN THE AIRPLANE HAS

IN 3,000 FLIGHT-CYCLES. DO EACH INSPECTION AGAIN STRUCTURAL REPAIR MANUAL.

REPAIR AS SHOWN IN THE BEFORE ANY MORE FLIGHTS, NO CRACKS FOUND CRACKS FOUND ORIGINAL RELEASE OF THIS AFTER THE DATE ON THE ORIGINAL RELEASE OF THIS424131

### APPENDIX B: LOGIC DIAGRAM - GROUP 2, 3, 4, 5, 7, 9, AND 10 AIRPLANES December 21, 2004 Revision 1: September 25, 2008 747-53A2500 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 

### 173 of 173 

### BOEING SERVICE BULLETIN 747-53A2500 **ALERT ALERT APPENDIX B: LOGIC DIAGRAM - GROUP 2, 3, 4, 5, 7, 9, AND 10 AIRPLANES** 

WHICHEVER IS LATER, DO

2, 3, 4 AND 7. DO INTERNAL

OF AREAS 6, 8, AND 9. AND EXTERNAL DETAILED INSPECTIONS INTERNAL DETAILED INSPECTIONS OF AREAS 1,

WHEN THE AIRPLANE HAS 22,000 TOTAL FLIGHT-CYCLES, OR 1,000 FLIGHT-CYCLES

SERVICE BULLETIN, WHICHEVER IS LATER, WHEN THE AIRPLANE HAS

INSPECTION OF AREA 5. DO AN INTERNAL DETAILED SERVICE BULLETIN, 25,000 TOTAL FLIGHT-CYCLES, OR 1,000 FLIGHT-CYCLES

IN 3,000 FLIGHT-CYCLES. DO EACH INSPECTION AGAIN STRUCTURAL REPAIR MANUAL.

REPAIR AS SHOWN IN THE BEFORE ANY MORE FLIGHTS, NO CRACKS FOUND CRACKS FOUND AFTER THE DATE ON THE ORIGINAL RELEASE OF THIS AFTER THE DATE ON THE ORIGINAL RELEASE OF THIS424133