Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2696

Original Issue: October 16, 2008

Revision 1: April 12, 2012

ATA System: 5321

SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor

Beam Upper Chord and Strap Replacement

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2008 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, DreamlinerTM,

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BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 9

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 23

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 58

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS (STA 340 - STA 440, STA 500,

STA 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500,

STA 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

FIGURE 3: INSPECTION OF HOLES IN STRUCTURE WHERE UPPER CHORDS WERE REMOVED (STA

340 - STA 440, STA 500, STA 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA

500, STA 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA

500, STA 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS (STA 340 - STA 440,

STA 500, STA 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780) . . 83

FIGURE 8: UPPER DECK FLOOR BEAMS - HOLE INSPECTION . . . . . . . . . . . . . . . . . . . 86

FIGURE 9: UPPER DECK FLOOR BEAM - UPPER CHORDS - FABRICATION (STA 540 - STA 780) . 88

FIGURE 10: UPPER DECK FLOOR BEAM - UPPER CHORDS - INSTALLATION (STA 540 - STA 780) . 90

Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA

520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780) . . . . . . 96

APPENDIX C: SECTION 42 - FASTENER REPLACEMENT GUIDE . . . . . . . . . . . . . . . . . . . . 100

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BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Commercial 

Airplanes 747

Service Bulletin

ALERT

Revision Transmittal Sheet Number: 747-53A2696

Original Issue: October 16, 2008

Revision 1: April 12, 2012

ATA System: 5321

SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor

Beam Upper Chord and Strap Replacement

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Do

the upper chord replacement at body stations 540 through 780 at the compliance time specified in Paragraph

1.E., Compliance.

Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2005-07-21, AD 2010-03-05

and AD 2010-07-03 are related to this service bulletin.

REASON FOR REVISION

This revision is sent to add replacement instructions for upper deck floor beam upper chords at body stations

540 through 780. Several other changes have also been made.

These sections were changed:

1. Throughout the service bulletin, the words "as given in" have been changed to "in accordance with".

However, this is not considered an important change, therefore, vertical lines have not been added to

the left side of the page at locations where only this change was made.

2. In Summary: Updated the Background and Action sections to reflect new work requirements. Also,

updated Compliance section with new AD numbers, updated Manpower estimates, and updated

Summary illustration.

3. In Paragraph 1.C., Reason: Added reason for new replacement requirements aft of station (STA) 520,

and added reference to service letter for Widespread Fatigue Damage (WFD).

4. In Paragraph 1.D., Description: Added summary of new replacement requirements aft of STA 520.

5. In Paragraph 1.E., Compliance: Updated titles of Tables 1 and 2. In Table 2, corrected the "Part" callout

in the "Action" column for the "no crack found" condition, and clarified repetitive post-replacement

inspection action. Added compliance Tables 3, 4, and 5 for replacement and post-replacement

requirements of STA 540 through STA 780. Revised grace period for the initial action in compliance

Table 1 to match the grace period given in AD 2010-03-05.

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6. In Paragraph 1.F., Approval: Removed Alternative Method of Compliance (AMOC) statement for

Airworthiness Directive (AD) 2006-08-02 that has been superseded. Added AMOC statements for AD

2010-07-03 and AD 2010-03-05. Updated AMOC statements for AD 2005-07-21 and AD 2004-07-22

R1.

7. In Paragraph 1.G., Manpower: Added manpower estimates for replacement of upper deck floor beam

upper chords for STA 540 through STA 780.

8. In Paragraph 1.H., Weight and Balance Changes: Removed previous weight and balance information

that was entered for Section 41 upper chord replacement. Although the previous revision specified

weight and balance changes, it has been determined that accomplishment of this service bulletin will

not result in a significant change to the airplane weight and balance.

9. In Paragraph 1.J., References: Updated existing data references and added Section 42 drawings used

to prepare the service bulletin.

10. In Paragraph 1.K., Damage Tolerance Based Structural Inspections: Added damage tolerance statement

appropriate for this service bulletin.

11. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added parts and materials needed

for replacement of upper deck floor beam upper chords at STA 540 through STA 780. Also, revised

the upper chord, radius filler, and strap part numbers for stations 340 through 520. Also, removed

original size bolt part numbers for stations 340 through 520. Boeing recommends installation of oversize

fasteners at all bolt locations.

12. In Paragraph 3.A., General Information: Updated existing general notes and added new general notes.

13. In Paragraph 3.B., Work Instructions: Added "Section 41" to Part 1 through Part 5 and designated these

Parts as "Work Package 1: Section 41 Replacement". Clarified post replacement inspection actions

and repetitive requirement in Part 4. Added new Part 6 through Part 10 as "Work Package 2: Section

42 Replacement".

14. In Figures 1 through 6: Updated figure titles to reflect the stations where each figure is applicable. Also,

clarified/corrected the illustrations in these figures and clarified the instructions and footnotes where

necessary.

15. In Figure 2: Upper chord part number for STA 520 has been corrected. Footnote (a) has been revised

to clarify to remove/discard any repair, modification, or splice parts that were previously installed on

the upper chord as part of a Service Bulletin 747-53A2429 repair or modification. Footnote (d) has

been added.

16. In Figure 3: Added step 2 and footnote (b) to clarify requirement to inspect frame where fasteners were

removed.

17. In Figure 5: Revised footnote (a) to clarify requirements at existing fastener locations in frames that

were previously oversized during accomplishment of Section 41 modification Service Bulletin

747-53-2272. Revised footnote (g) to clarify oversize allowances, and revised footnote (i) to clarify

requirement for wet installation of bolts.

18. Figures 7 through 10: Added these new figures for replacement of upper deck floor beam upper chords

at STA 540 through STA 780.

19. In Appendix A: Revised the title to reflect the stations where this appendix is applicable.

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ALERT ALERT
20. Appendix B: Added this new appendix to identify the parts to be replaced and the material used to

make replacement parts for STA 540 through STA 780.

21. Appendix C: Added this new appendix as a cross-reference between the production drawing fastener

codes and the replacement fasteners shown for Section 42 in Paragraph 2.C.2., Parts and Materials

Supplied by the Operator.

The data given in Information Notice 747-53A2696 IN01 is included in this revision. Information Notice

747-53A2696 IN01 was issued to inform operators that the upper chord, radius filler, and strap part numbers

shown in "Part Number / Specification" column of the material tables in paragraph 2.C.2., Parts Necessary For

Each Airplane of the original issue of the service bulletin are incorrect. The part numbers have been corrected

in this revision.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 747

Service Bulletin

ALERT

Summary Number: 747-53A2696

Original Issue: October 16, 2008

Revision 1: April 12, 2012

ATA System: 5321

SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor

Beam Upper Chord and Strap Replacement

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 instructions to replace the upper chords and straps on the upper deck floor beams

at STA 340, STA 360, STA 380, STA 400, STA 420, STA 440, STA 500, and STA 520. Analysis by Boeing

indicates that accomplishment of the inspections, repairs, and modifications currently in Service Bulletins

747-53A2420, 747-53A2429, and 747-53A2439 are not adequate to ensure the structural integrity of the affected

7075 aluminum upper deck floor beam upper chords on airplanes that are operated beyond 21,000 total

flight-cycles. On these airplanes, Boeing recommends that the affected upper deck floor beam upper chords be

replaced as shown in this service bulletin. Cracks in the floor beam upper chords that are not found and repaired

could become large and fully sever the floor beam. A severed floor beam can lead to large deflection or

deformation of the floor and of the body skin, frames, and stringers and could result in damage to the wire

bundles and unintended inputs to the flight control cables which could affect airplane controllability. Adjacent

severed floor beams could result in rapid decompression of the airplane, and the loss of structural integrity.

Flight critical wire bundles and control cables are routed through cut outs in the upper deck floor beams.

The affected upper deck floor beam upper chords are made from 7075 aluminum. Boeing has received many

reports from operators of upper chord cracks that have been found on the affected upper deck floor beams.

Cracks were found in the floor beam upper chords and straps common to floor panel fastener locations. The

airplanes had flown between 16,264 and 23,561 total flight cycles. As a result of these crack reports, Boeing

issued Service Bulletin 747-53A2439, "Fuselage Floors Upper Deck Floor Beam Upper Chord Inspection at

Floor Panel Attachment Fastener Holes". In addition, Boeing has received many reports of cracks in the affected

floor beam upper chords at the fastener locations where the upper chords attach to the body frames. As a result

of these crack reports, Boeing issued Service Bulletins 747-53A2420, "Fuselage Floors Upper Deck Floor Beam

Web and Chord Crack Inspection" and 747-53A2429, "Fuselage Floors Upper Deck Floor Beam Modification

and Repair".

Boeing Service Related Problem (SRP) 747OP-SRP-53-0238 is related to this service bulletin.

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Subsequent to the original issue of this service bulletin, Boeing has determined that upper deck floor beam

upper chord replacement is required at body stations aft of station (STA) 520. Upper deck floor beam upper

chords aft of STA 520 are made from 2024 aluminum. These upper chords have been determined to be structure

that is susceptible to Widespread Fatigue Damage (WFD). Ongoing inspection of this structure is not sufficient

to maintain an acceptable level of safety, and replacement of the structure is required.

For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.

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

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

AD Related Yes Paragraph 1.E., Compliance

Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected No Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Boeing supplied Kits/Parts No Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts and Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Get access to upper deck floor beams from STA 340 to STA 440, and at STA 500 and STA 520 from the upper

deck. Remove the floor beam upper chords, angles, straps and radius fillers. Do an open hole High Frequency

Eddy Current (HFEC) inspection at all accessed holes and repair if any crack is found. Fabricate new upper

chords, straps, angles and radius fillers. Install the new floor beam upper chords, angles, straps and radius

fillers. Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin 747-53A2429

should not be re-installed. Install all equipment and panels removed for access.

Group 1:

Get access to upper deck floor beams from STA 540 to STA 740 from the upper deck. Remove the floor beam

upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and do

a repair if any crack is found. Fabricate and install new floor beam upper chords. Re-install any repairs or parts

that are not replaced, except parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install

all equipment and panels removed for access.

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ALERT ALERT
Group 2:

Get access to upper deck floor beams from STA 540 to STA 780 from the upper deck. Remove the floor beam

upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and do

a repair if any crack is found. Fabricate and install new floor beam upper chords. Re-install any repairs or parts

that are not replaced, except parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install

all equipment and panels removed for access.

EFFECTIVITY

All 747-200C/200F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directives 2004-07-22 R1, 2005-07-21, 2010-03-05 and

2010-07-03 are related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

Work Package 1

Airplanes Total Task Hours Elapsed Hours

Group 1 and 2 541.00 135.25

Work Package 2

Airplanes Total Task Hours Elapsed Hours

Group 1 400.00 100.00

Group 2 463.25 115.81

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

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BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Commercial 

Airplanes 747

Service Bulletin

ALERT

Number: 747-53A2696

Original Issue: October 16, 2008

Revision 1: April 12, 2012

ATA System: 5321

SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor

Beam Upper Chord and Strap Replacement

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.

GROUP CONFIGURATION DESCRIPTION

1 - All 747-200F airplanes.

2 - All 747-200C airplanes.

Airplane Models:

747-200C, 747-200F

Variable Number Group

RJ131 - RJ133 2

RJ151 - RJ152 2

RJ301 - RJ303 2

RJ321 - RJ322 2

RJ331 - RJ333 2

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Variable Number Group

RR001 - RR005 1

RR021 - RR025 1

RR031 1

RR201 - RR206 1

RR221 - RR226 1

RR261 - RR267 1

RR301 - RR310 1

RR331 - RR332 1

RR336 1

RR341 - RR345 1

RR361 - RR362 1

RR421 - RR422 1

RR431 - RR432 1

RR441 - RR442 1

RR451 1

RR501 - RR504 1

RR521 - RR522 1

RR526 1

RR531 1

RR551 - RR556 1

RR561 1

RR566 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions to replace the upper chords and straps on the upper deck floor

beams at STA 340, STA 360, STA 380, STA 400, STA 420, STA 440, STA 500, and STA 520. Analysis

by Boeing indicates that accomplishment of the inspections, repairs, and modifications currently in

Service Bulletins 747-53A2420, 747-53A2429, and 747-53A2439 are not adequate to ensure the

structural integrity of the affected 7075 aluminum upper deck floor beam upper chords on airplanes

that are operated beyond 21,000 total flight-cycles. On these airplanes, Boeing recommends that the

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BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
affected upper deck floor beam upper chords be replaced as shown in this service bulletin. Cracks in

the floor beam upper chords that are not found and repaired could become large and fully sever the

floor beam. A severed floor beam can lead to large deflection or deformation of the floor and of the

body skin, frames, and stringers and could result in damage to the wire bundles and unintended inputs

to the flight control cables which could affect airplane controllability. Adjacent severed floor beams

could result in rapid decompression of the airplane, and the loss of structural integrity.

Flight critical wire bundles and control cables are routed through cut outs in the upper deck floor beams.

The affected upper deck floor beam upper chords are made from 7075 aluminum. Boeing has received

many reports from operators of upper chord cracks that have been found on the affected upper deck

floor beams. Cracks were found in the floor beam upper chords and straps common to floor panel

fastener locations. The airplanes had flown between 16,264 and 23,561 total flight cycles. As a result

of these crack reports, Boeing issued Service Bulletin 747-53A2439, "Fuselage Floors Upper Deck

Floor Beam Upper Chord Inspection at Floor Panel Attachment Fastener Holes". In addition, Boeing

has received many reports of cracks in the affected floor beam upper chords at the fastener locations

where the upper chords attach to the body frames. As a result of these crack reports, Boeing issued

Service Bulletins 747-53A2420, "Fuselage Floors Upper Deck Floor Beam Web and Chord Crack

Inspection" and 747-53A2429, "Fuselage Floors Upper Deck Floor Beam Modification and Repair".

Boeing Service Related Problem (SRP) 747OP-SRP-53-0238 is related to this service bulletin.

Subsequent to the original issue of this service bulletin, Boeing has determined that upper deck floor

beam upper chord replacement is required at body stations aft of station (STA) 520. Upper deck floor

beam upper chords aft of STA 520 are made from 2024 aluminum. These upper chords have been

determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). Ongoing inspection

of this structure is not sufficient to maintain an acceptable level of safety, and replacement of the

structure is required.

For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.

Revision 1 is sent to add replacement instructions for upper deck floor beam upper chords at body

stations 540 through 780. Other changes have also been made. A list of Revision 1 changes can be

found in the Revision Transmittal Sheet section of Revision 1.

D. Description

Get access to upper deck floor beams from STA 340 to STA 440, and at STA 500 and STA 520 from

the upper deck. Remove the floor beam upper chords, angles, straps and radius fillers. Do an open

hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and repair if any crack is

found. Fabricate new upper chords, straps, angles and radius fillers. Install the new floor beam upper

chords, angles, straps and radius fillers. Re-install any repairs or parts that are not replaced, except

parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install all equipment and

panels removed for access.

Group 1:

Get access to upper deck floor beams from STA 540 to STA 740 from the upper deck. Remove the

floor beam upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all

accessed holes and do a repair if any crack is found. Fabricate and install new floor beam upper chords.

Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin

747-53A2429 should not be re-installed. Install all equipment and panels removed for access.

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ALERT ALERT
Group 2:

Get access to upper deck floor beams from STA 540 to STA 780 from the upper deck. Remove the

floor beam upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all

accessed holes and do a repair if any crack is found. Fabricate and install new floor beam upper chords.

Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin

747-53A2429 should not be re-installed. Install all equipment and panels removed for access.

Revision 1 - More work is necessary on airplanes changed in accordance with the original issue of this

service bulletin. Do the upper chord replacement at body stations 540 through 780 at the compliance

time specified in Paragraph 1.E., Compliance.

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

747-200F 221, 222, 223, 224, 225, 226, 233, 234

Group 2:

Affected Maintenance Zones

Model Zone

747-200C 221, 222, 223, 224, 225, 226, 233, 234

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2005-07-21,

AD 2010-03-05 and AD 2010-07-03 are related to this service bulletin.

Table 1: Upper Deck Floor beam - Upper Chord Replacement - Section 41

Condition Action Compliance Time (Whichever Occurs Later)

Within 1,500 flight cycles

after March 11, 2010 (the

effective date of AD

2010-03-05).

Before 21,000 total flight

cycles. (a)

Do an open hole HFEC inspection at all

accessed fastener holes at STA 340

through STA 440, STA 500 and STA 520

for cracks in accordance with the Accomplishment Instructions, Paragraph 3.B,

Part 2.

All airplanes

Contact Boeing for repair instructions Before further flight -

and do the repair.

Any crack

found

Immediately after the in- -

spection in accordance

with the Accomplishment

Instructions, Paragraph

3.B, Part 2 is accomplished.

Install new upper deck floor beam upper

chords, straps, angles and radius fillers

at STA 340 through STA 440, STA 500

and STA 520 in accordance with the

Accomplishment Instructions, Paragraph

3.B, Part 3.

All airplanes

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ALERT ALERT
Table 1: Upper Deck Floor beam - Upper Chord Replacement - Section 41

Condition Action Compliance Time (Whichever Occurs Later)

(a) Due to the post-replacement requirements, and the possibility that it will be necessary to replace the upper

chords again, Boeing does not recommend upper chord replacement prior to 15,000 total flight-cycles.

Table 2: Post-Upper Chord Replacement Actions - Section 41

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 15,000 flight cycles after -

upper chord replacement in accordance with this service bulletin.

Do detailed and HFEC inspections

of the replaced upper deck floor

beam chords for cracks in accordance with the Accomplishment Instructions, paragraph 3.B, Part 4.

Upper chord replacement has

been accomplished

Contact Boeing for repair instruc- Before further flight. -

tions and do the repair.

Any crack is

found.

Repeat the detailed and HFEC in- - 3,000 flight cycles.

spections of the replaced upper

deck floor beam chords for cracks

in accordance with the Accomplishment Instructions, paragraph 3.B,

Part 4.

No crack is

found.

Within 5,000 flight cycles after the -

initial detailed and HFEC inspection was done in accordance with

the Accomplishment Instructions,

paragraph 3.B, Part 4.

Do the inspection and chord replacement actions again, in accordance

with the Accomplishment Instructions, paragraph 3.B, Part 2 and

paragraph 3.B, Part 3.

Group 1:

Table 3: Upper Deck Floor beam - Upper Chord Replacement - Section 42

Condition Action Compliance Time (Whichever Occurs Later)

Within 1,500 flight cycles

after the Revision 1 date

on this service bulletin.

Before 30,000 total flight

cycles. (a)

Do an open hole HFEC inspection at all

accessed fastener holes at STA 540

through STA 740 for cracks in accordance with the Accomplishment Instructions, paragraph 3.B, Part 7.

All airplanes

Contact Boeing for repair instructions Before further flight -

and do the repair.

Any crack

found

Immediately after the in- -

spection in accordance

with the Accomplishment

Instructions paragraph

3.B, Part 7 is accomplished.

Install new upper deck floor beam upper

chords at STA 540 through STA 740 in

accordance with the Accomplishment

Instructions paragraph 3.B, Part 8.

All airplanes

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ALERT ALERT
Group 1:

Table 3: Upper Deck Floor beam - Upper Chord Replacement - Section 42

Condition Action Compliance Time (Whichever Occurs Later)

(a) Due to the post-replacement requirements, and the possibility that it will be necessary to replace the upper

chords again, Boeing does not recommend upper chord replacement prior to 15,000 total flight-cycles.

Group 2:

Table 4: Upper Deck Floor beam - Upper Chord Replacement - Section 42

Condition Action Compliance Time (Whichever Occurs Later)

Within 1,500 flight cycles

after the Revision 1 date

on this service bulletin.

Before 30,000 total flight

cycles. (a)

Do an open hole HFEC inspection at all

accessed fastener holes at STA 540

through STA 780 for cracks in accordance with the Accomplishment Instructions, paragraph 3.B, Part 7.

All airplanes

Contact Boeing for repair instructions Before further flight -

and do the repair.

Any crack

found

Immediately after the in- -

spection in accordance

with the Accomplishment

Instructions, paragraph

3.B, Part 7 is accomplished.

Install new upper deck floor beam upper

chords at STA 540 through STA 780 in

accordance with the Accomplishment

Instructions, paragraph 3.B, Part 8.

All airplanes

(a) Due to the post-replacement requirements, and the possibility that it will be necessary to replace the upper

chords again, Boeing does not recommend upper chord replacement prior to 15,000 total flight-cycles.

Table 5: Post-Upper Chord Replacement Actions - Section 42

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Within 20,000 flight cycles after -

upper chord replacement in accordance with this service bulletin.

Do HFEC inspections of the replaced upper deck floor beam

chords for cracks in accordance with

the Accomplishment Instructions,

paragraph 3.B, Part 9.

Upper chord replacement has

been accomplished

Contact Boeing for repair instruc- Before further flight. -

tions and do the repair.

Any crack is

found.

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ALERT ALERT
Table 5: Post-Upper Chord Replacement Actions - Section 42

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Repeat the HFEC inspections of the - 6,000 flight cycles.

replaced upper deck floor beam

chords for cracks in accordance with

the Accomplishment Instructions,

paragraph 3.B, Part 9.

No crack is

found.

Within 10,000 flight cycles after -

the initial detailed and HFEC inspection was done in accordance

with the Accomplishment Instructions, paragraph 3.B, Part 9.

Do the inspection and chord replacement actions again, in accordance

with the Accomplishment Instructions, paragraph 3.B, Part 7 and

paragraph 3.B, Part 8.

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 Seattle Aircraft

Certification Office (ACO) approves the replacement and post replacement inspection actions with the

corresponding compliance times specified in Tables 1, 2, 3, 4, and 5 under paragraph 1.E., "Compliance",

of Service Bulletin 747-53A2696, Revision 1, as an Alternative Method of Compliance (AMOC) to the

inspection, repair, and modification actions with corresponding compliance times required by paragraphs

(g), (h), (i), (k), (l), and (m) of AD 2010-07-03. This AMOC is only for areas where upper deck floor

beam upper chords have been replaced in accordance with this service bulletin. When this service

bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by

the FAA in accordance with paragraph (o) of the AD. All provisions of AD 2010-07-03 that are not

specifically referenced in this paragraph remain fully applicable and must be complied with.

In addition, the Manager of the Seattle ACO approves the accomplishment of the applicable inspection,

repair, and modification procedures in this service bulletin, as an AMOC to the inspection, repair and

modification requirements of paragraphs (a), (b), (c), (e) and (i) of AD 2005-07-21. The Manager of the

Seattle ACO also approves the accomplishment of the applicable inspection, repair and modification

procedures in this service bulletin, as a method of compliance (MOC) to the inspection, repair, and

modification requirements of paragraphs (g)(1), (h)(2), (j), (k) and (l) of AD 2005-07-21. All provisions

of AD 2005-07-21 that are not specifically referenced in the preceding statement remain fully applicable

and must be complied with accordingly.

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ALERT ALERT
In addition, the Manager of the Seattle ACO approves the accomplishment of the replacement and

post replacement inspection actions with corresponding compliance times listed in Tables 1 and 2

under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, Revision 1, as an AMOC to the

replacement and post replacement inspection actions with corresponding compliance times specified

in Tables 1 and 2 under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, original issue,

dated October 16, 2008, required by paragraphs (g) and (h) of AD 2010-03-05. The Manager of the

Seattle ACO also approves the accomplishment of the replacement and post replacement inspection

actions with corresponding compliance times listed in Tables 1 and 2 under paragraph 1.E.,

"Compliance", of Service Bulletin 747-53A2696, Revision 1, as a MOC to the replacement and post

replacement inspection actions with corresponding compliance times specified in Tables 1 and 2 under

paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, original issue, dated October 16, 2008,

required by paragraph (i) of AD 2010-03-05. All provisions of AD 2010-03-05 that are not specifically

referenced in the preceding statement remain fully applicable and must be complied with accordingly.

In addition, the Manager of the Seattle ACO approves the accomplishment of the replacement and

post replacement inspection actions with corresponding compliance times specified in Tables 1, 2, 3,

4, and 5 under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, Revision 1, as an

AMOC to the corresponding inspection and repair requirements of paragraphs (h), (i), and (j) of AD

2004-07-22 R1, for the inspection of Structural Significant Items (SSI) F-19B, F-19C, F-19D, F-19E,

F-20A, and F-20G of Supplemental Structural Inspection Document (SSID) D6-35022, Revision G,

dated December 2000. This AMOC only applies to the areas where upper deck floor beam upper chords

were replaced in accordance with this service bulletin. When this service bulletin specifies contacting

Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with

paragraph (l) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically reference in this

paragraph, 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 change 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 inspect the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Table 1: Upper Deck Floor Beam Upper Chord Replacement at STA 340 - STA 440, STA

500, and STA 520 (Work Package 1)

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 4 60.00 15.00

Figure 1 4 31.00 7.75

Figure 2 4 111.00 27.75

Figure 3 4 42.00 10.50

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ALERT ALERT
Table 1: Upper Deck Floor Beam Upper Chord Replacement at STA 340 - STA 440, STA

500, and STA 520 (Work Package 1)

Number of Per- Task Hours Elapsed Hours

sons

Task

Figure 4 - (a) (a)

Figure 5 4 206.00 51.50

Figure 6 4 31.00 7.75

Close Access 4 60.00 15.00

Test - (b) (b)

TOTAL FOR EACH AIRPLANE 541.00 135.25

(a) Time to manufacture parts is not included in this estimate.

(b) Time to test systems will be dependant upon systems disturbed during access or chord replacement in accordance with this service bulletin.

Group 1:

Table 2: Upper Deck Floor Beam Upper Chord Replacement at STA 540 - STA 740 (Work

Package 2)

Number of Per- Task Hours Elapsed Hours

sons

Task

Access 4 25.25 6.31

Figure 7 - Removal 4 143.00 35.75

Figure 8 - Inspec- 4 58.00 14.50

tion

Figure 9 - Fabrica- - (a) (a)

tion

Figure 10 - Installa- 4 148.50 37.13

tion

Close Access 4 25.25 6.31

TOTAL FOR EACH AIRPLANE 400.00 100.00

(a) Time to manufacture parts is not included in this estimate.

Group 2:

Table 3: Upper Deck Floor Beam Upper Chord Replacement at STA 540 - STA 780 (Work

Package 2)

Number of Per- Task Hours Elapsed Hours

sons

Task

Access 4 25.25 6.31

Figure 7 - Removal 4 169.00 42.25

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ALERT ALERT
Group 2:

Table 3: Upper Deck Floor Beam Upper Chord Replacement at STA 540 - STA 780 (Work

Package 2)

Number of Per- Task Hours Elapsed Hours

sons

Task

Figure 8 - Inspec- 4 68.25 17.06

tion

Figure 9 - Fabrica- - (a) (a)

tion

Figure 10 - Installa- 4 175.50 43.88

tion

Close Access 4 25.25 6.31

TOTAL FOR EACH AIRPLANE 463.25 115.81

(a) Time to manufacture parts is not included in this estimate.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

J. References

1. Existing Data:

a. 747-100/200/300 Aircraft Maintenance Manual (AMM) 25-11-02, 25-11-03, 25-16-01, 25-16-02,

25-25-01 , 25-27-05 , 25-40-03, 53-21-02

b. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00

c. Boeing Service Bulletin 747-53A2429, "FUSELAGE - Floors - Upper Deck Floor Beam

Modification And Repair"

d. Boeing Service Bulletin 747-53A2439, FUSELAGE - Floors - Upper Deck Floor Beam Upper

Chord Inspection at Floor Panel Attachment Fastener Holes"

e. Boeing Service Bulletin 747-53A2420, FUSELAGE - Floors - Upper Deck Floor Beam Web

Chord Crack Inspection

f. Boeing Service Bulletin 747-53-2272, FUSELAGE-Nose Section 41 Body Frame Structure

Replacement and Reinforcement

g. Service Related Problem (SRP) 747OP-SRP-53-0238.

h. Standard Overhaul Practices Manual (SOPM) 20-43-03, 20-50-03.

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ALERT ALERT
i. Boeing Drawing 012W6100.

j. Boeing Parts Standards Document D-590.

k. Supplemental Structural Inspection Document (SSID) D6-35022, Revision G.

l. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1, 2005-07-21,

2010-03-05, 2010-07-03

m. Boeing Service Letter 747-SL-53-088A

2. Data Supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

65B07966 SHEAR TIE INSTL - CREW FLOOR, STA 330 TO STA 520

65B10927 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 340

65B10928 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 360

65B10929 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 380

65B10930 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 400

65B10931 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 420

65B10932 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 440

65B10935 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 500

65B10936 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 520

65B38517 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 540

65B38518 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 560

65B38519 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 580

65B38520 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 600

65B38521 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 620

65B38522 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 640

65B38523 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 660

65B38524 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 680

65B38525 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 700

65B38526 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 720

65B38527 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 740

65B17358 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 760

65B17359 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 780

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ALERT ALERT
These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected

are contained in Paragraph 1.E., Compliance of this service bulletin.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary

Not affected.

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ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary For Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

NOTE: For Section 41 (STA 340 - 520), if frames have previously been replaced in accordance

with Section 41 modification Service Bulletin 747-53-2272, then additional oversize

fasteners will be needed where holes have already been oversized in the frames.

NOTE: For Section 41 (STA 340 - 520), the replacement fasteners listed are based on original

production drawings and have not been updated to current specifications. Any fasteners

and their associated oversizes equivalent to the original production fasteners, as outlined

in the D-590 substitution document are acceptable.

NOTE: For Section 42 (STA 540 - 780), the replacement fasteners listed in this revision are

current specifications. Any fasteners and their associated oversizes equivalent to the

original production fasteners, as outlined in the D-590 substitution document are

acceptable. Also, replacement fasteners listed for Section 42 are based on Appendix C

- Fastener Replacement Guide.

Upper Deck Floor Beam Station (STA) 340

Part Number / QTY Name Existing Part Number Notes

Specification

65B10927-16 1 Chord-Upper (STA 340) 65B10927-16 (a) (c)

65B10927-19 1 Radius Filler L/H (STA 340) 65B10927-19 (b) (c)

65B10927-20 1 Radius Filler R/H (STA 340) 65B10927-20 (b) (c)

BACB30MC6A3 2 Bolt - (d) (e)

BACB30MC6A4 15 Bolt - (d) (e)

BACB30MC6A5 35 Bolt - (d) (e)

BACB30MC6A6 15 Bolt - (d) (e)

BACB30MC6A7 4 Bolt - (d) (e)

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ALERT ALERT
Upper Deck Floor Beam Station (STA) 340

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MC6A9 2 Bolt - (d) (e)

BACB30FQ6A3 1 Bolt - (d) (e)

BACB30FQ6A9 1 Bolt - (d) (e)

BACC30M6 73 Collar - (d)

BACR15BA6D5C 4 Rivet - (d) (e)

or

BACR15BA7D5C

BACR15BB5D5C 88 Rivet - (d) (e)

or

BACR15BB6D5C

BACR15BB5D6C 20 Rivet - (d) (e)

or

BACR15BB6D6C

BACR15BB6D6C 7 Rivet - (d) (e)

or

BACR15BB7D6C

BACR15BB6D7C 44 Rivet - (d) (e)

or

BACR15BB7D7C

BACR15BB6D8C 4 Rivet - (d) (e)

or

BACR15BB7D8C

BACR15BB8D6C 2 Rivet - (d) (e)

or

BACR15BB9D6C

BACR15BB8D7C 2 Rivet - (d) (e)

or

BACR15BB9D7C

BACR15BB8D8C 2 Rivet - (d) (e)

or

BACR15BB9D8C

BACR15GF6D8C 4 Rivet - (d) (e)

or

BACR15GF61D8C

BACR15GF6D8C 4 Rivet - (d) (e)

or

BACR15GF61D8C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (f)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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26 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 340

Part Number / QTY Name Existing Part Number Notes

Specification

BMS 10-11, 1/4 Pint Primer - (g)

Type I

BMS 5-95, Class 4 Ounces Sealant - (g)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.

(b) Fabricate from 2024-T3511 in accordance with APPENDIX A.

(c) Discard the existing part.

(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

(f) Refer to SOPM 20-43-03 for supplier data.

(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 360

Part Number / QTY Name Existing Part Number Notes

Specification

65B10928-40 1 Chord-Upper (STA 360) 65B10928-40 (a) (c)

65B10928-42 1 Radius Filler L/H (STA 360) 65B10928-42 (b) (c)

65B10928-43 1 Radius Filler R/H (STA 360) 65B10928-43 (b) (c)

BACB30MC6A3 2 Bolt - (d) (e)

BACB30MC6A4 3 Bolt - (d) (e)

BACB30MC6A5 12 Bolt - (d) (e)

BACB30MC6A6 4 Bolt - (d) (e)

BACB30MC6A7 2 Bolt - (d) (e)

BACB30MC6A8 4 Bolt - (d) (e)

BACB30MC6A10 2 Bolt - (d) (e)

BACB30MC6A12 2 Bolt - (d) (e)

BACB30NX6K5X 8 Bolt - (d) (e)

BACB30NX6K6X 12 Bolt - (d) (e)

BACB30NX6K7X 6 Bolt - (d) (e)

BACB30NX6K8X 14 Bolt - (d) (e)

BACB30NX6K9X 6 Bolt - (d) (e)

BACC30M6 81 Collar - (d)

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

27 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 360

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB5D5C 70 Rivet - (d) (e)

or

BACR15BB6D5C

BACR15BB5D6C 70 Rivet - (d) (e)

or

BACR15BB6D6C

BACR15BB5D7C 9 Rivet - (d) (e)

or

BACR15BB6D7C

BACR15GF6D8C 6 Rivet - (d) (e)

or

BACR15GF61D8C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (f)

BMS 10-11, 1/4 pint Primer - (g)

Type I

BMS 5-95, Class 4 Ounces Sealant - (g)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.

(b) Fabricate from 2024-T3511 in accordance with APPENDIX A .

(c) Discard the existing part.

(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

(f) Refer to SOPM 20-43-03 for supplier data.

(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 380

Part Number / QTY Name Existing Part Number Notes

Specification

65B10929-518 1 Chord-Upper (STA 380) 65B10929-518 (a) (c)

65B10929-537 1 Radius Filler L/H (STA 380) 65B10929-537 (b) (c)

65B10929-566 1 Radius Filler R/H (STA 380) 65B10929-566 (b) (c)

BACB30FM6A7 1 Bolt - (d) (e)

BACB30MC6A3 2 Bolt - (d) (e)

BACB30MC6A4 16 Bolt - (d) (e)

Export Controlled ECCN: 9E991 - BOEING

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28 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 380

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MC6A5 18 Bolt - (d) (e)

BACB30MC6A6 3 Bolt - (d) (e)

BACB30MC6A7 7 Bolt - (d) (e)

BACB30MC6A8 1 Bolt - (d) (e)

BACB30NX6K8X 2 Bolt - (d) (e)

BACC30M6 50 Collar - (d)

BACR15BB5D6C 138 Rivet - (d) (e)

or

BACR15BB6D6C

BACR15BB5D7C 161 Rivet - (d) (e)

or

BACR15BB6D7C

BACR15BB5D8C 42 Rivet - (d) (e)

or

BACR15BB6D8C

BACR15BB6D7C 10 Rivet - (d) (e)

or

BACR15BB7D7C

BACR15BB6D8C 9 Rivet - (d) (e)

or

BACR15BB7D8C

BACR15BB8D8C 20 Rivet - (d) (e)

or

BACR15BB9D8C

BACR15GF6D8C 2 Rivet - (d) (e)

or

BACR15GF61D8C

BACR15GF6D9C 4 Rivet - (d) (e)

or

BACR15GF61D9C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (f)

BMS 10-11, 1/4 Pint Primer - (g)

Type I

BMS 5-95, Class 4 Ounces Sealant - (g)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A .

(b) Fabricate from 7075-T6 in accordance with APPENDIX A .

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: October 16, 2008

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29 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 380

Part Number / QTY Name Existing Part Number Notes

Specification

(c) Discard the existing part.

(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

(f) Refer to SOPM 20-43-03 for supplier data.

(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 400

Part Number / QTY Name Existing Part Number Notes

Specification

65B10930-65 or (a) (c)

65B10930-509

65B10930-65 or 1 Chord-Upper

65B10930-509

65B10930-66 or (b) (c)

65B10930-525

65B10930-66 or 1 Radius Filler L/H

65B10930-525

65B10930-156 or (b) (c)

65B10930-528

65B10930-156 1 Radius Filler R/H

or

65B10930-528

BACB30MC6A4 11 Bolt - (d) (e)

BACB30MC6A5 14 Bolt - (d) (e)

BACB30MC6A6 5 Bolt - (d) (e)

BACB30MC6A7 2 Bolt - (d) (e)

BACB30MY6K6 1 Bolt - (d) (e)

BACB30NX6K5X 14 Bolt - (d) (e)

BACB30NX6K6X 3 Bolt - (d) (e)

BACB30NX6K7X 2 Bolt - (d) (e)

BACB30MY8K4X 9 Bolt - (d) (e)

BACB30MY8K5X 8 Bolt - (d) (e)

BACB30NX8K7X 2 Bolt - (d) (e)

BACC30M6 43 Collar (d)

BACC30M8 13 Collar - (d)

BACR15BA5D6C 6 Rivet - (d) (e)

or

BACR15BA6D6C

Export Controlled ECCN: 9E991 - BOEING

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30 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 400

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BA6D7C 1 Rivet - (d) (e)

or

BACR15BA7D7C

BACR15BB5D5C 134 Rivet - (d) (e)

or

BACR15BB6D5C

BACR15BB5D6C 14 Rivet - (d) (e)

or

BACR15BB6D6C

BACR15BB5D7C 2 Rivet - (d) (e)

or

BACR15BB6D7C

BACR15BB6D7C 35 Rivet - (d) (e)

or

BACR15BB7D7C

BACR15BB8D6C 8 Rivet - (d) (e)

or

BACR15BB9D6C

BACR15BB8D8C 2 Rivet - (d) (e)

or

BACR15BB9D8C

BACR15BB8D9C 18 Rivet - (d) (e)

or

BACR15BB9D9C

BACR15GF6D8C 6 Rivet - (d) (e)

or

BACR15GF61D8C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (f)

BMS 10-11, 1/4 Pint Primer - (g)

Type I

BMS 5-95, Class 4 Ounces Sealant - (g)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A .

(b) Fabricate from 7075-T6 in accordance with APPENDIX A .

(c) Discard the existing part.

(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

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31 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 400

Part Number / QTY Name Existing Part Number Notes

Specification

(f) Refer to SOPM 20-43-03 for supplier data.

(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 420

Part Number / QTY Name Existing Part Number Notes

Specification

65B10931-64 or (a) (b)

65B10931-508

65B10931-64 or 1 Chord-Upper

65B10931-508

65B10931-65 or (a) (b)

65B10931-531

65B10931-65 or 1 Radius Filler L/H

65B10931-531

65B10931-511 1 Radius Filler R/H 65B10931-511 (a) (b)

BACB30NX6K3X 6 Bolt - (c) (d)

BACB30NX6K4X 25 Bolt - (c) (d)

BACB30NX6K5X 20 Bolt - (c) (d)

BACB30NX6K6X 5 Bolt - (c) (d)

BACB30NX6K7X 1 Bolt - (c) (d)

BACB30MY8K5X 1 Bolt - (c) (d)

BACB30MY8K6X 2 Bolt - (c) (d)

BACB30MY8K7X 16 Bolt - (c) (d)

BACB30MY8K10X 1 Bolt - (c) (d)

BACB30NW6K3X 11 Bolt - (c) (d)

BACC30BL8 2 Collar - (c)

BACC30M6 68 Collar - (c)

BACC30M8 20 Collar - (c)

BACR15BB5D6C 7 Rivet - (c) (d)

or

BACR15BB6D6C

BACR15BB5D7C 3 Rivet - (c) (d)

or

BACR15BB6D7C

BACR15BB6D6C 148 Rivet - (c) (d)

or

BACR15BB7D6C

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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Original Issue: October 16, 2008

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32 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 420

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB8D6C 9 Rivet - (c) (d)

or

BACR15BB9D6C

BACR15BB8D7C 1 Rivet - (c) (d)

or

BACR15BB9D7C

BACR15BB6D7C 50 Rivet - (c) (d)

or

BACR15BB7D7C

BACR15GF6D8C 4 Rivet - (c) (d)

or

BACR15GF61D8C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 440

Part Number / QTY Name Existing Part Number Notes

Specification

65B10932-508 or (a) (c)

65B10932-541

65B10932-508 1 Chord-Upper

or

65B10932-541

65B10932-513 1 Radius Filler L/H 65B10932-513 (b) (c)

65B10932-514 1 Radius Filler R/H 65B10932-514 (b) (c)

65B10932-516 1 Radius Filler 65B10932-516 (a) (c)

65B10932-515 1 Radius Filler 65B10932-515 (a) (c)

BACB30MC6A6 2 Bolt - (d) (e)

Export Controlled ECCN: 9E991 - BOEING

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33 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 440

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MC6A7 2 Bolt - (d) (e)

BACB30MC6A6 1 Bolt - (d) (e)

BACB30MC6A8 1 Bolt - (d) (e)

BACB30FQ6A8 4 Bolt - (d) (e)

BACB30MC6A5 1 Bolt - (d) (e)

BACB30MC6A7 4 Bolt - (d) (e)

BACB30MC6A8 2 Bolt - (d) (e)

BACB30NX6K5X 71 Bolt - (d) (e)

BACB30NX6K6X 16 Bolt - (d) (e)

BACB30NX6K7X 21 Bolt - (d) (e)

BACB30NX6K8X 13 Bolt - (d) (e)

BACB30NX6K10X 2 Bolt - (d) (e)

BACB30MY8K8X 4 Bolt - (d) (e)

BACB30MY8K9X 12 Bolt - (d) (e)

BACB30MY8K10X 4 Bolt - (d) (e)

BACB30MY8K11X 2 Bolt - (d) (e)

BACB30MY8K13X 2 Bolt - (d) (e)

BACB30NW8K8X 2 Bolt - (d) (e)

BACB30VN10K6 1 Bolt - (d) (e)

BACB30VN10K8 1 Bolt - (d) (e)

BACB30NW8K8X 2 Bolt - (d) (e)

BACC30BH6 7 Collar - (d)

BACC30BK8 2 Collar - (d)

BACC30BL8 2 Collar - (d)

BACC30M6 131 Collar - (d)

BACC30M8 28 Collar - (d)

BACR15BB6D6C 4 Rivet - (d) (e)

or

BACR15BB7D6C

BACR15BB6D7C 87 Rivet - (d) (e)

or

BACR15BB7D7C

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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Original Issue: October 16, 2008

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34 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 440

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB6D8C 21 Rivet - (d) (e)

or

BACR15BB7D8C

BACR15BB6D9C 4 Rivet - (d) (e)

or

BACR15BB7D9C

BACR15BB6D10C 1 Rivet - (d) (e)

or

BACR15BB7D10C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (f)

BMS 10-11, 1/4 Pint Primer - (g)

Type I

BMS 5-95, Class 4 Ounces Sealant - (g)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A .

(b) Fabricate from 7075-T6 in accordance with APPENDIX A.

(c) Discard the existing part.

(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

(f) Refer to SOPM 20-43-03 for supplier data.

(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 500

Part Number / QTY Name Existing Part Number Notes

Specification

65B10935-144 or (a) (c)

65B10935-507

65B10935-144 1 Chord-Upper R/H

or

65B10935-507

65B10935-506 1 Chord-Upper L/H 65B10935-506 (a) (c)

65B10935-515 or (b) (c)

65B10935-145

Reinforcement Angle Radius Filler

L/H

65B10935-515 1

or

65B10935-145

65B10935-146 or (b) (c)

65B10935-516

Reinforcement Angle Radius Filler

R/H

65B10935-146 1

or

65B10935-516

BACB30MC6A4 11 Bolt - (d) (e)

Export Controlled ECCN: 9E991 - BOEING

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35 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 500

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MC6A5 19 Bolt - (d) (e)

BACB30MC6A6 5 Bolt - (d) (e)

BACB30MC6A7 4 Bolt - (d) (e)

BACB30MC6A8 2 Bolt - (d) (e)

BACB30MC6A9 1 Bolt - (d) (e)

BACB30FP8A5 1 Bolt - (d) (e)

BACB30FQ6A7 4 Bolt - (d) (e)

BACB30MY8K7X 20 Bolt - (d) (e)

8BACB30MY8K8X 4 Bolt - (d) (e)

BACB30MY8K11X 4 Bolt - (d) (e)

BACB30NW8K7X 2 Bolt - (d) (e)

BACB30VN8K4 8 Bolt - (d) (e)

BACB30VN8K6 2 Bolt - (d) (e)

BACB30VN10K7 1 Bolt - (d) (e)

BACB30NW8K7X 2 Bolt - (d) (e)

BACC30BK6 10 Collar - (d)

BACC30BK8 1 Collar - (d)

BACC30BL8 2 Collar - (d)

BACC30M6 46 Collar - (d)

BACC30M8 31 Collar - (d)

BACR15BB5D6C 2 Rivet - (d) (e)

or

BACR15BB6D6C

BACR15BB5D7C 42 Rivet - (d) (e)

or

BACR15BB6D7C

BACR15BB5D8C 24 Rivet - (d) (e)

or

BACR15BB6D8C

BACR15BB6D8C 42 Rivet - (d) (e)

or

BACR15BB7D8C

BACR15BB6D10C 5 Rivet - (d) (e)

or

BACR15BB7D10C

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: October 16, 2008

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36 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 500

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB6D11C 38 Rivet - (d) (e)

or

BACR15BB7D11C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (f)

BMS 10-11, 1/4 Pint Primer - (g)

Type I

BMS 5-95, Class 4 Ounces Sealant - (g)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.

(b) Fabricate from 7075-T73511 or 7075-T6 in accordance with APPENDIX A.

(c) Discard the existing part.

(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

(f) Refer to SOPM 20-43-03 for supplier data.

(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 520

Part Number / QTY Name Existing Part Number Notes

Specification

65B10936-507 or (a) (c)

65B10936-525 or

65B10936-146 or

65B10936-147

65B10936-507 1 Chord-Upper

or

65B10936-525

or

65B10936-146

or

65B10936-147

65B10936-511 or (b) (c)

65B10936-133

65B10936-511 1 Radius Filler L/H

or

65B10936-133

65B10936-512 or (b) (c)

65B10936-132

65B10936-512 1 Radius Filler R/H

or

65B10936-132

65B10936-509 or (a) (c)

65B10936-524

65B10936-509 1 Strap

or

65B10936-524

Export Controlled ECCN: 9E991 - BOEING

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37 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 520

Part Number / QTY Name Existing Part Number Notes

Specification

65B10936-508 or (a) (c)

65B10936-523

65B10936-508 1 Strap

or

65B10936-523

BACB30MC6A4 145 Bolt - (d) (e)

BACB30MC6A5 29 Bolt - (d) (e)

BACB30MC6A6 87 Bolt - (d) (e)

BACB30MC6A7 2 Bolt - (d) (e)

BACB30MC6A8 8 Bolt - (d) (e)

BACB30FQ6A4 1 Bolt - (d) (e)

BACB30FQ6A6 4 Bolt - (d) (e)

BACB30MC6A7 1 Bolt - (d) (e)

BACB30MC6A8 3 Bolt - (d) (e)

BACB30MY10K8X 8 Bolt - (d) (e)

BACB30MY10K13X 4 Bolt - (d) (e)

BACB30NW8K8X 1 Bolt - (d) (e)

BACB30VN8K5 6 Bolt - (d) (e)

BACB30VN8K7 2 Bolt - (d) (e)

BACB30NW8K8X 1 Bolt - (d) (e)

BACC30BH6 4 Collar - (d)

BACC30BK6 8 Collar - (d)

BACC30BL8 1 Collar - (d)

BACC30M6 276 Collar - (d)

BACC30M8 1 Collar - (d)

BACC30M10 12 Collar - (d)

BACR15BB6D7C 1 Rivet - (d) (e)

or

BACR15BB7D7C

Type 2, Class A 4 Ounces Chemical Conversion Coating - (f)

BMS 10-11, 1/4 Pint Primer - (g)

Type I

BMS 5-95, Class 4 Ounces Sealant - (g)

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.

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BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 520

Part Number / QTY Name Existing Part Number Notes

Specification

(b) Fabricate from 7075-T6 in accordance with APPENDIX A .

(c) Discard the existing part.

(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment.

(f) Refer to SOPM 20-43-03 for supplier data.

(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Upper Deck Floor Beam Station (STA) 540

Part Number / QTY Name Existing Part Number Notes

Specification

65B38517-3 1 Chord-Upper 65B38517-3 (a) (b)

BACB30VT6K4 5 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 14 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 3 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 28 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 12 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 1 Bolt BACB30DX6* (c) (d)

BACB30NX6K6X 1 Bolt BACB30DX6* (c) (d)

BACB30MY8K7X 4 Bolt BACB30MY8C* (c) (d)

BACB30MY8K9X 4 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 124 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 153 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 18 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D8C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACB30MY8K6X 10 Bolt BACB30MY8C* (c) (d)

Export Controlled ECCN: 9E991 - BOEING

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39 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 540

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D6C

BACR15BA3D6C 10 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D7C

BACC30BL6 66 Collar - (c) (g)

BACC30BH6 46 Collar - (c) (g)

BACC30M8 18 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 560

Part Number / QTY Name Existing Part Number Notes

Specification

65B38518-3 1 Chord-Upper 65B38518-3 (a) (b)

BACB30VT6K4 6 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 26 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 3 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 2 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 20 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 8 Bolt BACB30FM6* (c) (d)

Export Controlled ECCN: 9E991 - BOEING

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40 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 560

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30NX6K7X 4 Bolt BACB30FM6 (c) (d)

BACB30MY8K6X 8 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 119 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 137 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 16 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D8C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACB30MY8K5X 10 Bolt BACB30MY8* (c) (d)

BACR15BA3D5C 8 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 4 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 69 Collar - (c) (g)

BACC30BH6 34 Collar - (c) (g)

BACC30M8 18 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

41 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 560

Part Number / QTY Name Existing Part Number Notes

Specification

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 580

Part Number / QTY Name Existing Part Number Notes

Specification

65B38519-3 1 Chord-Upper 65B38519-3 (a) (b)

BACB30VT6K4 7 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 25 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 4 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 20 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 10 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 16 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 125 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 136 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 15 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D8C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 70 Collar - (c) (g)

BACC30BH6 34 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: October 16, 2008

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42 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 580

Part Number / QTY Name Existing Part Number Notes

Specification

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 600

Part Number / QTY Name Existing Part Number Notes

Specification

65B38520-3 1 Chord-Upper 65B38520-3 (a) (b)

BACB30VT6K5 19 Bolt BACB30FM5* (c) (d)

BACB30NX6K5X 38 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 14 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 12 Bolt BACB30MY8C* (c) (d)

BACB30MY8K7X 4 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 141 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 89 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 13 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

43 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 600

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 71 Collar - (c) (g)

BACC30BH6 52 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 620

Part Number / QTY Name Existing Part Number Notes

Specification

65B38521-3 1 Chord-Upper 65B38521-3 (a) (b)

BACB30VT6K4 11 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 18 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 1 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 16 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 14 Bolt BACB30FM6* (c) (d)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

44 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 620

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MY8K6X 16 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 126 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 136 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 16 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D6C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D7C

BACC30BL6 64 Collar - (c) (g)

BACC30BH6 34 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

45 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 640

Part Number / QTY Name Existing Part Number Notes

Specification

65B38522-3 1 Chord-Upper 65B38522-3 (a) (b)

BACB30VT6K4 11 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 17 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 1 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 16 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 14 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 10 Bolt BACB30MY8C* (c) (d)

BACB30MY8K7X 4 Bolt BACB30MY8C* (c) (d)

BACB30MY8K8X 2 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 123 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 129 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 17 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15GF5D7 1 Rivet BACR15GF5D* (c) (d)

or

BACR15GF6D*

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 63 Collar - (c) (g)

BACC30BH6 34 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

46 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 640

Part Number / QTY Name Existing Part Number Notes

Specification

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 660

Part Number / QTY Name Existing Part Number Notes

Specification

65B38523-3 1 Chord-Upper 65B38523-3 (a) (b)

BACB30VT6K4 6 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 17 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 4 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 16 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 14 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 16 Bolt BACB30MY8C* (c) (d)

BACR15BA5D6C 1 Rivet BACR15BA5D* (c) (d)

or

BACR15BA6D*C

BACR15BB5D6C 125 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 149 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

47 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 660

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB5D8C 17 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 61 Collar - (c) (g)

BACC30BH6 34 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 680

Part Number / QTY Name Existing Part Number Notes

Specification

65B38524-3 1 Chord-Upper 65B38524-3 (a) (b)

BACB30VT6K4 7 Bolt BACB30FM5* (c) (d)

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: October 16, 2008

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48 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 680

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30VT6K5 24 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 4 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 20 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 10 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 12 Bolt BACB30MY8C* (c) (d)

BACB30MY8K7X 4 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 126 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 135 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 16 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 69 Collar - (c) (g)

BACC30BH6 34 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

Revision 1: April 12, 2012 747-53A2696

49 of 101

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 680

Part Number / QTY Name Existing Part Number Notes

Specification

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 700

Part Number / QTY Name Existing Part Number Notes

Specification

65B38525-3 1 Chord-Upper 65B38525-3 (a) (b)

BACB30VT6K4 6 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 17 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 16 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 6 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 20 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 16 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 8 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 122 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 136 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 17 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACB30MY8K5X 8 Bolt BACB30MY8C* (c) (d)

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

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ALERT ALERT
Upper Deck Floor Beam Station (STA) 700

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 81 Collar - (c) (g)

BACC30BH6 42 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Upper Deck Floor Beam Station (STA) 720

Part Number / QTY Name Existing Part Number Notes

Specification

65B38526-3 1 Chord-Upper 65B38526-3 (a) (b)

BACB30VT6K4 11 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 18 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 1 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 16 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 14 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 4 Bolt BACB30MY8C* (c) (d)

BACB30MY8K7X 4 Bolt BACB30MY8C* (c) (d)

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ALERT ALERT
Upper Deck Floor Beam Station (STA) 720

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB5D6C 122 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 136 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 16 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACB30MY8K5X 8 Bolt BACB30MY8C* (c) (d)

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 64 Collar - (c) (g)

BACC30BH6 34 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

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ALERT ALERT
Upper Deck Floor Beam Station (STA) 740

Part Number / QTY Name Existing Part Number Notes

Specification

65B38527-3 or (a) (b)

65B38527-603

65B38527-3 or 1 Chord-Upper

65B38527-603

BACB30VT6K4 6 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 18 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

BACB30NX6K5X 16 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 6 Bolt BACB30FM6* (c) (d)

BACB30NX6K4X 2 Bolt BACB30DX6* (c) (d)

BACB30NX6K5X 10 Bolt BACB30DX6* (c) (d)

BACB30NX6K6X 2 Bolt BACB30DX6* (c) (d)

BACR15GF5D7 2 Rivet BACR15CE5D* (c) (d)

or

BACR15GF6D7

BACR15GF5D8 2 Rivet BACR15CE5D* (c) (d)

or

BACR15GF6D8

BACB30NX6K6X 2 Bolt BACB30MB6* (c) (d)

BACB30NX6K7X 2 Bolt BACB30MB6* (c) (d)

BACB30MY8K6X 16 Bolt BACB30MY8C* (c) (d)

BACR15BA5D6C 4 Rivet BACR15BA5D* (c) (d)

or

BACR15BA6D*C

BACR15BA5D7C 5 Rivet BACR15BA5D* (c) (d)

or

BACR15BA6D*C

BACR15BB5D6C 171 Rivet BACR15BB5D* (c) (d)

or

BACR15BA6D*C

BACR15BB5D7C 112 Rivet BACR15BB5D* (c) (d)

or

BACR15BA6D*C

BACR15BB5D8C 13 Rivet BACR15BB5D* (c) (d)

or

BACR15BA6D*C

BACR15BB6D8C 3 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

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ALERT ALERT
Upper Deck Floor Beam Station (STA) 740

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 50 Collar - (c) (g)

BACC30BH6 44 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Group 2:

Upper Deck Floor Beam Station (STA) 760

Part Number / QTY Name Existing Part Number Notes

Specification

65B17358-3 1 Chord-Upper 65B17358-3 (a) (b)

BACB30VT6K4 6 Bolt BACB30FM5* (c) (d)

BACB30VT6K5 18 Bolt BACB30FM5* (c) (d)

BACB30NX6K4X 4 Bolt BACB30FM6* (c) (d)

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ALERT ALERT
Group 2:

Upper Deck Floor Beam Station (STA) 760

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30NX6K5X 16 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 4 Bolt BACB30FM6* (c) (d)

BACB30MY8K6X 8 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 120 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 109 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D8C 11 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D8C 1 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BB6D9C 2 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACB30MY8K5X 8 Bolt BACB30MY8C* (c) (d)

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 48 Collar - (c) (g)

BACC30BH6 24 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

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ALERT ALERT
Group 2:

Upper Deck Floor Beam Station (STA) 760

Part Number / QTY Name Existing Part Number Notes

Specification

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

Group 2:

Upper Deck Floor Beam Station (STA) 780

Part Number / QTY Name Existing Part Number Notes

Specification

65B17359-3 1 Chord-Upper 65B17359-3 (a) (b)

BACB30VT6K5 1 Bolt BACB30FM5* (c) (d)

BACB30VT6K6 4 Bolt BACB30FM5* (c) (d)

BACB30NX6K5X 14 Bolt BACB30FM6* (c) (d)

BACB30NX6K6X 5 Bolt BACB30FM6* (c) (d)

BACB30NW6K6 1 Bolt BACB30FN6* (c) (d)

BACB30NX6K5 2 Bolt BACB30DX5* (c) (d)

BACB30NX6K5X 14 Bolt BACB30DX5* (c) (d)

BACB30NX6K6X 3 Bolt BACB30DX5* (c) (d)

BACR15GF5D7 2 Rivet BACR15CE5D* (c) (d)

or

BACR15GF6D7

BACR15GF5D8 3 Rivet BACR15CE5D* (c) (d)

or

BACR15GF6D8

BACB30MY8K6X 8 Bolt BACB30MY8C* (c) (d)

BACR15BB5D6C 74 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB5D7C 118 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

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ALERT ALERT
Group 2:

Upper Deck Floor Beam Station (STA) 780

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB5D8C 15 Rivet BACR15BB5D* (c) (d)

or

BACR15BB6D*C

BACR15BB6D7C 7 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BB6D8C 18 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACR15BB6D9C 5 Rivet BACR15BB6D* (c) (d)

or

BACR15BB7D*C

BACB30MY8K5X 8 Bolt BACB30MY8C* (c) (d)

BACR15BA3D5C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACR15BA3D6C 6 Rivet BACR15BA3D* (c) (d)

or

BACR15BA4D*C

BACC30BL6 24 Collar - (c) (g)

BACC30BH6 38 Collar - (c) (g)

BACC30M8 16 Collar - (c)

Type 2, Class A 4 Ounces Chemical Conversion Coating - (e)

BMS 10-11, 1/4 Pint Primer - (f)

Type I

BMS 5-95, Class 4 Ounces Sealant - (f)

B-1/2, -2, -4

(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.

(b) Discard the existing part.

(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.

(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be

oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, determine grip length on installation.

(e) Refer to SOPM 20-43-03 for supplier data.

(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

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ALERT ALERT
Group 2:

Upper Deck Floor Beam Station (STA) 780

Part Number / QTY Name Existing Part Number Notes

Specification

(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity

shown is the maximum number that could be needed.

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BOEING SERVICE BULLETIN 747-53A2696

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 SRM, Chapter 51

— Torque limits to tighten nuts and bolts are given in 747 SRM, Chapter 51.

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

6. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

7. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

8. Refer to Appendix A to identify the parts to be replaced and the material used to

make replacement parts for STA 340 - STA 440, STA 500, and STA 520 . The

appendix lists the drawing numbers for the fabrication, installation and fastener

requirements.

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ALERT ALERT
9. Fasteners may be oversized 1/64 or 1/32 inch as needed. Maintain 1.7D edge margin

on the upper chord and all adjacent parts. Edge margin is defined as the distance

from the edge of the part to the center of the hole, and "D" is the hole diameter.

10. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

11. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

12. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

13. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

14. The work instructions are divided into work packages. Task Hours and Elapsed Hours

for each package are given in Paragraph 1.G., Manpower. You can do each work

package independently.

15. Shaded areas in Figures are reference only. Shaded areas in Figures may look

different than your airplane.

16. Refer to Appendix B to identify the parts to be replaced and the material used to

make replacement parts for STA 540 through STA 780. The appendix lists the drawing

numbers for the fabrication, installation and fastener requirements.

17. Install all bolts in transition fit holes. Transition fit hole sizes are given in 747 SRM,

Chapter 51.

18. Boeing recommends installation of oversize fasteners at all bolt locations. At rivet

locations, install the original size rivet provided the hole meets the acceptable surface

defect criteria for fastener holes given in SRM, Chapter 51.

19. Do a detailed inspection of any parts that are removed and re-installed during upper

chord replacement. Replace any parts that are found damaged.

20. Refer to Appendix C for Section 42 Fastener Replacement Guide.

B. WORK INSTRUCTIONS

Work Package 1: Section 41 Upper Deck Floor Beam Upper Chord Replacement

1. PART 1 - ACCESS - Section 41

a. Remove electrical power and place the battery switch in the off position.

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ALERT ALERT
b. For access to the right side of the floor beam at stations (STA) 340, STA 360, STA 380, and

STA 400, remove the P4 flight engineers panel and the P6 main circuit breaker panel. Refer

to Boeing Service Bulletin 747-53-2272 or Boeing Service Bulletin 747-53A2732 for an accepted

procedure.

c. Get access to the STA 340 - STA 440, STA 500, and STA 520 upper deck floor beams in

accordance with FIGURE 1.

2. PART 2 - CHORD REMOVAL AND INSPECTION - Section 41

CAUTION: DO NOT REMOVE ADJACENT FLOOR BEAM UPPER CHORDS AT THE SAME

TIME. IF ADJACENT FLOOR BEAM UPPER CHORDS ARE REMOVED AT THE

SAME TIME, DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR.

a. Remove the upper chords from the upper deck floor beams at STA 340 - STA 440, STA 500,

and STA 520 in accordance with FIGURE 2.

b. Do an open hole High Frequency Eddy Current (HFEC) inspection at all locations in the floor

beam webs and side of body frames where fasteners were removed to remove the upper

chords. The inspection is required at all open fastener holes in the webs at STA 340 through

STA 440, STA 500, and STA 520. Do this inspection in accordance with FIGURE 3.

(1) If any crack is found, contact Boeing for repair instructions and do the repair.

3. PART 3 - CHORD FABRICATION AND INSTALLATION - Section 41

a. Make new upper chords, straps, angles and radius fillers at the STA 340 - STA 440, STA 500

and STA 520 upper deck floor beams in accordance with FIGURE 4.

b. Install new upper chords, straps, angles and radius fillers at the STA 340 - STA 440, STA 500

and STA 520 upper deck floor beams in accordance with FIGURE 5.

NOTE: It is acceptable to install the chord in two pieces using a splice as defined in drawing

141U0044 in accordance with Service Bulletin 747-53A2429.

4. PART 4 - POST-UPPER CHORD REPLACEMENT ACTIONS - Section 41

a. At the time given in Paragraph 1.E., Compliance, of this service bulletin, do detailed and open

hole HFEC inspections of the replaced upper deck floor beam chords, in accordance with

Service Bulletin 747-53A2429.

b. At the time given in Paragraph 1.E., Compliance, of this service bulletin, do open hole HFEC

inspection at the floor panel attachment holes and surface HFEC inspection at the permanent

fastener locations of the replaced upper deck floor beam chords, in accordance with Service

Bulletin 747-53A2439.

c. If any crack is found, contact Boeing for repair instructions and do the repair.

d. If no crack is found, repeat the detailed and open hole HFEC inspections of replaced upper

deck floor beam chords in accordance with Service Bulletin 747-53A2429, and repeat open

hole HFEC inspection at floor panel attachment holes and surface HFEC inspection at

permanent fastener locations in accordance with Service Bulletin 747-53A2439, at the interval

given in Paragraph 1.E., Compliance.

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e. Repeat the upper deck floor beam chord replacement in accordance with PART 2 and PART

3, at the time given in Paragraph 1.E., Compliance.

5. PART 5 - CLOSE ACCESS - Section 41

a. Close access to the STA 340 - STA 440, STA 500 and STA 520 upper deck floor beams in

accordance with FIGURE 6.

b. If removed for access to STA 340, STA 360, STA 380 or STA 400 floor beams, install the P4

flight engineers panel and the P6 main circuit breaker panel and test all disturbed flight deck

systems. Refer to Boeing Service Bulletin 747-53-2272 or Boeing Service Bulletin 747-53A2732

for an accepted procedure.

NOTE: Only those airplane systems disturbed during the access and chord replacement

require testing.

c. Put the airplane back to a serviceable condition.

Work Package 2: Section 42 Upper Deck Floor Beam Upper Chord Replacement

1. PART 6 - ACCESS - Section 42

a. If necessary, remove electrical power and place the battery switch in the off position.

b. Group 2:

If necessary, remove/keep upper deck passenger seats from STA 540 to STA 780. Refer to

747-100/200/300 AMM 25-25-01 as an accepted procedure.

c. Remove/keep upper deck floor coverings from STA 540 to STA 780, as necessary. Refer to

747-100/200/300 AMM 25-27-05 as an accepted procedure.

d. Remove/keep upper deck floor panels from STA 540 to STA 780, as necessary. Refer to

747-100/200/300 AMM 53-21-02 as an accepted procedure.

2. PART 7 - CHORD REMOVAL AND INSPECTION - Section 42

CAUTION: DO NOT REMOVE ADJACENT FLOOR BEAM UPPER CHORDS AT THE SAME

TIME. IF ADJACENT FLOOR BEAM UPPER CHORDS ARE REMOVED AT THE

SAME TIME, DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR.

a. Group 1:

Remove the upper chords from the upper deck floor beams at STA 540 - STA 740 in

accordance with FIGURE 7.

b. Group 2:

Remove the upper chords from the upper deck floor beams at STA 540 - STA 780 in

accordance with FIGURE 7.

c. Group 1:

Do an open hole High Frequency Eddy Current (HFEC) inspection at all locations in the floor

beam webs and side of body frames where fasteners were removed to remove the upper

chords. The inspection is required at all open fastener holes in the webs at STA 540 through

STA 740. Do this inspection in accordance with FIGURE 8

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(1) If any crack is found, contact Boeing for repair instructions and do the repair.

d. Group 2:

Do an open hole High Frequency Eddy Current (HFEC) inspection at all locations in the floor

beam webs and side of body frames where fasteners were removed to remove the upper

chords. The inspection is required at all open fastener holes in the webs at STA 540 through

STA 780. Do this inspection in accordance with FIGURE 8.

(1) If any crack is found, contact Boeing for repair instructions and do the repair.

3. PART 8- CHORD FABRICATION AND INSTALLATION - Section 42

a. Group 1:

Make new upper chords for the STA 540 - STA 740 upper deck floor beams in accordance

with FIGURE 9.

b. Group 2:

Make new upper chords for the STA 540 - STA 780 upper deck floor beams in accordance

with FIGURE 9.

c. Group 1:

Install new upper chords at the STA 540 - STA 740 upper deck floor beams in accordance

with FIGURE 10.

d. Group 2:

Install new upper chords at the STA 540 - STA 780 upper deck floor beams in accordance

with FIGURE 10.

4. PART 9 - POST-UPPER CHORD REPLACEMENT ACTIONS - Section 42

a. At the time given in Paragraph 1.E., Compliance, of this service bulletin, do open hole HFEC

inspection at the floor panel attachment holes and surface HFEC inspection at the permanent

fastener locations of the replaced upper deck floor beam chords, in accordance with Service

Bulletin 747-53A2439.

b. If any crack is found, contact Boeing for repair instructions and do the repair.

c. If no crack is found, repeat open hole HFEC inspection at floor panel attachment holes and

surface HFEC inspection at permanent fastener locations in accordance with Service Bulletin

747-53A2439, at the interval given in Paragraph 1.E., Compliance.

d. Repeat the upper deck floor beam chord replacement in accordance with PART 7 and PART

8, at the time given in Paragraph 1.E., Compliance.

5. PART 10 - CLOSE ACCESS - Section 42

a. Install upper deck floor panels from STA 540 to STA 780, as necessary. Refer to

747-100/200/300 AMM 53-21-02 as an accepted procedure.

b. Install upper deck floor coverings from STA 540 to STA 780, as necessary. Refer to

747-100/200/300 AMM 25-27-05 as an accepted procedure.

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c. Group 2:

If necessary, install upper deck passenger seats from STA 540 to STA 780. Refer to

747-100/200/300 AMM 25-25-01 as an accepted procedure.

d. Put the airplane back to a serviceable condition.

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FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS (STA 340 - STA 440, STA 500, STA

520)

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove/Keep Flight Engineer's Seat - 1 as necessary. (a)

2 Remove/Keep Observer's Seat - 2 as necessary. (b)

Flight Compartment - - as necessary. (c)

Floor Covering

3 Remove/Keep

4 Remove/Keep Lavatory - 1 as necessary. (d)

Personnel Accommoda- - - as necessary. (e)

tions Area Floor Covering

5 Remove/Keep

Upper Deck Floor Pan- - - as necessary. (f)

el

6 Remove/Keep

(a) Refer to 747-100/200/300 AMM 25-11-02 as an accepted procedure.

(b) Refer to 747-100/200/300 AMM 25-11-03 as an accepted procedure.

(c) Refer to 747-100/200/300 AMM 25-16-01 as an accepted procedure.

(d) Refer to 747-100/200/300 AMM 25-40-03 as an accepted procedure.

(e) Refer to 747-100/200/300 AMM 25-16-02 as an accepted procedure.

(f) Refer to 747-100/200/300 AMM 53-21-02 as an accepted procedure.

FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS (STA 340 - STA 440, STA 500, STA

520)

(SHEET 2 OF 2)

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FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA

520)

(SHEET 1 OF 5)

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FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA

520)

(SHEET 2 OF 5)

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FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA

520)

(SHEET 3 OF 5)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME STA IDENTIFICATION QTY MORE DATA

CAUTION: DO NOT REMOVE ADJACENT FLOOR BEAM UPPER CHORDS AT THE SAME TIME. IF

ADJACENT FLOOR BEAM UPPER CHORDS ARE REMOVED AT THE SAME TIME, DAMAGE

TO THE AIRPLANE STRUCTURE MAY OCCUR.

1 Remove Upper Chord 340 65B10927-16 1 (a) (b) (c)

360 65B10928-40 1 (a) (b) (c)

380 65B10929-518 1 (a) (b) (c)

400 65B10930-65 or -509 1 (a) (b) (c)

420 65B10931-64 or -508 1 (a) (b) (c)

440 65B10932-508 or -541 1 (a) (b) (c)

500 Left - 65B10935-506 1 (a) (b) (c)

Right - 65B10935-144 or -507 1 (a) (b) (c)

65B10936-146 or -147 or -507 1 (a) (b) (c)

or -525

520

Left Strap 340 65B10927-19 1 (b) (c)

Left Strap 360 65B10928-42 1 (b) (c)

Left Strap 380 65B10929-537 1 (b) (c)

Left Strap or Angle 400 65B10930-525 or -66 1 (b) (c) (d)

Left Strap 420 65B10931-531 or -65 1 (b) (c)

Left Strap 440 65B10932-513 1 (b) (c)

Left Strap or Angle 500 65B10935-515 or -145 1 (b) (c) (d)

Left Strap 520 65B10936-511 or -133 1 (b) (c)

Right Strap 340 65B10927-20 1 (b) (c)

Right Strap 360 65B10928-43 1 (b) (c)

Right Strap 380 65B10929-566 1 (b) (c)

Right Angle 400 65B10930-156 or -528 1 (b) (c)

Right Strap 420 65B10931-511 1 (b) (c)

Right Strap 440 65B10932-514 1 (b) (c)

Right Strap or Angle 500 65B10935-516 or -146 1 (b) (c) (d)

Right Strap 520 65B10936-512 or -132 1 (b) (c)

Fwd Radius Filler 440 65B10932-516 1 (b) (c)

FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA

520)

(SHEET 4 OF 5)

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STEP TASK NAME STA IDENTIFICATION QTY MORE DATA

Aft Radius Filler (b) (c) 65B10932-515 1

Fwd Radius Filler 520 65B10936-509 or -524 1 (b) (c)

Aft Radius Filler 65B10936-508 or -523 1 (b) (c)

(a) Also remove and discard any repair, modification, or splice parts that were previously installed on the

upper chord as part of a Service Bulletin 747-53A2429 repair or modification.

(b) Keep the existing parts to use as a guide when making the new parts and for profiling the chord to frame

attachment.

(c) Any other production parts not listed that are removed during the chord removal should be kept for reinstallation.

(d) Some airplanes have an angle at STA 400 and STA 500 instead of a strap.

FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA

520)

(SHEET 5 OF 5)

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ALERT ALERT
FIGURE 3: INSPECTION OF HOLES IN STRUCTURE WHERE UPPER CHORDS WERE REMOVED (STA

340 - STA 440, STA 500, STA 520)

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fastener Holes - - in floor beam webs.(a)

This step not shown on

the illustration. Inspect

the fastener holes in

frames. (b)

2 Inspect Fastener Holes - -

(a) Do a High Frequency Eddy Current (HFEC) open hole inspection at all locations in the floor beam

webs where fasteners were removed to remove the upper chords. The inspection is required at all

open fastener holes in the webs at STA 340 through STA 440, STA 500, and STA 520. Do this inspection for cracks in accordance with 747 NDT, Part 6, 51-00-00 Figure 16.

(b) Do a High Frequency Eddy Current (HFEC) open hole inspection at all locations in the frames where

fasteners were removed to remove the upper chords. The inspection is required at all open fastener

holes in the frames at STA 340 through STA 440, STA 500, and STA 520. Do this inspection for cracks

in accordance with 747 NDT, Part 6, 51-00-00 Figure 16.

FIGURE 3: INSPECTION OF HOLES IN STRUCTURE WHERE UPPER CHORDS WERE REMOVED (STA

340 - STA 440, STA 500, STA 520)

(SHEET 2 OF 2)

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FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA 500,

STA 520)

(SHEET 1 OF 3)

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FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA 500,

STA 520)

(SHEET 2 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Make Upper Chord - 9 (a) (d)

Left Strap or Angle - 8 (b) (d)

Right Strap or Angle - 8

Radius Filler - 4 (c) (d)

Chemical Conversion Type 2, Class A - (e)

Coating

2 Apply

3 Apply Primer BMS 10-11, Type 1 - (f)

(a) STA 500 has a left chord and a right chord.

(b) Some airplanes have an angle at STA 400 and STA 500 instead of a strap.

(c) STA 440 and STA 520 only.

(d) Refer to Appendix A for the applicable parts and fabrication requirements. Use the existing parts as a guide

and to match the profile of existing chord to frame attachment.

(e) Apply one coat of chemical conversion coating.

(f) Apply two coats of BMS 10-11, Type 1 primer.

FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA 500,

STA 520)

(SHEET 3 OF 3)

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FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA 500,

STA 520)

(SHEET 1 OF 4)

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FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA 500,

STA 520)

(SHEET 2 OF 4)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Install Upper Chord - 9 (a) (b) (e) (f) (g) (h) (i)

Left Strap or Angle - 8 (a) (c) (e) (g) (h) (i)

Right Strap or Angle - 8

Radius Filler - 4 (a) (d) (e) (g) (h) (i)

(a) To install new floor beam parts, refer to the initial production drawings and Service Bulletin 747-53-2272

as applicable. At rivet locations where the hole was already oversized during accomplishment of Service

Bulletin 747-53-2272, do not further oversize the hole, and install the same diameter rivet as was called

out for SB 747-53-2272. At bolt locations where the hole was already oversized during accomplishment

of Service Bulletin 747-53-2272, make the hole an additional 1/64 inch oversize and install oversize fastener. If further oversizing is necessary to meet hole quality requirements, contact Boeing for instructions.

(b) STA 500 has a left chord and a right chord.

(c) Some airplanes have an angle at STA 400 and STA 500 instead of a strap.

(d) STA 440 and STA 520 only.

(e) Refer to Appendix A for fastener and installation requirements.

(f) Optionally to make installation easier, it is acceptable to install the chord in two pieces using a splice as

defined in Drawing 141U0044 in accordance with Service Bulletin 747-53A2429.

(g) Fastener holes may be oversized up to 1/32 inch to correct damage or misalignment. If more than 1/32

inch oversize is necessary, contact Boeing.

FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA 500,

STA 520)

(SHEET 3 OF 4)

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ALERT ALERT
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(h) Make sure a minimum edge margin of 1.7D is maintained, in both floor beam and body frame.

(i) Install bolts common to the upper chord wet using BMS 5-95 sealant. Refer to SOPM 20-50-19 as an

accepted procedure.

FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA 500,

STA 520)

(SHEET 4 OF 4)

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FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS (STA 340 - STA 440, STA

500, STA 520)

(SHEET 1 OF 2)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Upper Deck Floor Pan- - - (a)

el

1 Install (Kept)

Personnel Accommoda- - - (b)

tions Area Floor Covering

2 Install (Kept)

3 Install (Kept) Lavatory - 1 (c)

Flight Compartment - - (d)

Floor Covering

4 Install (Kept)

5 Install (Kept) Observer's Seat - 2 (e)

6 Install (Kept) Flight Engineer's Seat - 1 (f)

(a) Refer to 747-100/200/300 AMM 53-21-02 as an accepted procedure.

(b) Refer to 747-100/200/300 AMM 25-16-02 as an accepted procedure.

(c) Refer to 747-100/200/300 AMM 25-40-03 as an accepted procedure.

(d) Refer to 747-100/200/300 AMM 25-16-01 as an accepted procedure

(e) Refer to 747-100/200/300 AMM 25-11-03 as an accepted procedure.

(f) Refer to 747-100/200/300 AMM 25-11-02 as an accepted procedure.

FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS (STA 340 - STA 440, STA

500, STA 520)

(SHEET 2 OF 2)

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FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780)

(SHEET 1 OF 3)

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FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780)

(SHEET 2 OF 3)

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ALERT ALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME STA IDENTIFICATION QTY MORE DATA

CAUTION: DO NOT REMOVE ADJACENT FLOOR BEAM UPPER CHORDS AT THE SAME TIME. IF

ADJACENT FLOOR BEAM UPPER CHORDS ARE REMOVED AT THE SAME TIME, DAMAGE

TO THE AIRPLANE STRUCTURE MAY OCCUR.

1 Remove Upper Chord 540 65B38517-3 1 (a) (b) (c)

560 65B38518-3 1 (a) (b)

580 65B38519-3 1 (a) (b)

600 65B38520-3 1 (a) (b)

620 65B38521-3 1 (a) (b)

640 65B38522-3 1 (a) (b)

660 65B38523-3 1 (a) (b)

680 65B38524-3 1 (a) (b)

700 65B38525-3 1 (a) (b)

720 65B38526-3 1 (a) (b)

740 65B38527-3 or 65B38527-603 1 (a) (b)

760 65B17358-3 1 (a) (b) (e)

780 65B17359-3 1 (a) (b) (e)

Upper Chord - Left 540 65B38517-604 1 (d)

Side

Remove

Upper Chord - Right 540 65B38517-603 1 (d)

Side

Splice Plate 540 65B38517-600 1 (d)

Splice Angle 540 65B38517-601 1 (d)

Stiffener 540 65B38517-602 1 (d)

(a) Keep the existing parts to use as a guide when making the new parts and for profiling the chord to frame

attachment.

(b) Any other parts not listed that are removed during the chord removal should be kept for re-installation.

(c) All affected airplanes, except RR341 - RR343.

(d) RR341 - RR343.

(e) Group 2 only.

FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780)

(SHEET 3 OF 3)

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ALERT ALERT
FIGURE 8: UPPER DECK FLOOR BEAMS - HOLE INSPECTION

(SHEET 1 OF 2)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fastener Holes - - in floor beam webs. (a)

This step not shown on

the illustration. Inspect

the fastener holes in

frames. (b)

2 Inspect Fastener Holes - -

(a) Do a High Frequency Eddy Current (HFEC) open hole inspection at all locations in the floor beam

webs where fasteners were removed to remove the upper chords (STA 540 through STA 740 for

Group 1 airplanes; STA 540 through STA 780 for Group 2 airplanes). Do this inspection for cracks in

accordance with 747 NDT, Part 6, 51-00-00 Figure 16.

(b) Do a High Frequency Eddy Current (HFEC) open hole inspection at all locations in the frames where

fasteners were removed to remove the upper chords (STA 540 through STA 740 for Group 1 airplanes;

STA 540 through STA 780 for Group 2 airplanes). Do this inspection for cracks in accordance with

747 NDT, Part 6, 51-00-00 Figure 16.

FIGURE 8: UPPER DECK FLOOR BEAMS - HOLE INSPECTION

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FIGURE 9: UPPER DECK FLOOR BEAM - UPPER CHORDS - FABRICATION (STA 540 - STA 780)

(SHEET 1 OF 2)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Make Upper Chords - 11 (a) (d)

Make Upper Chords - 13 (a) (e)

Chemical Conversion Type 2, Class A - (b)

Coating

2 Apply

3 Apply Primer BMS 10-11, Type 1 - (c)

(a) Refer to Appendix B for the applicable parts and fabrication requirements. Use the existing parts as a guide

and to match the profile of existing chord to frame attachment.

(b) Apply one coat of chemical conversion coating.

(c) Apply two coats of BMS 10-11, Type 1 primer.

(d) Group 1 only.

(e) Group 2 only.

FIGURE 9: UPPER DECK FLOOR BEAM - UPPER CHORDS - FABRICATION (STA 540 - STA 780)

(SHEET 2 OF 2)

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FIGURE 10: UPPER DECK FLOOR BEAM - UPPER CHORDS - INSTALLATION (STA 540 - STA 780)

(SHEET 1 OF 2)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Install Upper Chord - 11 (a) (b) (c) (d) (e) (f)

Install Upper Chord - 13 (a) (b) (c) (d) (e) (g)

(a) To install new floor beam, refer to the initial production drawings.

(b) Refer to Appendix B for fastener and installation requirements.

(c) Fastener holes may be oversized up to 1/32 inch to correct damage or misalignment. If more than 1/32

inch oversize is necessary, contact Boeing.

(d) Make sure a minimum edge margin of 1.7D is maintained, in both floor beam and body frame.

(e) Install bolts common to the upper chord wet using BMS 5-95 sealant. Refer to SOPM 20-50-19 as an

accepted procedure.

(f) Group 1 only.

(g) Group 2 only.

FIGURE 10: UPPER DECK FLOOR BEAM - UPPER CHORDS - INSTALLATION (STA 540 - STA 780)

(SHEET 2 OF 2)

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ALERT ALERT
The tables below define the parts to be replaced and the material used to make replacement parts. Use the

drawing numbers listed for fabrication, installation and fastener requirements. Use the material specified in the

tables below to make the replacement parts provided a minimum edge margin of 1.7D can be maintained. If

edge margin is below 1.7D, contact Boeing for instructions.

TABLE 1: STATION 340 FLOOR BEAM INSTALLATION - DRAWING 65B10927

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord Left Strap Right Strap

sic Numbers)

1, 4, PL, -503 Production -16 -19 -20

PSDL

All affected airplanes.

(a) (b) (c)

(a) Make equivalent replacement part from AND10136-2006 x 152.9 inches 7075-T6511.

(b) Make equivalent replacement part from BAC1512-3341 x 22.3 inches 2024-T3511.

(c) Make equivalent replacement part from BAC1512-3341 x 23.1 inches 2024-T3511.

TABLE 2: STATION 360 FLOOR BEAM INSTALLATION - DRAWING 65B10928

Airplane Effectivity (Basic Sheet Installation Part Usage Upper Chord Left Strap Right Strap

Numbers)

1, 4, 7, -511, -97 Production -40 -42 -43

PL, PSDL

All affected airplanes.

(a) (b) (c)

(a) Make equivalent replacement part from AND10136-2402 x 163.7 inches 7075-T6511.

(b) Make equivalent replacement part from BAC1512-3361 x 26.0 inches 2024-T3511.

(c) Make equivalent replacement part from BAC1512-3361 x 29.5 inches 2024-T3511.

TABLE 3: STATION 380 FLOOR BEAM INSTALLATION - DRAWING 65B10929

Upper Left Strap Right Strap

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

-65, -109, - Production -518 -537 -566

158, -514

1, 4, 5,

9 PL,

PSDL

All affected airplanes.

(a) (b) (c)

(a) Make equivalent replacement part from AND10136-2408 x 178.9 inches 7075-T6511.

(b) Make equivalent replacement part from 0.063 x 1.7 x 19.2 inches 7075-T6.

(c) Make equivalent replacement part from 0.063 x 1.7 x 20.3 inches 7075-T6.

Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA

520)

(SHEET 1 OF 4)

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TABLE 4: STATION 400 FLOOR BEAM INSTALLATION - DRAWING 65B10930

Left Right Angle

Strap/Angle

Upper

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

1, 3, 4, -61 Production -65 -66 -528

5, PL,

PSDL

R4103-R4105, R4107, R6002-

R6004, R6009-R6012, R6015,

R6101,R6106, R6110-R6111,

R6113-R6114, R6118-R6119,

R6122-R6123, R6125, R6133-

R6135, R6143

(a) (d) (d)

1, 4, 10, -163 Production -509 -525 -156

PL, PSDL

R6144-R6153, R6155-R6156

(a) (b) (c)

1, 4, 5, -204 Production -65 -66 -156

PL, PSDL

R4108, R6154, R6157

(a) (d) (c)

1, 4, 10, -504 Production -509 -525 -528

PL, PSDL

R4005-R4102, R4106, R6001,

R6005-R6008, R6013-R6014,

R6016, R6102-R6105, R6107-

R6109, R6112, R6115-R6117,

R6120-R6121, R6124, R6126-

R6132, R6136-R6142

(a) (b) (d)

(a) Make equivalent replacement part from BAC1505-100365 x 180.5 inches 7075-T6511.

(b) Make equivalent replacement part from BAC1512-3341 x 18 inches 7075-T6511.

(c) Make equivalent replacement part from BAC1490-2570 x 22.5 inches 7075-T6.

(d) Make equivalent replacement part from BAC1490-2570 x 18.0 inches 7075-T6.

TABLE 5: STATION 420 FLOOR BEAM INSTALLATION - DRAWING 65B10931

Upper Left Strap Right Strap

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

1, 3, 4, -60, -238 Production -64 -65 -511

5 PL,

PSDL

R4103-R4105, R4107- R4108,

R6002-R6004, R6009-R6012,

R6015, R6101, R6106, R6110-

R6111, R6113-R6114, R6118-

R6119, R6122-R6123, R6125,

R6133-R6135, R6143,R6154,

R6157

(a) (b) (c)

Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA

520)

(SHEET 2 OF 4)

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TABLE 5: STATION 420 FLOOR BEAM INSTALLATION - DRAWING 65B10931

Upper Left Strap Right Strap

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

1, 4, 10 -186, -503 Production -508 -531 -511

PL, PSDL

R4005-R4102, R4106, R6001,

R6005-R6008, R6013-R6014,

R6016, R6102-R6105, R6107-

R6109, R6112, R6115-R6117,

R6120-R6121, R6124, R6126-

R6132, R6136-R6142, R6144-

R6153, R6155-R6156

(a) (b) (c)

(a) Make equivalent replacement part from AND10136-2008 x 185.3 inches 7075-T6511.

(b) Make equivalent replacement part from BAC1512-335 x 18.3 inches 7075-T6511.

(c) Make equivalent replacement part from BAC1512-3341 x 15.7 inches 7075-T6511.

TABLE 6: STATION 440 FLOOR BEAM INSTALLATION - DRAWING 65B10932

Aft Radius

Filler

Fwd Radius

Filler

Right

Strap

Left

Strap

Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

1, 4, 5, -157, -503 Production -508 -513 -514 -516 -515

PL,

PSDL

R4005-R4009, R4101-

R4108 (a) (b) (b) (c) (d)

1, 4, 5, -157, -503 Production -541 -513 -514 -516 -515

11,

PL,

PSDL

R6001-R6016, R6101-

R6157 (a) (b) (b) (c) (d)

(a) Make equivalent replacement part from AND10136-3006 x 191.5 inches 7075-T6511.

(b) Make equivalent replacement part from 0.156 x 2.2 x 17.4 inches 7075-T6.

(c) Make equivalent replacement part from BAC1511-1618 x 191.5 inches 7075-T6511.

(d) Make equivalent replacement part from BAC1511-1618 x 178.7 inches 7075-T6511.

TABLE 7: STATION 500 FLOOR BEAM INSTALLATION - DRAWING 65B10935

Right

Strap/Angle

Left

Strap/Angle

Right

Upper

Chord

Left Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

-140, -142, - Production -506 -144 -145 -146

191, -195

1, 3,

4, 10,

PL,

PSDL

R4108, R6144-

R6157 (a) (a) (b) (c)

Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA

520)

(SHEET 3 OF 4)

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TABLE 7: STATION 500 FLOOR BEAM INSTALLATION - DRAWING 65B10935

Right

Strap/Angle

Left

Strap/Angle

Right

Upper

Chord

Left Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

-115, -502, - Production -506 -507 -515 -516

503, -65

3, 4,

PL,

PSDL

R4005-R4107,

R6001-R6143 (a) (a) (d) (d)

(a) Make equivalent replacement part from BAC1505-100300 x 66.0 inches 7075-T6511.

(b) Make equivalent replacement part from BAC1503-100333 x 33.3 inches 7075-T73511.

(c) Make equivalent replacement part from BAC1503-100133 x 30.6 inches 7075-T73511.

(d) Make equivalent replacement part from 0.125 x 2.0 x 18.3 inches 7075-T6.

TABLE 8: STATION 520 FLOOR BEAM INSTALLATION - DRAWING 65B10936

Aft Radius

Filler

Fwd

Radius

Filler

Right

Strap

Left

Strap

Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

1, 5, -131 Production -147 -133 -132 -524 -523

PL,

PSDL

R6144-R6157

(d) (b) (b) (c) (c)

1, 4, -134 Production -146 -133 -132 -509 -508

PL,

PSDL

R4108

(a) (b) (b) (c) (c)

1, 4, -501 Production -507 -511 -512 -509 -508

12,

PL,

PSDL

R4001-R4107

(a) (b) (b) (c) (c)

1, 5, -518 Production -525 -511 -512 -524 -523

12,

PL,

PSDL

R6001-R6143

(d) (b) (b) (c) (c)

(a) Make equivalent replacement part from AND10136-3005 x 203.0 inches 7075-T6511.

(b) Make equivalent replacement part from 0.125 x 2.1 x 15.5 inches 7075-T6.

(c) Make equivalent replacement part from BAC1512-3410 x 203.0 inches 7075-T6511.

(d) Make equivalent replacement part from AND10136-3005 x 203.9 inches 7075-T6511.

Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA

520)

(SHEET 4 OF 4)

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ALERT ALERT
The tables below define the parts to be replaced and the material used to make replacement parts. Use the

drawing numbers listed for fabrication, installation and fastener requirements. Use the material specified in the

tables below to make the replacement parts provided a minimum edge margin of 1.7D can be maintained. If

edge margin is below 1.7D, contact Boeing for instructions.

TABLE 1: STATION 540 FLOOR BEAM INSTALLATION - DRAWING 65B38517

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

-1, -309, - Production -3

35, -37

2, 3, 4,

5, 6, 7,

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 202.1 inches.

Material and Temper = 2024-T3511.

TABLE 2: STATION 560 FLOOR BEAM INSTALLATION - DRAWING 65B38518

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -9 Production -3

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 203.4 inches.

Material and Temper = 2024-T3511.

TABLE 3: STATION 580 FLOOR BEAM INSTALLATION - DRAWING 65B38519

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -8 Production -3

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 204.3 inches.

Material and Temper = 2024-T3511.

TABLE 4: STATION 600 FLOOR BEAM INSTALLATION - DRAWING 65B38520

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -11 Production -3

PL, PSDL

All affected airplanes.

(a)

APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780)

(SHEET 1 OF 4)

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TABLE 4: STATION 600 FLOOR BEAM INSTALLATION - DRAWING 65B38520

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

(a) Make equivalent replacement part from BAC1505-101034 X 205.1 inches.

Material and Temper = 2024-T3511.

TABLE 5: STATION 620 FLOOR BEAM INSTALLATION - DRAWING 65B38521

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -7 Production -3

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 205.6 inches.

Material and Temper = 2024-T3511.

TABLE 6: STATION 640 FLOOR BEAM INSTALLATION - DRAWING 65B38522

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -7 Production -3

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 205.7 inches.

Material and Temper = 2024-T3511.

TABLE 7: STATION 660 FLOOR BEAM INSTALLATION - DRAWING 65B38523

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -9 Production -3

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 205.5 inches.

Material and Temper = 2024-T3511.

APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780)

(SHEET 2 OF 4)

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TABLE 8: STATION 680 FLOOR BEAM INSTALLATION - DRAWING 65B38524

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -7 Production -3

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 205.3 inches.

Material and Temper = 2024-T3511.

TABLE 9: STATION 700 FLOOR BEAM INSTALLATION - DRAWING 65B38525

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

2, 3, 4, -1, -7 Production -3

PL, PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 204.6 inches.

Material and Temper = 2024-T3511.

TABLE 10: STATION 720 FLOOR BEAM INSTALLATION - DRAWING 65B38526

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

1, 2, 3, -1, -7 Production -3

4, PL,

PSDL

All affected airplanes.

(a)

(a) Make equivalent replacement part from BAC1505-101034 X 204.2 inches.

Material and Temper = 2024-T3511.

TABLE 11: STATION 740 FLOOR BEAM INSTALLATION - DRAWING 65B38527

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

1, 2, 3, -1 Production -3

PL, PSDL

R6001-R6016, R6101-

R6157 (a)

1, 4, 5, -601 Production -603

PL, PSDL

R4005-R4009, R4101-

R4108 (b)

(a) Make equivalent replacement part from BAC1505-101034 X 203.9 inches.

Material and Temper = 2024-T3511.

APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780)

(SHEET 3 OF 4)

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TABLE 11: STATION 740 FLOOR BEAM INSTALLATION - DRAWING 65B38527

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

(b) Make equivalent replacement part from BAC1505-101034 X 210.0 inches.

Material and Temper = 2024-T3511.

TABLE 12: STATION 760 FLOOR BEAM INSTALLATION - DRAWING 65B17358 (Group 2

only)

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

1, 2, 3, -1 Production -3

PL, PSDL

R4005-R4009, R4101-

R4108 (a)

(a) Make equivalent replacement part from BAC1505-101034 X 203.3 inches.

Material and Temper = 2024-T3511.

TABLE 13: STATION 780 FLOOR BEAM INSTALLATION - DRAWING 65B17359 (Group 2

only)

Airplane Effectivity (Ba- Sheet Installation Part Usage Upper Chord

sic Numbers)

1, 2, 3, -1 Production -3

PL, PSDL

R4005-R4009, R4101-

R4108 (a)

(a) Make equivalent replacement part from BAC1505-101034 X 201.5 inches.

Material and Temper = 2024-T3511.

APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780)

(SHEET 4 OF 4)

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ALERT ALERT
Original production fastener codes and part numbers are replaced with nominal or oversize repair fasteners as

shown in the table below.

FASTENER REPLACEMENT GUIDE

Fastener Code Part Number FASTENER

LOCATION Production Nominal Oversize Production Nominal Oversize

XCZ5 YTV5H YTV6 BACB30FM5* BACB30VT5HK* BACB30VT6K*

SIDE OF

CHORD

BACC30M5 BACC30BL5 BACC30BL6

XCZ6 YTV6 ZWG6 BACB30FM6* BACB30VT6K* BACB30NX6K*X

BACC30M6 BACC30BL6 BACC30BH6

XEP5 YYT5 YYT6 BACB30DX5* BACB30NX5HK* BACB30NX6K*

NAS1080 BACC30BH5 BACC30BH6

XEP6 YYT6 ZWG6 BACB30DX6* BACB30NX6K* BACB30NX6K*X

NAS1080 BACC30BH6 BACC30BH6

XMX6 YYT6 ZWG6 BACB30MB6* BACB30NX6K* BACB30NX6K*X

BACC30X6 BACC30BH6 BACC30BH6

XTJ8 YHY8 YLC8 BACB30MY8C* BACB30MY8K* BACB30MY8K*X

BACC30M8 BACC30M8 BACC30M8

XDA6 YJA YLE BACB30FN6* BACB30NW6K* BACB30NW6K*X

BACC30M6 BACC30M6 BACC30M6

YAX6 YJJ - BACB30MY6C* BACB30MY6K* BACB30NX6K*X

(a) (a)

BACC30BH6 +

BACW10CA104CC

+

BACW10CA31PV

BACC30AG6

(a)

BACC30AG6

(a)

XZK5 ZGY5 ZGY6 BACR15BB5D* BACR15BB5D*C BACR15BB6D*C

XZK6 ZGY6 ZGY7 BACR15BB6D* BACR15BB6D*C BACR15BB7D*C

XF5 ZSE5 ZSE6 BACR15CE5D* BACR15GF5D* BACR15GF6D*

APPENDIX C: SECTION 42 - FASTENER REPLACEMENT GUIDE

(SHEET 1 OF 2)

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FASTENER REPLACEMENT GUIDE

Fastener Code Part Number FASTENER

LOCATION Production Nominal Oversize Production Nominal Oversize

TOP OF XCZ6 YTV6 ZWG6 BACB30FM6* BACB30VT6K* BACB30NX6K*X

CHORD BACC30M6 BACC30BL6 BACC30BH6

XTJ8 YHY8 YLC8 BACB30MY8C* BACB30MY8K* BACB30MY8K*X

BACC30M8 BACC30M8 BACC30M8

XZG3 ZHD3 ZHD4 BACR15BA3D* BACR15BA3D*C BACR15BA4D*C

XZG5 ZHD5 ZHD6 BACR15BA5D* BACR15BA5D*C BACR15BA6D*C

YAY6 YJK6 YUG6 BACB30NW6C* BACB30NW6K* BACB30NW6K*X

(a) (a)

BACC30AG6 BACC30AG6 BACC30AG6

(a) (a)

YAY8 YJK8 YUG8 BACB30NW8C* BACB30NW8K* BACB30NW8K*X

(a) (a)

BACC30AG8 BACC30AG8 BACC30AG8

(a) (a)

(a) Only needed if spliced configuration is re-installed on RR341 - RR343 at STA 540.

APPENDIX C: SECTION 42 - FASTENER REPLACEMENT GUIDE

(SHEET 2 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: October 16, 2008

Revision 1 April 12, 2012 747-53A2696

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