### 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.9E991 ECCN: 

## 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 Unpublished Work.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, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management Company.

Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 1 of 101 5.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 2 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**

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 OFHOLES 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 3 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 4 of 101 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 5 of 1016. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 6 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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** October 16, 2008 Original Issue: April 12, 2012 Revision 1:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 7 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 8 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**

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### 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 9 of 101Subsequent 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.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Compliance Yes AD Related Paragraph 1.H., Weight and Balance Changes Yes Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Boeing supplied Kits/Parts Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts and Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 10 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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**  **Elapsed Hours Total Task Hours**  **Airplanes** 135.25 541.00 Group 1 and 2 **Work Package 2 Elapsed Hours**  **Total Task Hours Airplanes**  100.00 400.00 Group 1 115.81 463.25 Group 2
**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 11 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 12 of 101 **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.
**DESCRIPTION CONFIGURATION**  **GROUP** All 747-200F airplanes.

- 1 All 747-200C airplanes.

- 2

Airplane Models: 747-200C, 747-200F **Group Variable Number** 2 RJ131 - RJ133 2 RJ151 - RJ152 2 RJ301 - RJ303 2 RJ321 - RJ322 2 RJ331 - RJ333

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 13 of 101**Group Variable Number** 1 RR001 - RR0051 RR021 - RR0251 RR031 1 RR201 - RR2061 RR221 - RR2261 RR261 - RR2671 RR301 - RR3101 RR331 - RR3321 RR336 1 RR341 - RR3451 RR361 - RR3621 RR421 - RR4221 RR431 - RR4321 RR441 - RR4421 RR451 1 RR501 - RR5041 RR521 - RR5221 RR526 1 RR531 1 RR551 - RR5561 RR561 1 RR566 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 14 of 101 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 15 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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 Zone**  **Model** 221, 222, 223, 224, 225, 226, 233, 234 747-200F **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 221, 222, 223, 224, 225, 226, 233, 234 747-200C **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**  **Compliance Time (Whichever Occurs Later) Action**  **Condition** 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 520for cracks in accordance with the Accomplishment Instructions, Paragraph 3.B, Part 2. All airplanes

- Before further flight Contact Boeing for repair instructions and do the repair. Any crack found

- Immediately after the in- spection in accordance with the Accomplishment Instructions, Paragraph3.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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 16 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Table 1: Upper Deck Floor beam - Upper Chord Replacement -** **Section 41 Compliance Time (Whichever Occurs Later)**  **Action Condition**  (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)**  **Compliance Time Action**  **Condition**

- Within 15,000 flight cycles afterupper chord replacement in accordance with this service bulletin. Do detailed and HFEC inspections of the replaced upper deck floorbeam chords for cracks in accordance with the Accomplishment Instructions, paragraph 3.B, Part 4.Upper chord replacement hasbeen accomplished

- Before further flight. Contact Boeing for repair instruc- tions and do the repair. Any crack is found. 3,000 flight cycles.

- Repeat the detailed and HFEC in- spections of the replaced upper deck floor beam chords for cracksin accordance with the Accomplishment Instructions, paragraph 3.B, Part 4. No crack is found.

- Within 5,000 flight cycles after theinitial 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 accordancewith 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 Compliance Time (Whichever Occurs Later)**  **Action Condition**  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 540through STA 740 for cracks in accordance with the Accomplishment Instructions, paragraph 3.B, Part 7. All airplanes

- Before further flight Contact Boeing for repair instructions and do the repair. Any crack found

- Immediately after the in- spection in accordance with the Accomplishment Instructions paragraph3.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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 17 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Group 1:**  **Table 3: Upper Deck Floor beam - Upper Chord Replacement - Section 42**  **Compliance Time (Whichever Occurs Later) Action**  **Condition** (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 Compliance Time (Whichever Occurs Later)**  **Action Condition**  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 540through STA 780 for cracks in accordance with the Accomplishment Instructions, paragraph 3.B, Part 7. All airplanes

- Before further flight Contact Boeing for repair instructions and do the repair. Any crack found

- Immediately after the in- spection in accordance with the Accomplishment Instructions, paragraph3.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)**  **Compliance Time Action**  **Condition**

- Within 20,000 flight cycles afterupper 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 hasbeen accomplished

- Before further flight. Contact Boeing for repair instruc- tions and do the repair. Any crack is found.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 18 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Table 5: Post-Upper Chord Replacement Actions -** **Section 42 Repeat Interval**  **(Not to Exceed) Compliance Time**  **Action Condition**  6,000 flight cycles.

- Repeat the HFEC inspections of the 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 afterthe initial detailed and HFEC inspection was done in accordancewith the Accomplishment Instructions, paragraph 3.B, Part 9.Do the inspection and chord replacement actions again, in accordancewith 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 19 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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)**  **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task**

15.00 60.00 4 Open Access 7.75 31.00 4 Figure 1 27.75 111.00 4 Figure 2 10.50 42.00 4 Figure 3

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 20 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Table 1: Upper Deck Floor Beam Upper Chord Replacement at STA 340 - STA 440, STA**  **500, and STA 520 (Work Package 1) Elapsed Hours**  **Task Hours Number of Per-**  **sons Task**  (a) (a)

- Figure 4 51.50 206.00 4 Figure 5 7.75 31.00 4 Figure 6 15.00 60.00 4 Close Access (b) (b)

- Test 135.25 541.00 TOTAL FOR EACH AIRPLANE (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) Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 

6.31 25.25 4 Access 35.75 143.00 4 Figure 7 - Removal 14.50 58.00 4 Figure 8 - Inspec- tion (a) (a)

- Figure 9 - Fabrica- tion 37.13 148.50 4 Figure 10 - Installa- tion 6.31 25.25 4 Close Access 100.00 400.00 TOTAL FOR EACH AIRPLANE (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) Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 

6.31 25.25 4 Access 42.25 169.00 4 Figure 7 - Removal

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 21 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Group 2:**  **Table 3: Upper Deck Floor Beam Upper Chord Replacement at STA 540 - STA 780 (Work Package 2)**  **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task**

17.06 68.25 4 Figure 8 - Inspec- tion (a) (a)

- Figure 9 - Fabrica- tion 43.88 175.50 4 Figure 10 - Installa- tion 6.31 25.25 4 Close Access 115.81 463.25 TOTAL FOR EACH AIRPLANE (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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 22 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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:
**Title Drawing Number** SHEAR TIE INSTL - CREW FLOOR, STA 330 TO STA 520 65B07966 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 340 65B10927 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 360 65B10928 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 380 65B10929 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 400 65B10930 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 420 65B10931 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 440 65B10932 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 500 65B10935 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 520 65B10936 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 540 65B38517 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 560 65B38518 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 580 65B38519 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 600 65B38520 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 620 65B38521 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 640 65B38522 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 660 65B38523 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 680 65B38524 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 700 65B38525 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 720 65B38526 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 740 65B38527 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 760 65B17358 FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 780 65B17359

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 23 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 24 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10927-16 Chord-Upper (STA 340) 1 65B10927-16 (b) (c) 65B10927-19 Radius Filler L/H (STA 340) 1 65B10927-19 (b) (c) 65B10927-20 Radius Filler R/H (STA 340) 1 65B10927-20 (d) (e)

- Bolt 2 BACB30MC6A3 (d) (e)

- Bolt 15 BACB30MC6A4 (d) (e)

- Bolt 35 BACB30MC6A5 (d) (e)

- Bolt 15 BACB30MC6A6 (d) (e)

- Bolt 4 BACB30MC6A7

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 25 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 340** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 2 BACB30MC6A9 (d) (e)

- Bolt 1 BACB30FQ6A3 (d) (e)

- Bolt 1 BACB30FQ6A9 (d)

- Collar 73 BACC30M6 (d) (e)

- Rivet 4 BACR15BA6D5C or BACR15BA7D5C (d) (e)

- Rivet 88 BACR15BB5D5C or BACR15BB6D5C (d) (e)

- Rivet 20 BACR15BB5D6C or BACR15BB6D6C (d) (e)

- Rivet 7 BACR15BB6D6C or BACR15BB7D6C (d) (e)

- Rivet 44 BACR15BB6D7C or BACR15BB7D7C (d) (e)

- Rivet 4 BACR15BB6D8C or BACR15BB7D8C (d) (e)

- Rivet 2 BACR15BB8D6C or BACR15BB9D6C (d) (e)

- Rivet 2 BACR15BB8D7C or BACR15BB9D7C (d) (e)

- Rivet 2 BACR15BB8D8C or BACR15BB9D8C (d) (e)

- Rivet 4 BACR15GF6D8C or BACR15GF61D8C (d) (e)

- Rivet 4 BACR15GF6D8C or BACR15GF61D8C (f)

- Chemical Conversion Coating 4 Ounces Type 2, Class A

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 26 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 340** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (g)

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

- Sealant 4 Ounces BMS 5-95, Class 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10928-40 Chord-Upper (STA 360) 1 65B10928-40 (b) (c) 65B10928-42 Radius Filler L/H (STA 360) 1 65B10928-42 (b) (c) 65B10928-43 Radius Filler R/H (STA 360) 1 65B10928-43 (d) (e)

- Bolt 2 BACB30MC6A3 (d) (e)

- Bolt 3 BACB30MC6A4 (d) (e)

- Bolt 12 BACB30MC6A5 (d) (e)

- Bolt 4 BACB30MC6A6 (d) (e)

- Bolt 2 BACB30MC6A7 (d) (e)

- Bolt 4 BACB30MC6A8 (d) (e)

- Bolt 2 BACB30MC6A10 (d) (e)

- Bolt 2 BACB30MC6A12 (d) (e)

- Bolt 8 BACB30NX6K5X (d) (e)

- Bolt 12 BACB30NX6K6X (d) (e)

- Bolt 6 BACB30NX6K7X (d) (e)

- Bolt 14 BACB30NX6K8X (d) (e)

- Bolt 6 BACB30NX6K9X (d)

- Collar 81 BACC30M6

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 27 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 360** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Rivet 70 BACR15BB5D5C or BACR15BB6D5C (d) (e)

- Rivet 70 BACR15BB5D6C or BACR15BB6D6C (d) (e)

- Rivet 9 BACR15BB5D7C or BACR15BB6D7C (d) (e)

- Rivet 6 BACR15GF6D8C or BACR15GF61D8C (f)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10929-518 Chord-Upper (STA 380) 1 65B10929-518 (b) (c) 65B10929-537 Radius Filler L/H (STA 380) 1 65B10929-537 (b) (c) 65B10929-566 Radius Filler R/H (STA 380) 1 65B10929-566 (d) (e)

- Bolt 1 BACB30FM6A7 (d) (e)

- Bolt 2 BACB30MC6A3 (d) (e)

- Bolt 16 BACB30MC6A4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 28 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 380** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 18 BACB30MC6A5 (d) (e)

- Bolt 3 BACB30MC6A6 (d) (e)

- Bolt 7 BACB30MC6A7 (d) (e)

- Bolt 1 BACB30MC6A8 (d) (e)

- Bolt 2 BACB30NX6K8X (d)

- Collar 50 BACC30M6 (d) (e)

- Rivet 138 BACR15BB5D6C or BACR15BB6D6C (d) (e)

- Rivet 161 BACR15BB5D7C or BACR15BB6D7C (d) (e)

- Rivet 42 BACR15BB5D8C or BACR15BB6D8C (d) (e)

- Rivet 10 BACR15BB6D7C or BACR15BB7D7C (d) (e)

- Rivet 9 BACR15BB6D8C or BACR15BB7D8C (d) (e)

- Rivet 20 BACR15BB8D8C or BACR15BB9D8C (d) (e)

- Rivet 2 BACR15GF6D8C or BACR15GF61D8C (d) (e)

- Rivet 4 BACR15GF6D9C or BACR15GF61D9C (f)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 29 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 380** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10930-65 or 65B10930-509 Chord-Upper 1 65B10930-65 or 65B10930-509 (b) (c) 65B10930-66 or 65B10930-525 Radius Filler L/H 1 65B10930-66 or 65B10930-525 (b) (c) 65B10930-156 or 65B10930-528 Radius Filler R/H 1 65B10930-156 or 65B10930-528 (d) (e)

- Bolt 11 BACB30MC6A4 (d) (e)

- Bolt 14 BACB30MC6A5 (d) (e)

- Bolt 5 BACB30MC6A6 (d) (e)

- Bolt 2 BACB30MC6A7 (d) (e)

- Bolt 1 BACB30MY6K6 (d) (e)

- Bolt 14 BACB30NX6K5X (d) (e)

- Bolt 3 BACB30NX6K6X (d) (e)

- Bolt 2 BACB30NX6K7X (d) (e)

- Bolt 9 BACB30MY8K4X (d) (e)

- Bolt 8 BACB30MY8K5X (d) (e)

- Bolt 2 BACB30NX8K7X (d) Collar 43 BACC30M6 (d)

- Collar 13 BACC30M8 (d) (e)

- Rivet 6 BACR15BA5D6C or BACR15BA6D6C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 30 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 400** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Rivet 1 BACR15BA6D7C or BACR15BA7D7C (d) (e)

- Rivet 134 BACR15BB5D5C or BACR15BB6D5C (d) (e)

- Rivet 14 BACR15BB5D6C or BACR15BB6D6C (d) (e)

- Rivet 2 BACR15BB5D7C or BACR15BB6D7C (d) (e)

- Rivet 35 BACR15BB6D7C or BACR15BB7D7C (d) (e)

- Rivet 8 BACR15BB8D6C or BACR15BB9D6C (d) (e)

- Rivet 2 BACR15BB8D8C or BACR15BB9D8C (d) (e)

- Rivet 18 BACR15BB8D9C or BACR15BB9D9C (d) (e)

- Rivet 6 BACR15GF6D8C or BACR15GF61D8C (f)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 747-53A2696 Revision 1: April 12, 2012 31 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 400** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B10931-64 or 65B10931-508 Chord-Upper 1 65B10931-64 or 65B10931-508 (a) (b) 65B10931-65 or 65B10931-531 Radius Filler L/H 1 65B10931-65 or 65B10931-531 (a) (b) 65B10931-511 Radius Filler R/H 1 65B10931-511 (c) (d)

- Bolt 6 BACB30NX6K3X (c) (d)

- Bolt 25 BACB30NX6K4X (c) (d)

- Bolt 20 BACB30NX6K5X (c) (d)

- Bolt 5 BACB30NX6K6X (c) (d)

- Bolt 1 BACB30NX6K7X (c) (d)

- Bolt 1 BACB30MY8K5X (c) (d)

- Bolt 2 BACB30MY8K6X (c) (d)

- Bolt 16 BACB30MY8K7X (c) (d)

- Bolt 1 BACB30MY8K10X (c) (d)

- Bolt 11 BACB30NW6K3X (c)

- Collar 2 BACC30BL8 (c)

- Collar 68 BACC30M6 (c)

- Collar 20 BACC30M8 (c) (d)

- Rivet 7 BACR15BB5D6C or BACR15BB6D6C (c) (d)

- Rivet 3 BACR15BB5D7C or BACR15BB6D7C (c) (d)

- Rivet 148 BACR15BB6D6C or BACR15BB7D6C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 32 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 420** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d)

- Rivet 9 BACR15BB8D6C or BACR15BB9D6C (c) (d)

- Rivet 1 BACR15BB8D7C or BACR15BB9D7C (c) (d)

- Rivet 50 BACR15BB6D7C or BACR15BB7D7C (c) (d)

- Rivet 4 BACR15GF6D8C or BACR15GF61D8C (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10932-508 or 65B10932-541 Chord-Upper 1 65B10932-508 or 65B10932-541 (b) (c) 65B10932-513 Radius Filler L/H 1 65B10932-513 (b) (c) 65B10932-514 Radius Filler R/H 1 65B10932-514 (a) (c) 65B10932-516 Radius Filler 1 65B10932-516 (a) (c) 65B10932-515 Radius Filler 1 65B10932-515 (d) (e)

- Bolt 2 BACB30MC6A6

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 33 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 440** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 2 BACB30MC6A7 (d) (e)

- Bolt 1 BACB30MC6A6 (d) (e)

- Bolt 1 BACB30MC6A8 (d) (e)

- Bolt 4 BACB30FQ6A8 (d) (e)

- Bolt 1 BACB30MC6A5 (d) (e)

- Bolt 4 BACB30MC6A7 (d) (e)

- Bolt 2 BACB30MC6A8 (d) (e)

- Bolt 71 BACB30NX6K5X (d) (e)

- Bolt 16 BACB30NX6K6X (d) (e)

- Bolt 21 BACB30NX6K7X (d) (e)

- Bolt 13 BACB30NX6K8X (d) (e)

- Bolt 2 BACB30NX6K10X (d) (e)

- Bolt 4 BACB30MY8K8X (d) (e)

- Bolt 12 BACB30MY8K9X (d) (e)

- Bolt 4 BACB30MY8K10X (d) (e)

- Bolt 2 BACB30MY8K11X (d) (e)

- Bolt 2 BACB30MY8K13X (d) (e)

- Bolt 2 BACB30NW8K8X (d) (e)

- Bolt 1 BACB30VN10K6 (d) (e)

- Bolt 1 BACB30VN10K8 (d) (e)

- Bolt 2 BACB30NW8K8X (d)

- Collar 7 BACC30BH6 (d)

- Collar 2 BACC30BK8 (d)

- Collar 2 BACC30BL8 (d)

- Collar 131 BACC30M6 (d)

- Collar 28 BACC30M8 (d) (e)

- Rivet 4 BACR15BB6D6C or BACR15BB7D6C (d) (e)

- Rivet 87 BACR15BB6D7C or BACR15BB7D7C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 34 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 440** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Rivet 21 BACR15BB6D8C or BACR15BB7D8C (d) (e)

- Rivet 4 BACR15BB6D9C or BACR15BB7D9C (d) (e)

- Rivet 1 BACR15BB6D10C or BACR15BB7D10C (f)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10935-144 or 65B10935-507 Chord-Upper R/H 1 65B10935-144 or 65B10935-507 (a) (c) 65B10935-506 Chord-Upper L/H 1 65B10935-506 (b) (c) 65B10935-515 or 65B10935-145 Reinforcement Angle Radius Filler L/H 1 65B10935-515 or 65B10935-145 (b) (c) 65B10935-146 or 65B10935-516 Reinforcement Angle Radius Filler R/H 1 65B10935-146 or 65B10935-516 (d) (e)

- Bolt 11 BACB30MC6A4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 35 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 500** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 19 BACB30MC6A5 (d) (e)

- Bolt 5 BACB30MC6A6 (d) (e)

- Bolt 4 BACB30MC6A7 (d) (e)

- Bolt 2 BACB30MC6A8 (d) (e)

- Bolt 1 BACB30MC6A9 (d) (e)

- Bolt 1 BACB30FP8A5 (d) (e)

- Bolt 4 BACB30FQ6A7 (d) (e)

- Bolt 20 BACB30MY8K7X (d) (e)

- Bolt 4 8BACB30MY8K8X (d) (e)

- Bolt 4 BACB30MY8K11X (d) (e)

- Bolt 2 BACB30NW8K7X (d) (e)

- Bolt 8 BACB30VN8K4 (d) (e)

- Bolt 2 BACB30VN8K6 (d) (e)

- Bolt 1 BACB30VN10K7 (d) (e)

- Bolt 2 BACB30NW8K7X (d)

- Collar 10 BACC30BK6 (d)

- Collar 1 BACC30BK8 (d)

- Collar 2 BACC30BL8 (d)

- Collar 46 BACC30M6 (d)

- Collar 31 BACC30M8 (d) (e)

- Rivet 2 BACR15BB5D6C or BACR15BB6D6C (d) (e)

- Rivet 42 BACR15BB5D7C or BACR15BB6D7C (d) (e)

- Rivet 24 BACR15BB5D8C or BACR15BB6D8C (d) (e)

- Rivet 42 BACR15BB6D8C or BACR15BB7D8C (d) (e)

- Rivet 5 BACR15BB6D10C or BACR15BB7D10C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 36 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 500** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Rivet 38 BACR15BB6D11C or BACR15BB7D11C (f)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10936-507 or 65B10936-525 or 65B10936-146 or 65B10936-147 Chord-Upper 1 65B10936-507 or 65B10936-525 or 65B10936-146 or 65B10936-147 (b) (c) 65B10936-511 or 65B10936-133 Radius Filler L/H 1 65B10936-511 or 65B10936-133 (b) (c) 65B10936-512 or 65B10936-132 Radius Filler R/H 1 65B10936-512 or 65B10936-132 (a) (c) 65B10936-509 or 65B10936-524 Strap 1 65B10936-509 or 65B10936-524

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 37 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 520** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10936-508 or 65B10936-523 Strap 1 65B10936-508 or 65B10936-523 (d) (e)

- Bolt 145 BACB30MC6A4 (d) (e)

- Bolt 29 BACB30MC6A5 (d) (e)

- Bolt 87 BACB30MC6A6 (d) (e)

- Bolt 2 BACB30MC6A7 (d) (e)

- Bolt 8 BACB30MC6A8 (d) (e)

- Bolt 1 BACB30FQ6A4 (d) (e)

- Bolt 4 BACB30FQ6A6 (d) (e)

- Bolt 1 BACB30MC6A7 (d) (e)

- Bolt 3 BACB30MC6A8 (d) (e)

- Bolt 8 BACB30MY10K8X (d) (e)

- Bolt 4 BACB30MY10K13X (d) (e)

- Bolt 1 BACB30NW8K8X (d) (e)

- Bolt 6 BACB30VN8K5 (d) (e)

- Bolt 2 BACB30VN8K7 (d) (e)

- Bolt 1 BACB30NW8K8X (d)

- Collar 4 BACC30BH6 (d)

- Collar 8 BACC30BK6 (d)

- Collar 1 BACC30BL8 (d)

- Collar 276 BACC30M6 (d)

- Collar 1 BACC30M8 (d)

- Collar 12 BACC30M10 (d) (e)

- Rivet 1 BACR15BB6D7C or BACR15BB7D7C (f)

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

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

- Sealant 4 Ounces BMS 5-95, Class B-1/2, -2, -4 (a) Fabricate from 7075-T6511 in accordance with APPENDIX A.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 38 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 520** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38517-3 Chord-Upper 1 65B38517-3 (c) (d) BACB30FM5* Bolt 5 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 14 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 3 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 28 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 12 BACB30NX6K6X (c) (d) BACB30DX6* Bolt 1 BACB30NX6K5X (c) (d) BACB30DX6* Bolt 1 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 4 BACB30MY8K7X (c) (d) BACB30MY8C* Bolt 4 BACB30MY8K9X (c) (d) BACR15BB5D* Rivet 124 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 153 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 18 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D8C or BACR15BB7D*C (c) (d) BACB30MY8C* Bolt 10 BACB30MY8K6X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 39 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 540** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D6C (c) (d) BACR15BA3D* Rivet 10 BACR15BA3D6C or BACR15BA4D7C (c) (g)

- Collar 66 BACC30BL6 (c) (g)

- Collar 46 BACC30BH6 (c)

- Collar 18 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38518-3 Chord-Upper 1 65B38518-3 (c) (d) BACB30FM5* Bolt 6 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 26 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 3 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 2 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 20 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 8 BACB30NX6K6X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 40 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 560** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACB30FM6 Bolt 4 BACB30NX6K7X (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K6X (c) (d) BACR15BB5D* Rivet 119 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 137 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 16 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D8C or BACR15BB7D*C (c) (d) BACB30MY8* Bolt 10 BACB30MY8K5X (c) (d) BACR15BA3D* Rivet 8 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 4 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 69 BACC30BL6 (c) (g)

- Collar 34 BACC30BH6 (c)

- Collar 18 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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 747-53A2696 Revision 1: April 12, 2012 41 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 560** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38519-3 Chord-Upper 1 65B38519-3 (c) (d) BACB30FM5* Bolt 7 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 25 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 4 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 20 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 10 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 16 BACB30MY8K6X (c) (d) BACR15BB5D* Rivet 125 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 136 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 15 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D8C or BACR15BB7D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 70 BACC30BL6 (c) (g)

- Collar 34 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

- Chemical Conversion Coating 4 Ounces Type 2, Class A

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 42 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 580** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (f)

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38520-3 Chord-Upper 1 65B38520-3 (c) (d) BACB30FM5* Bolt 19 BACB30VT6K5 (c) (d) BACB30FM6* Bolt 38 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 14 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 12 BACB30MY8K6X (c) (d) BACB30MY8C* Bolt 4 BACB30MY8K7X (c) (d) BACR15BB5D* Rivet 141 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 89 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 13 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 43 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 600** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 71 BACC30BL6 (c) (g)

- Collar 52 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38521-3 Chord-Upper 1 65B38521-3 (c) (d) BACB30FM5* Bolt 11 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 18 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 1 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 16 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 14 BACB30NX6K6X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 44 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 620** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACB30MY8C* Bolt 16 BACB30MY8K6X (c) (d) BACR15BB5D* Rivet 126 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 136 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 16 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D6C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D7C (c) (g)

- Collar 64 BACC30BL6 (c) (g)

- Collar 34 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 45 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 640** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38522-3 Chord-Upper 1 65B38522-3 (c) (d) BACB30FM5* Bolt 11 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 17 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 1 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 16 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 14 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 10 BACB30MY8K6X (c) (d) BACB30MY8C* Bolt 4 BACB30MY8K7X (c) (d) BACB30MY8C* Bolt 2 BACB30MY8K8X (c) (d) BACR15BB5D* Rivet 123 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 129 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 17 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACR15GF5D* Rivet 1 BACR15GF5D7 or BACR15GF6D* (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 63 BACC30BL6 (c) (g)

- Collar 34 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

- Chemical Conversion Coating 4 Ounces Type 2, Class A

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 46 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 640** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (f)

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38523-3 Chord-Upper 1 65B38523-3 (c) (d) BACB30FM5* Bolt 6 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 17 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 4 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 16 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 14 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 16 BACB30MY8K6X (c) (d) BACR15BA5D* Rivet 1 BACR15BA5D6C or BACR15BA6D*C (c) (d) BACR15BB5D* Rivet 125 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 149 BACR15BB5D7C or BACR15BB6D*C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 47 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 660** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACR15BB5D* Rivet 17 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 61 BACC30BL6 (c) (g)

- Collar 34 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38524-3 Chord-Upper 1 65B38524-3 (c) (d) BACB30FM5* Bolt 7 BACB30VT6K4

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 48 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 680** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACB30FM5* Bolt 24 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 4 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 20 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 10 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 12 BACB30MY8K6X (c) (d) BACB30MY8C* Bolt 4 BACB30MY8K7X (c) (d) BACR15BB5D* Rivet 126 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 135 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 16 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 69 BACC30BL6 (c) (g)

- Collar 34 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 747-53A2696 Revision 1: April 12, 2012 49 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 680** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must beoversized 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38525-3 Chord-Upper 1 65B38525-3 (c) (d) BACB30FM5* Bolt 6 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 17 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 16 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 6 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 20 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 16 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K6X (c) (d) BACR15BB5D* Rivet 122 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 136 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 17 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K5X (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 50 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 700** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 81 BACC30BL6 (c) (g)

- Collar 42 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38526-3 Chord-Upper 1 65B38526-3 (c) (d) BACB30FM5* Bolt 11 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 18 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 1 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 16 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 14 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 4 BACB30MY8K6X (c) (d) BACB30MY8C* Bolt 4 BACB30MY8K7X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 51 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 720** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACR15BB5D* Rivet 122 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 136 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 16 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K5X (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 64 BACC30BL6 (c) (g)

- Collar 34 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 52 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 740** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B38527-3 or 65B38527-603 Chord-Upper 1 65B38527-3 or 65B38527-603 (c) (d) BACB30FM5* Bolt 6 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 18 BACB30VT6K5 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X (c) (d) BACB30FM6* Bolt 16 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 6 BACB30NX6K6X (c) (d) BACB30DX6* Bolt 2 BACB30NX6K4X (c) (d) BACB30DX6* Bolt 10 BACB30NX6K5X (c) (d) BACB30DX6* Bolt 2 BACB30NX6K6X (c) (d) BACR15CE5D* Rivet 2 BACR15GF5D7 or BACR15GF6D7 (c) (d) BACR15CE5D* Rivet 2 BACR15GF5D8 or BACR15GF6D8 (c) (d) BACB30MB6* Bolt 2 BACB30NX6K6X (c) (d) BACB30MB6* Bolt 2 BACB30NX6K7X (c) (d) BACB30MY8C* Bolt 16 BACB30MY8K6X (c) (d) BACR15BA5D* Rivet 4 BACR15BA5D6C or BACR15BA6D*C (c) (d) BACR15BA5D* Rivet 5 BACR15BA5D7C or BACR15BA6D*C (c) (d) BACR15BB5D* Rivet 171 BACR15BB5D6C or BACR15BA6D*C (c) (d) BACR15BB5D* Rivet 112 BACR15BB5D7C or BACR15BA6D*C (c) (d) BACR15BB5D* Rivet 13 BACR15BB5D8C or BACR15BA6D*C (c) (d) BACR15BB6D* Rivet 3 BACR15BB6D8C or BACR15BB7D*C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 53 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Upper Deck Floor Beam Station (STA) 740** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 50 BACC30BL6 (c) (g)

- Collar 44 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B17358-3 Chord-Upper 1 65B17358-3 (c) (d) BACB30FM5* Bolt 6 BACB30VT6K4 (c) (d) BACB30FM5* Bolt 18 BACB30VT6K5 (c) (d) BACB30FM6* Bolt 4 BACB30NX6K4X

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 54 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Group 2:**  **Upper Deck Floor Beam Station (STA) 760**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACB30FM6* Bolt 16 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 4 BACB30NX6K6X (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K6X (c) (d) BACR15BB5D* Rivet 120 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 109 BACR15BB5D7C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 11 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 1 BACR15BB6D8C or BACR15BB7D*C (c) (d) BACR15BB6D* Rivet 2 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K5X (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 48 BACC30BL6 (c) (g)

- Collar 24 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 747-53A2696 Revision 1: April 12, 2012 55 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Group 2:**  **Upper Deck Floor Beam Station (STA) 760**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must beoversized 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** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B17359-3 Chord-Upper 1 65B17359-3 (c) (d) BACB30FM5* Bolt 1 BACB30VT6K5 (c) (d) BACB30FM5* Bolt 4 BACB30VT6K6 (c) (d) BACB30FM6* Bolt 14 BACB30NX6K5X (c) (d) BACB30FM6* Bolt 5 BACB30NX6K6X (c) (d) BACB30FN6* Bolt 1 BACB30NW6K6 (c) (d) BACB30DX5* Bolt 2 BACB30NX6K5 (c) (d) BACB30DX5* Bolt 14 BACB30NX6K5X (c) (d) BACB30DX5* Bolt 3 BACB30NX6K6X (c) (d) BACR15CE5D* Rivet 2 BACR15GF5D7 or BACR15GF6D7 (c) (d) BACR15CE5D* Rivet 3 BACR15GF5D8 or BACR15GF6D8 (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K6X (c) (d) BACR15BB5D* Rivet 74 BACR15BB5D6C or BACR15BB6D*C (c) (d) BACR15BB5D* Rivet 118 BACR15BB5D7C or BACR15BB6D*C

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 56 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Group 2:**  **Upper Deck Floor Beam Station (STA) 780**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d) BACR15BB5D* Rivet 15 BACR15BB5D8C or BACR15BB6D*C (c) (d) BACR15BB6D* Rivet 7 BACR15BB6D7C or BACR15BB7D*C (c) (d) BACR15BB6D* Rivet 18 BACR15BB6D8C or BACR15BB7D*C (c) (d) BACR15BB6D* Rivet 5 BACR15BB6D9C or BACR15BB7D*C (c) (d) BACB30MY8C* Bolt 8 BACB30MY8K5X (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D5C or BACR15BA4D*C (c) (d) BACR15BA3D* Rivet 6 BACR15BA3D6C or BACR15BA4D*C (c) (g)

- Collar 24 BACC30BL6 (c) (g)

- Collar 38 BACC30BH6 (c)

- Collar 16 BACC30M8 (e)

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

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

- Sealant 4 Ounces BMS 5-95, Class 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 beoversized 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 747-53A2696 Revision 1: April 12, 2012 57 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT Group 2:**  **Upper Deck Floor Beam Station (STA) 780**
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 58 of 101 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 59 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 60 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 61 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 62 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**(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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 63 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1: April 12, 2012 64 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS (STA 340 - STA 440, STA 500, STA**  **520) (SHEET 1 OF 2)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 65 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  as necessary. (a) 1

- Flight Engineer's Seat Remove/Keep 1 as necessary. (b) 2

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

- - Flight Compartment Floor Covering Remove/Keep 3 as necessary. (d) 1

- Lavatory Remove/Keep 4 as necessary. (e)

- - Personnel Accommoda-tions Area Floor Covering Remove/Keep 5

as necessary. (f)

- - Upper Deck Floor Pan- el Remove/Keep 6 (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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 66 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA**  **520) (SHEET 1 OF 5)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 67 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA**  **520) (SHEET 2 OF 5)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 68 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA**  **520) (SHEET 3 OF 5)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 69 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION STA**  **NAME TASK**  **STEP 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) (b) (c) 1 65B10927-16 340 Upper Chord Remove 1 (a) (b) (c) 1 65B10928-40 360 (a) (b) (c) 1 65B10929-518 380 (a) (b) (c) 1 65B10930-65 or -509 400 (a) (b) (c) 1 65B10931-64 or -508 420 (a) (b) (c) 1 65B10932-508 or -541 440 (a) (b) (c) 1 Left - 65B10935-506 500 (a) (b) (c) 1 Right - 65B10935-144 or -507 (a) (b) (c) 1 65B10936-146 or -147 or -507 or -525 520 (b) (c) 1 65B10927-19 340 Left Strap (b) (c) 1 65B10928-42 360 Left Strap (b) (c) 1 65B10929-537 380 Left Strap (b) (c) (d) 1 65B10930-525 or -66 400 Left Strap or Angle (b) (c) 1 65B10931-531 or -65 420 Left Strap (b) (c) 1 65B10932-513 440 Left Strap (b) (c) (d) 1 65B10935-515 or -145 500 Left Strap or Angle (b) (c) 1 65B10936-511 or -133 520 Left Strap (b) (c) 1 65B10927-20 340 Right Strap (b) (c) 1 65B10928-43 360 Right Strap (b) (c) 1 65B10929-566 380 Right Strap (b) (c) 1 65B10930-156 or -528 400 Right Angle (b) (c) 1 65B10931-511 420 Right Strap (b) (c) 1 65B10932-514 440 Right Strap (b) (c) (d) 1 65B10935-516 or -146 500 Right Strap or Angle (b) (c) 1 65B10936-512 or -132 520 Right Strap (b) (c) 1 65B10932-516 440 Fwd Radius Filler

**FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500, STA 520)**  **(SHEET 4 OF 5)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 70 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **STA NAME**  **TASK STEP**  Aft Radius Filler (b) (c) 1 65B10932-515 (b) (c) 1 65B10936-509 or -524 520 Fwd Radius Filler (b) (c) 1 65B10936-508 or -523 Aft Radius Filler (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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 71 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 72 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in floor beam webs.(a)

- - Fastener Holes Inspect 1 This step not shown on the illustration. Inspect the fastener holes in frames. (b) - - Fastener Holes Inspect 2

(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 allopen 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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 73 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA 500,**  **STA 520) (SHEET 1 OF 3)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 74 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA 500,**  **STA 520) (SHEET 2 OF 3)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 75 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (d) 9

- Upper Chord Make 1 (b) (d) 8

- Left Strap or Angle 8

- Right Strap or Angle (c) (d) 4

- Radius Filler (e)

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

- BMS 10-11, Type 1 Primer Apply 3 (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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 76 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA 500,**  **STA 520) (SHEET 1 OF 4)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 77 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA 500,**  **STA 520) (SHEET 2 OF 4)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 78 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b) (e) (f) (g) (h) (i) 9

- Upper Chord Install 1 (a) (c) (e) (g) (h) (i) 8

- Left Strap or Angle 8

- Right Strap or Angle (a) (d) (e) (g) (h) (i) 4

- Radius Filler (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 accomplishmentof 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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 79 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 80 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS (STA 340 - STA 440, STA**  **500, STA 520) (SHEET 1 OF 2)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 81 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a)

- - Upper Deck Floor Pan- el Install (Kept) 1 (b)

- - Personnel Accommoda-tions Area Floor Covering Install (Kept) 2

(c) 1

- Lavatory Install (Kept) 3 (d)

- - Flight Compartment Floor Covering Install (Kept) 4 (e) 2

- Observer's Seat Install (Kept) 5 (f) 1

- Flight Engineer's Seat Install (Kept) 6 (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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 82 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780)**  **(SHEET 1 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 83 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780)**  **(SHEET 2 OF 3)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 84 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION STA**  **NAME TASK**  **STEP 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) (b) (c) 1 65B38517-3 540 Upper Chord Remove 1 (a) (b) 1 65B38518-3 560 (a) (b) 1 65B38519-3 580 (a) (b) 1 65B38520-3 600 (a) (b) 1 65B38521-3 620 (a) (b) 1 65B38522-3 640 (a) (b) 1 65B38523-3 660 (a) (b) 1 65B38524-3 680 (a) (b) 1 65B38525-3 700 (a) (b) 1 65B38526-3 720 (a) (b) 1 65B38527-3 or 65B38527-603 740 (a) (b) (e) 1 65B17358-3 760 (a) (b) (e) 1 65B17359-3 780 (d) 1 65B38517-604 540 Upper Chord - Left Side Remove (d) 1 65B38517-603 540 Upper Chord - Right Side (d) 1 65B38517-600 540 Splice Plate (d) 1 65B38517-601 540 Splice Angle (d) 1 65B38517-602 540 Stiffener (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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 85 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 8: UPPER DECK FLOOR BEAMS - HOLE INSPECTION**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 86 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  in floor beam webs. (a)

- - Fastener Holes Inspect 1 This step not shown on the illustration. Inspect the fastener holes in frames. (b) - - Fastener Holes Inspect 2

(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 (SHEET 2 OF 2)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 87 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 9: UPPER DECK FLOOR BEAM - UPPER CHORDS - FABRICATION (STA 540 - STA 780)**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 88 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (d) 11

- Upper Chords Make 1 (a) (e) 13

- Upper Chords Make (b)

- Type 2, Class A Chemical Conversion Coating Apply 2 (c)

- BMS 10-11, Type 1 Primer Apply 3 (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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 89 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FIGURE 10: UPPER DECK FLOOR BEAM - UPPER CHORDS - INSTALLATION (STA 540 - STA 780)**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 90 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) (b) (c) (d) (e) (f) 11

- Upper Chord Install 1 (a) (b) (c) (d) (e) (g) 13

- Upper Chord Install (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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 91 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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 Right Strap**  **Left Strap Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -20 -19 -16 Production -503 1, 4, PL, PSDL All affected airplanes. (c) (b) (a) (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 Right Strap**  **Left Strap Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Basic**  **Numbers)** -43 -42 -40 Production -511, -97 1, 4, 7,PL, PSDL All affected airplanes. (c) (b) (a) (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 Right Strap**  **Left Strap Upper**  **Chord Parts Usage**  **Installation Sheet**  **Airplane Effectivity (Basic Numbers)**  -566 -537 -518 Production -65, -109, - 158, -514 1, 4, 5, 9 PL, PSDL All affected airplanes. (c) (b) (a) (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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 92 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT TABLE 4: STATION 400 FLOOR BEAM INSTALLATION - DRAWING 65B10930**  **Right Angle Left** **Strap/An gle**  **Upper Chord**  **Parts Usage Installation**  **Sheet Airplane Effectivity (Basic**  **Numbers)**

-528 -66 -65 Production -61 1, 3, 4, 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 (d) (d) (a)

-156 -525 -509 Production -163 1, 4, 10,PL, PSDL R6144-R6153, R6155-R6156 (c) (b) (a)

-156 -66 -65 Production -204 1, 4, 5,PL, PSDL R4108, R6154, R6157 (c) (d) (a)

-528 -525 -509 Production -504 1, 4, 10,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 (d) (b) (a)

(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 Right Strap**  **Left Strap Upper**  **Chord Parts Usage**  **Installation Sheet**  **Airplane Effectivity (Basic Numbers)**  -511 -65 -64 Production -60, -238 1, 3, 4, 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 (c) (b) (a)

**Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA 520)**  **(SHEET 2 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 93 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT TABLE 5: STATION 420 FLOOR BEAM INSTALLATION - DRAWING 65B10931**  **Right Strap Left Strap**  **Upper Chord**  **Parts Usage Installation**  **Sheet Airplane Effectivity (Basic**  **Numbers)** -511 -531 -508 Production -186, -503 1, 4, 10PL, 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 (c) (b) (a)

(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 Ra dius**  **Filler Fwd Ra**  **dius Filler**  **Right Strap**  **Left Strap**  **Upper Chord**  **Parts Usage Installation**  **Sheet Airplane Effectivity**  **(Basic Numbers)**

-515 -516 -514 -513 -508 Production -157, -503 1, 4, 5, PL, PSDL R4005-R4009, R4101- R4108 (d) (c) (b) (b) (a)

-515 -516 -514 -513 -541 Production -157, -503 1, 4, 5, 11, PL, PSDL R6001-R6016, R6101- R6157 (d) (c) (b) (b) (a)

(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/An gle**  **Right Upper**  **Chord Left Upper**  **Chord Parts Usage**  **Installation Sheet**  **Airplane Effectivity (Basic Numbers)** 

-146 -145 -144 -506 Production -140, -142, - 191, -195 1, 3, 4, 10, PL, PSDL R4108, R6144- R6157 (c) (b) (a) (a)

**Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA 520)**  **(SHEET 3 OF 4)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 94 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT TABLE 7: STATION 500 FLOOR BEAM INSTALLATION - DRAWING 65B10935**  **Right Strap/Angle**  **Left Strap/An**  **gle Right**  **Upper Chord**  **Left Upper Chord**  **Parts Usage Installation**  **Sheet Airplane Effectivity**  **(Basic Numbers)**

-516 -515 -507 -506 Production -115, -502, - 503, -65 3, 4, PL, PSDL R4005-R4107, R6001-R6143 (d) (d) (a) (a) (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 Ra dius**  **Filler Fwd**  **Radius Filler**  **Right Strap**  **Left Strap**  **Upper Chord**  **Parts Usage Installation**  **Sheet Airplane Effectivity**  **(Basic Numbers)**

-523 -524 -132 -133 -147 Production -131 1, 5, PL, PSDL R6144-R6157 (c) (c) (b) (b) (d)

-508 -509 -132 -133 -146 Production -134 1, 4, PL, PSDL R4108 (c) (c) (b) (b) (a)

-508 -509 -512 -511 -507 Production -501 1, 4, 12, PL, PSDL R4001-R4107 (c) (c) (b) (b) (a)

-523 -524 -512 -511 -525 Production -518 1, 5, 12, PL, PSDL R6001-R6143 (c) (c) (b) (b) (d)

(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)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 95 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -309, - 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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -9 2, 3, 4,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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -8 2, 3, 4,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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -11 2, 3, 4,PL, PSDL All affected airplanes. (a)

**APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780) (SHEET 1 OF 4)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 96 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT TABLE 4: STATION 600 FLOOR BEAM INSTALLATION - DRAWING 65B38520**  **Upper Chord Part Usage**  **Installation Sheet**  **Airplane Effectivity (Ba- 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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -7 2, 3, 4,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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -7 2, 3, 4,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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -9 2, 3, 4,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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 97 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT TABLE 8: STATION 680 FLOOR BEAM INSTALLATION - DRAWING 65B38524**  **Upper Chord Part Usage**  **Installation Sheet**  **Airplane Effectivity (Ba- sic Numbers)**  -3 Production -1, -7 2, 3, 4,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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -7 2, 3, 4,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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1, -7 1, 2, 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 Upper Chord**  **Part Usage Installation**  **Sheet Airplane Effectivity (Ba-**  **sic Numbers)** -3 Production -1 1, 2, 3,PL, PSDL R6001-R6016, R6101- R6157 (a)

-603 Production -601 1, 4, 5,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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 98 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT TABLE 11: STATION 740 FLOOR BEAM INSTALLATION - DRAWING 65B38527**  **Upper Chord Part Usage**  **Installation Sheet**  **Airplane Effectivity (Ba- 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)**  **Upper Chord Part Usage**  **Installation Sheet**  **Airplane Effectivity (Ba- sic Numbers)**  -3 Production -1 1, 2, 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)**  **Upper Chord Part Usage**  **Installation Sheet**  **Airplane Effectivity (Ba- sic Numbers)**  -3 Production -1 1, 2, 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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 99 of 101 **BOEING SERVICE BULLETIN 747-53A2696 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 Part Number**  **Fastener Code FASTENER**  **LOCATION Oversize**  **Nominal Production**  **Oversize Nominal**  **Production** BACB30VT6K* BACB30VT5HK* BACB30FM5* YTV6 YTV5H XCZ5

SIDE OF CHORD BACC30BL6 BACC30BL5 BACC30M5 BACB30NX6K*X BACB30VT6K* BACB30FM6* ZWG6 YTV6 XCZ6 BACC30BH6 BACC30BL6 BACC30M6 BACB30NX6K* BACB30NX5HK* BACB30DX5* YYT6 YYT5 XEP5 BACC30BH6 BACC30BH5 NAS1080 BACB30NX6K*X BACB30NX6K* BACB30DX6* ZWG6 YYT6 XEP6 BACC30BH6 BACC30BH6 NAS1080 BACB30NX6K*X BACB30NX6K* BACB30MB6* ZWG6 YYT6 XMX6 BACC30BH6 BACC30BH6 BACC30X6 BACB30MY8K*X BACB30MY8K* BACB30MY8C* YLC8 YHY8 XTJ8 BACC30M8 BACC30M8 BACC30M8 BACB30NW6K*X BACB30NW6K* BACB30FN6* YLE YJA XDA6 BACC30M6 BACC30M6 BACC30M6 BACB30NX6K*X BACB30MY6K* BACB30MY6C*

- YJJ YAX6 (a) (a) BACC30BH6 + BACW10CA104CC + BACW10CA31PV BACC30AG6 (a) BACC30AG6

(a) BACR15BB6D*C BACR15BB5D*C BACR15BB5D* ZGY6 ZGY5 XZK5 BACR15BB7D*C BACR15BB6D*C BACR15BB6D* ZGY7 ZGY6 XZK6 BACR15GF6D* BACR15GF5D* BACR15CE5D* ZSE6 ZSE5 XF5

**APPENDIX C: SECTION 42 - FASTENER REPLACEMENT GUIDE (SHEET 1 OF 2)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 16, 2008 747-53A2696 Revision 1 April 12, 2012 100 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT FASTENER REPLACEMENT GUIDE** **Part Number Fastener Code**  **FASTENER LOCATION**  **Oversize Nominal**  **Production Oversize**  **Nominal Production**  BACB30NX6K*X BACB30VT6K* BACB30FM6* ZWG6 YTV6 XCZ6 TOP OF CHORD BACC30BH6 BACC30BL6 BACC30M6 BACB30MY8K*X BACB30MY8K* BACB30MY8C* YLC8 YHY8 XTJ8 BACC30M8 BACC30M8 BACC30M8 BACR15BA4D*C BACR15BA3D*C BACR15BA3D* ZHD4 ZHD3 XZG3 BACR15BA6D*C BACR15BA5D*C BACR15BA5D* ZHD6 ZHD5 XZG5 BACB30NW6K*X BACB30NW6K* BACB30NW6C* YUG6 YJK6 YAY6 (a) (a) BACC30AG6 BACC30AG6 BACC30AG6 (a) (a) BACB30NW8K*X BACB30NW8K* BACB30NW8C* YUG8 YJK8 YAY8 (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 747-53A2696 Revision 1 April 12, 2012 101 of 101 **BOEING SERVICE BULLETIN 747-53A2696 ALERT**  **ALERT**