Commercial 

Airplane

Group 747

Service Bulletin

ALERT

Number: 747-53A2696

Date: October 16, 2008

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 730-774). An export license may be required before it is used for development, production or use by foreign

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

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2008 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more

information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

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

BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

1 of 62

4.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

2 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT

BLANK PAGE
Table of Contents

Summary ..................................................... 5

1. PLANNING INFORMATION ......................................... 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 15

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 35

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS . . . . . . . . . . . . . . . 40

FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL . . . . . . . . . . . . . . . . 42

FIGURE 3: UPPER DECK FLOOR BEAMS - HOLE INSPECTION . . . . . . . . . . . . . . . . . . . 47

FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION . . . . . . . . . . . . . . 49

FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION . . . . . . . . . . . . . 53

FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS . . . . . . . . . . . 57

Appendix A: UPPER DECK FLOORBEAM - UPPER CHORD DATA . . . . . . . . . . . . . . . . . . . 59

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

3 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

4 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT

BLANK PAGE
Commercial 

Airplane

Group 747

Service Bulletin

ALERT

Summary Number: 747-53A2696

Date: October 16, 2008

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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

5 of 62
ACTION

Get access to upper deck floor beams at station (STA) 340 - STA 440, 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. Install all equipment and panels removed for access.

EFFECTIVITY

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

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

Federal Aviation Administration (FAA) Airworthiness Directives 2004-07-22 R1, 2005-07-21, and 2006-08-02

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

Airplanes Total Task Hours Elapsed Hours

Group 1 541.00 135.25

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

6 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

7 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

8 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT

BLANK PAGE
Commercial 

Airplane

Group 747

Service Bulletin

ALERT

Number: 747-53A2696

Date: October 16, 2008

ATA System: 5321

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

Beam Upper Chord and Strap Replacement

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

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - All 747-200C/200F Series Airplanes.

Airplane Models:

747-200C, 747-200F

Variable Number Group

RJ131 - RJ133 1

RJ151 - RJ152 1

RJ301 - RJ303 1

RJ321 - RJ322 1

RJ331 - RJ333 1

RR001 - RR005 1

RR021 - RR025 1

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

9 of 62
Variable Number Group

RR031 1

RR201 - RR206 1

RR221 - RR226 1

RR261 - RR267 1

RR301 - RR310 1

RR331 - RR332 1

RR336 1

RR341 - RR345 1

RR361 - RR362 1

RR421 - RR422 1

RR431 - RR432 1

RR441 - RR442 1

RR451 1

RR501 - RR504 1

RR521 - RR522 1

RR526 1

RR531 1

RR551 - RR556 1

RR561 1

RR566 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

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

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

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

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

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

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

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

10 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
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.

D. Description

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

Affected Maintenance Zones

Model Zone

747-200C, 747-200F 221, 222, 223, 224

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin.The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

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

2006-08-02 are related to this service bulletin.

Table 1: Upper Deck Floor beam - Upper Chord Replacement Modification

Condition Action Compliance Time (Whichever Occurs Later)

Within 1,500 flight cycles

from the date on this

service bulletin.

Before 21,000 Total

Flight Cycles. (a)

Do an open hole HFEC Inspection at all

accessed fastener holes at STA 340 through

STA 440, STA 500 and STA 520 for cracks as

given in Accomplishment Instructions

Paragraph 3.B.2, Part 2.

All

Airplanes

Contact Boeing for repair information and Before Further Flight -

repair.

Any Crack

found

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

11 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Table 1: Upper Deck Floor beam - Upper Chord Replacement Modification

Condition Action Compliance Time (Whichever Occurs Later)

Immediately after the -

inspection given in

Accomplishment

Instruction Paragraph

3.B.2., 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

as given in Accomplishment Instructions

Paragraph 3.B.3, Part 3.

All

Airplanes

(a) Due to the after-modification 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 Modification Actions

Condition Action Compliance Time

Within 15,000 flight cycles after the upper

chord replacement modification given in

this service bulletin.

Do detailed and HFEC inspection of

the modified upper deck floor beams

for cracks as given in

Accomplishment Instructions

Paragraph 3.B.4., Part 4.

Upper chord Replacement

modification has been

accomplished

Do repair. Contact Boeing for repair Before further flight.

instructions.

Any crack is found.

Within 6,000 flight cycles after the initial

detailed and HFEC inspection given in

Accomplishment Instructions Paragraph

3.B.4., Part 4.

Repeat the upper chord replacement

modification as given in

Accomplishment Instructions

Paragraph 3.B.4., Part 4.

No crack is found or crack

has been repaired.

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 Federal Aviation Administration (FAA). In addition, the

Manager of the Seattle Aircraft Certification Office (ACO) approves the accomplishment of the applicable

inspection, repair, and modification procedures in this service bulletin, at the corresponding compliance

times specified in paragraph 1.E., "Compliance," as an alternative method of compliance (AMOC) to

the inspection and repair requirements of paragraphs (f) and (g) of AD 2006-08-02. All provisions of

AD 2006-08-02 that are not specifically referenced in the preceding statement remain fully applicable

and must be complied with.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

12 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
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 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.

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 and repair

requirements of paragraphs (h), (i), and (j) of AD 2004-07-22 R1 for the inspection of Supplemental

Structural Inspection Document (SSID), D6-35022, Items F-19C, F-19E, F-20A, F-20C, and F-20G.

This AMOC only applies to the areas covered by this service bulletin. All provisions of AD 2004-07-22

R1 that are not specifically referenced in the preceding statement 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.

Number of Task Hours Elapsed Hours

Persons

Task

Open Access 4 60.00 15.00

Figure 1 4 31.00 7.75

Figure 2 4 111.00 27.75

Figure 3 4 42.00 10.50

Figure 4 - (a) (a)

Figure 5 4 206.00 51.50

Figure 6 4 31.00 7.75

Close Access 4 60.00 15.00

Test - (b) (b)

TOTAL FOR EACH AIRPLANE 541.00 135.25

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

(b) Time to test systems will be dependant upon systems disturbed during

access or chord modifications as given in this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

13 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

(Pounds)

Airplane

747-200C -2.8 lbs -1063.3 lb-in

747-200F -2.8 lbs -1063.3 lb-in

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,

25-40-03, 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.

i. Boeing Drawing 012W6100.

j. Boeing Parts Standards Document D-590.

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

l. FAA Airworthiness Directive 2004-07-22 R1, Amendment 39-15326

2. Data supplied with this Service Bulletin:

None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

14 of 62

BOEING SERVICE BULLETIN 747-53A2696

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

Drawing Number Title

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

65B10927 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 340

65B10928 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 360

65B10929 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 380

65B10930 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 400

65B10931 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 420

65B10932 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 440

65B10935 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 500

65B10936 FLOOR BEAM INSTL - CREW COMPARTMENT, STA 520

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

None.

L. Interchangeability and Intermixability of Parts

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

15 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

16 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT

BLANK PAGE
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:

Upper Deck Floor Beam Station (STA) 340

Part Number / QTY Name Existing Part Number Notes

Specification

65B10927-101 1 Chord-Upper (STA 340) 65B10927-16 (a) (c)

65B10927-102 1 Radius Filler L/H (STA 340) 65B10927-19 (b) (c)

65B10927-103 1 Radius Filler R/H (STA 340) 65B10927-20 (b) (c)

BACB30FM6A3 2 Bolt - (d) (e)

Or

BACB30MC6A3

BACB30FM6A4 15 Bolt - (d) (e)

Or

BACB30MC6A4

BACB30FM6A5 35 Bolt - (d) (e)

Or

BACB30MC6A5

BACB30FM6A6 15 Bolt - (d) (e)

Or

BACB30MC6A6

BACB30FM6A7 4 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30FM6A9 2 Bolt - (d) (e)

Or

BACB30MC6A9

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

17 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 340

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30FN6A3 1 Bolt - (d) (e)

Or

BACB30FQ6A3

BACB30FN6A9 1 Bolt - (d) (e)

Or

BACB30FQ6A9

BACC30M6 73 Collar - (d)

BACR15BA6D5C 4 Rivet - (d) (e)

BACR15BA7D5C

BACR15BB5D5C 88 Rivet - (d) (e)

Or

BACR15BB6D5C

BACR15BB5D6C 20 Rivet - (d) (e)

Or

BACR15BB6D6C

BACR15BB6D6C 7 Rivet - (d) (e)

Or

BACR15BB7D6C

BACR15BB6D7C 44 Rivet - (d) (e)

Or

BACR15BB7D7C

BACR15BB6D8C 4 Rivet - (d) (e)

Or

BACR15BB7D8C

BACR15BB8D6C 2 Rivet - (d) (e)

Or

BACR15BB9D6C

BACR15BB8D7C 2 Rivet - (d) (e)

Or

BACR15BB9D7C

BACR15BB8D8C 2 Rivet - (d) (e)

Or

BACR15BB9D8C

BACR15GF6D8C 4 Rivet - (d) (e)

Or

BACR15GF61D8C

BACR15GF6D8C 4 Rivet - (d) (e)

Or

BACR15GF61D8C

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

18 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 340

Part Number / QTY Name Existing Part Number Notes

Specification

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

Type I

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

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 as given in APPENDIX A.

(b) Fabricate from 2024-T3511 as given in APPENDIX A.

(c) Discard the existing part.

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

(e) Use oversize bolts or rivets when the existing hole in the web or the frame must be oversized to correct

damage or misalignment.

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

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

Upper Deck Floor Beam Station (STA) 360

Part Number / QTY Name Existing Part Number Notes

Specification

65B10928-148 1 Chord-Upper (STA 360) 65B10928-40 (a) (c)

65B10928-149 1 Radius Filler L/H (STA 360) 65B10928-42 (b) (c)

65B10928-150 1 Radius Filler R/H (STA 360) 65B10928-43 (b) (c)

BACB30FM6A3 2 Bolt - (d) (e)

Or

6BACB30MC6A3

BACB30FM6A4 3 Bolt - (d) (e)

Or

BACB30MC6A4

BACB30FM6A5 12 Bolt - (d) (e)

Or

BACB30MC6A5

BACB30FM6A6 4 Bolt - (d) (e)

Or

BACB30MC6A6

BACB30FM6A7 2 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30FM6A8 4 Bolt - (d) (e)

Or

BACB30MC6A8

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

19 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 360

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30FM6A10 2 Bolt - (d) (e)

Or

BACB30MC6A10

BACB30FM6A12 2 Bolt - (d) (e)

Or

BACB30MC6A12

BACB30MY6K5 8 Bolt - (d) (e)

Or

BACB30NX6K5X

BACB30MY6K6 12 Bolt - (d) (e)

Or

BACB30NX6K6X

BACB30MY6K7 6 Bolt - (d) (e)

Or

BACB30NX6K7X

BACB30MY6K8 14 Bolt - (d) (e)

Or

BACB30NX6K8X

BACB30MY6K9 6 Bolt - (d) (e)

Or

BACB30NX6K9X

BACC30M6 81 Collar - (d)

BACR15BB5D5C 70 Rivet - (d) (e)

Or

BACR15BB6D5C

BACR15BB5D6C 70 Rivet - (d) (e)

Or

BACR15BB6D6C

BACR15BB5D7C 9 Rivet - (d) (e)

Or

BACR15BB6D7C

BACR15GF6D8C 6 Rivet - (d) (e)

Or

BACR15GF61D8C

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

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

Type I

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

B-1/2, -2, -4

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

20 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 360

Part Number / QTY Name Existing Part Number Notes

Specification

(a) Fabricate from 7075-T6511 as given in APPENDIX A.

(b) Fabricate from 2024-T3511 as given in APPENDIX A .

(c) Discard the existing part.

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

(e) Use oversize bolts or rivets when the existing hole in the web or the frame must be oversized to correct

damage or misalignment.

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

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

Upper Deck Floor Beam Station (STA) 380

Part Number / QTY Name Existing Part Number Notes

Specification

65B10929-167 1 Chord-Upper (STA 380) 65B10929-518 (a) (c)

65B10929-168 1 Radius Filler L/H (STA 380) 65B10929-537 (b) (c)

65B10929-169 1 Radius Filler R/H (STA 380) 65B10929-566 (b) (c)

BACB30FM5A7 1 Bolt - (d) (e)

Or

BACB30FM6A7

BACB30FM6A3 2 Bolt - (d) (e)

Or

BACB30MC6A3

BACB30FM6A4 16 Bolt - (d) (e)

Or

BACB30MC6A4

BACB30FM6A5 18 Bolt - (d) (e)

Or

BACB30MC6A5

BACB30FM6A6 3 Bolt - (d) (e)

Or

BACB30MC6A6

BACB30FM6A7 7 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30FM6A8 1 Bolt - (d) (e)

Or

BACB30MC6A8

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

21 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 380

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MY6K8 2 Bolt - (d) (e)

Or

BACB30NX6K8X

BACC30M5 1 Collar - (d)

BACC30M6 50 Collar - (d)

BACR15BB5D6C 138 Rivet - (d) (e)

Or

BACR15BB6D6C

BACR15BB5D7C 161 Rivet - (d) (e)

Or

BACR15BB6D7C

BACR15BB5D8C 42 Rivet - (d) (e)

Or

BACR15BB6D8C

BACR15BB6D7C 10 Rivet - (d) (e)

Or

BACR15BB7D7C

BACR15BB6D8C 9 Rivet - (d) (e)

Or

BACR15BB7D8C

BACR15BB8D8C 20 Rivet - (d) (e)

Or

BACR15BB9D8C

BACR15GF6D8C 2 Rivet - (d) (e)

Or

BACR15GF61D8C

BACR15GF6D9C 4 Rivet - (d) (e)

Or

BACR15GF61D9C

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

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

Type I

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

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 as given in APPENDIX A .

(b) Fabricate from 7075-T6 as given in APPENDIX A .

(c) Discard the existing part.

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

22 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 380

Part Number / QTY Name Existing Part Number Notes

Specification

(e) Use oversize bolts or rivets when the existing hole in the web or the frame must be oversized to correct

damage or misalignment.

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

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

Upper Deck Floor Beam Station (STA) 400

Part Number / QTY Name Existing Part Number Notes

Specification

65B10930-65 Or (a) (c)

65B10930-509

65B10930-213 1 Chord-Upper

Or

65B10930-216

65B10930-66 Or (b) (c)

65B10930-525

65B10930-215 1 Radius Filler L/H

Or

65B10930-217

65B10930-156 Or (b) (c)

65B10930-528

65B10930-214 1 Radius Filler R/H

Or

65B10930-218

BACB30FM6A4 11 Bolt - (d) (e)

Or

BACB30MC6A4

BACB30FM6A5 14 Bolt - (d) (e)

Or

BACB30MC6A5

BACB30FM6A6 5 Bolt - (d) (e)

Or

BACB30MC6A6

BACB30FM6A7 2 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30MY5K6 1 Bolt - (d) (e)

Or

BACB30MY6K6

BACB30MY6K5 14 Bolt - (d) (e)

Or

BACB30NX6K5X

BACB30MY6K6 3 Bolt - (d) (e)

Or

BACB30NX6K6X

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

23 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 400

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MY6K7 2 Bolt - (d) (e)

Or

BACB30NX6K7X

BACB30MY8K4 9 Bolt - (d) (e)

Or

BACB30MY8K4X

BACB30MY8K5 8 Bolt - (d) (e)

Or

BACB30MY8K5X

BACB30MY8K7 2 Bolt - (d) (e)

Or

BACB30NX8K7X

BACC30M5 1 Collar - (d)

BACC30M6 43 Collar (d)

BACC30M8 13 Collar - (d)

BACR15BA5D6C 6 Rivet - (d) (e)

Or

BACR15BA6D6C

BACR15BA6D7C 1 Rivet - (d) (e)

Or

BACR15BA7D7C

BACR15BB5D5C 134 Rivet - (d) (e)

Or

BACR15BB6D5C

BACR15BB5D6C 14 Rivet - (d) (e)

Or

BACR15BB6D6C

BACR15BB5D7C 2 Rivet - (d) (e)

Or

BACR15BB6D7C

BACR15BB6D7C 35 Rivet - (d) (e)

Or

BACR15BB7D7C

BACR15BB8D6C 8 Rivet - (d) (e)

Or

BACR15BB9D6C

BACR15BB8D8C 2 Rivet - (d) (e)

Or

BACR15BB9D8C

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

24 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 400

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB8D9C 18 Rivet - (d) (e)

Or

BACR15BB9D9C

BACR15GF6D8C 6 Rivet - (d) (e)

Or

BACR15GF61D8C

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

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

Type I

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

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 as given in APPENDIX A .

(b) Fabricate from 7075-T6 as given in APPENDIX A .

(c) Discard the existing part.

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

(e) Use oversize bolts or rivets when the existing 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) 420

Part Number / QTY Name Existing Part Number Notes

Specification

65B10931-64 Or (a) (b)

65B10931-508

65B10931-265 1 Chord-Upper

Or

65B10931-268

65B10931-65 Or (a) (b)

65B10931-531

65B10931-266 1 Radius Filler L/H

Or

65B10931-269

65B10931-267 1 Radius Filler R/H 65B10931-511 (a) (b)

BACB30MY6K3 6 Bolt - (c) (d)

Or

BACB30NX6K3X

BACB30MY6K4 25 Bolt - (c) (d)

Or

BACB30NX6K4X

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

25 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 420

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MY6K5 20 Bolt - (c) (d)

Or

BACB30NX6K5X

BACB30MY6K6 5 Bolt - (c) (d)

Or

BACB30NX6K6X

BACB30MY6K7 1 Bolt - (c) (d)

Or

BACB30NX6K7X

BACB30MY8K5 1 Bolt - (c) (d)

Or

BACB30MY8K5X

BACB30MY8K6 2 Bolt - (c) (d)

Or

BACB30MY8K6X

BACB30MY8K7 16 Bolt - (c) (d)

Or

BACB30MY8K7X

BACB30MY8K10 1 Bolt - (c) (d)

Or

BACB30MY8K10X

BACB30NW6K3 11 Bolt - (c) (d)

Or

BACB30NW6K3X

BACC30BL8 2 Collar - (c)

BACC30M6 68 Collar - (c)

BACC30M8 20 Collar - (c)

BACR15BB5D6C 7 Rivet - (c) (d)

Or

BACR15BB6D6C

BACR15BB5D7C 3 Rivet - (c) (d)

Or

BACR15BB6D7C

BACR15BB6D6C 148 Rivet - (c) (d)

Or

BACR15BB7D6C

BACR15BB8D6C 9 Rivet - (c) (d)

Or

BACR15BB9D6C

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

26 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 420

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB8D7C 1 Rivet - (c) (d)

Or

BACR15BB9D7C

BACR15BB6D7C 50 Rivet - (c) (d)

Or

BACR15BB7D7C

BACR15GF6D8C 4 Rivet - (c) (d)

Or

BACR15GF61D8C

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

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

Type I

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

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 as given in APPENDIX A.

(b) Discard the existing part.

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

(d) Use oversize bolts or rivets when the existing hole in the web or the frame must be oversized to correct

damage or misalignment.

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

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

Upper Deck Floor Beam Station (STA) 440

Part Number / QTY Name Existing Part Number Notes

Specification

65B10932-508 Or (a) (c)

65B10932-541

65B10932-211 1 Chord-Upper

Or

65B10932-216

65B10932-212 1 Radius Filler L/H 65B10932-513 (b) (c)

65B10932-213 1 Radius Filler R/H 65B10932-514 (b) (c)

65B10932-214 1 Radius Filler 65B10932-516 (a) (c)

65B10932-215 1 Radius Filler 65B10932-515 (a) (c)

BACB30FM6A6 2 Bolt - (d) (e)

Or

BACB30MC6A6

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

27 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 440

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30FM6A7 2 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30FM6A6 1 Bolt - (d) (e)

Or

BACB30MC6A6

BACB30FM6A8 1 Bolt - (d) (e)

Or

BACB30MC6A8

BACB30FN6A8 4 Bolt - (d) (e)

Or

BACB30FQ6A8

BACB30MB6A5 1 Bolt - (d) (e)

Or

BACB30MC6A5

BACB30MB6A7 4 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30MB6A8 2 Bolt - (d) (e)

Or

BACB30MC6A8

BACB30MY6K5 71 Bolt - (d) (e)

Or

BACB30NX6K5X

BACB30MY6K6 16 Bolt - (d) (e)

Or

BACB30NX6K6X

BACB30MY6K7 21 Bolt - (d) (e)

Or

BACB30NX6K7X

BACB30MY6K8 13 Bolt - (d) (e)

Or

BACB30NX6K8X

BACB30MY6K10 2 Bolt - (d) (e)

Or

BACB30NX6K10X

BACB30MY8K8 4 Bolt - (d) (e)

Or

BACB30MY8K8X

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

28 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 440

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30MY8K9 12 Bolt - (d) (e)

Or

BACB30MY8K9X

BACB30MY8K10 4 Bolt - (d) (e)

Or

BACB30MY8K10X

BACB30MY8K11 2 Bolt - (d) (e)

Or

BACB30MY8K11X

BACB30MY8K13 2 Bolt - (d) (e)

Or

BACB30MY8K13X

BACB30NW8K8 2 Bolt - (d) (e)

Or

BACB30NW8K8X

BACB30VN8K6 1 Bolt - (d) (e)

Or

BACB30VN10K6

BACB30VN8K8 1 Bolt - (d) (e)

Or

BACB30VN10K8

BACB30YP8K8 2 Bolt - (d) (e)

Or

BACB30NW8K8X

BACC30BH6 7 Collar - (d)

BACC30BK8 2 Collar - (d)

BACC30BL8 2 Collar - (d)

BACC30M6 131 Collar - (d)

BACC30M8 28 Collar - (d)

BACR15BB6D6C 4 Rivet - (d) (e)

Or

BACR15BB7D6C

BACR15BB6D7C 87 Rivet - (d) (e)

Or

BACR15BB7D7C

BACR15BB6D8C 21 Rivet - (d) (e)

Or

BACR15BB7D8C

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

29 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 440

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB6D9C 4 Rivet - (d) (e)

Or

BACR15BB7D9C

BACR15BB6D10C 1 Rivet - (d) (e)

Or

BACR15BB7D10C

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

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

Type I

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

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 as given in APPENDIX A .

(b) Fabricate from 7075-T6 as given in APPENDIX A.

(c) Discard the existing part.

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

(e) Use oversize bolts or rivets when the existing hole in the web or the frame must be oversized to correct

damage or misalignment.

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

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

Upper Deck Floor Beam Station (STA) 500

Part Number / QTY Name Existing Part Number Notes

Specification

65B10935-144Or (a) (c)

65B10935-507

65B10935-211 1 Chord-Upper R/H

Or

65B10935-213

65B10935-215 1 Chord-Upper L/H 65B10935-506 (a) (c)

65B10935-515 Or (b) (c)

65B10935-145

Reinforcement Angle Radius Filler

L/H

65B10935-216 1

Or

65B10935-217

65B10935-146 Or (b) (c)

65B10935-516

Reinforcement Angle Radius Filler

R/H

65B10935-212 1

Or

65B10935-214

BACB30FM6A4 11 Bolt - (d) (e)

Or

BACB30MC6A4

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

30 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 500

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30FM6A5 19 Bolt - (d) (e)

Or

BACB30MC6A5

BACB30FM6A6 5 Bolt - (d) (e)

Or

BACB30MC6A6

BACB30FM6A7 4 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30FM6A8 2 Bolt - (d) (e)

Or

BACB30MC6A8

BACB30FM6A9 1 Bolt - (d) (e)

Or

BACB30MC6A9

BACB30FM8A5 1 Bolt - (d) (e)

Or

BACB30FP8A5

BACB30FN6A7 4 Bolt - (d) (e)

Or

BACB30FQ6A7

BACB30MY8K7 20 Bolt - (d) (e)

Or

BACB30MY8K7X

BACB30MY8K8 4 Bolt - (d) (e)

Or

8BACB30MY8K8X

BACB30MY8K11 4 Bolt - (d) (e)

Or

BACB30MY8K11X

BACB30NW8K7 2 Bolt - (d) (e)

Or

BACB30NW8K7X

BACB30VN6K4 8 Bolt - (d) (e)

Or

BACB30VN8K4

BACB30VN6K6 2 Bolt - (d) (e)

Or

BACB30VN8K6

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

31 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 500

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30VN8K7 1 Bolt - (d) (e)

Or

BACB30VN10K7

BACB30YP8K7 2 Bolt - (d) (e)

Or

BACB30NW8K7X

BACC30BK6 10 Collar - (d)

BACC30BK8 1 Collar - (d)

BACC30BL8 2 Collar - (d)

BACC30M6 46 Collar - (d)

BACC30M8 31 Collar - (d)

BACR15BB5D6C 2 Rivet - (d) (e)

Or

BACR15BB6D6C

BACR15BB5D7C 42 Rivet - (d) (e)

Or

BACR15BB6D7C

BACR15BB5D8C 24 Rivet - (d) (e)

Or

BACR15BB6D8C

BACR15BB6D8C 42 Rivet - (d) (e)

Or

BACR15BB7D8C

BACR15BB6D10C 5 Rivet - (d) (e)

Or

BACR15BB7D10C

BACR15BB6D11C 38 Rivet - (d) (e)

Or

BACR15BB7D11C

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

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

Type I

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

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 as given in APPENDIX A.

(b) Fabricate from 2024-T3511 as given in APPENDIX A.

(c) Discard the existing part.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

32 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 500

Part Number / QTY Name Existing Part Number Notes

Specification

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

(e) Use oversize bolts or rivets when the existing hole in the web or the frame must be oversized to correct

damage or misalignment.

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

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

Upper Deck Floor Beam Station (STA) 520

Part Number / QTY Name Existing Part Number Notes

Specification

65B10936-507 Or (a) (c)

65B10936-525 Or

65B10936-146 Or

65B10936-147

65B10936-187 1 Chord-Upper

Or

65B10936-192

Or

65B10936-197

Or

65B10936-198

65B10936-511 Or (b) (c)

65B10936-133

65B10936-188 1 Radius Filler L/H

Or

65B10936-196

65B10936-512 Or (b) (c)

65B10936-132

65B10936-189 1 Radius Filler R/H

Or

65B10936-195

65B10936-509 Or (a) (c)

65B10936-524

65B10936-190 1 Strap

Or

65B10936-193

65B10936-508 Or (a) (c)

65B10936-523

65B10936-191 1 Strap

Or

65B10936-194

BACB30FM6A4 145 Bolt - (d) (e)

Or

BACB30MC6A4

BACB30FM6A5 29 Bolt - (d) (e)

Or

BACB30MC6A5

BACB30FM6A6 87 Bolt - (d) (e)

Or

BACB30MC6A6

BACB30FM6A7 2 Bolt - (d) (e)

Or

BACB30MC6A7

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

33 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 520

Part Number / QTY Name Existing Part Number Notes

Specification

BACB30FM6A8 8 Bolt - (d) (e)

Or

BACB30MC6A8

BACB30FN6A4 1 Bolt - (d) (e)

Or

BACB30FQ6A4

BACB30FN6A6 4 Bolt - (d) (e)

Or

BACB30FQ6A6

BACB30MB6A7 1 Bolt - (d) (e)

Or

BACB30MC6A7

BACB30MB6A8 3 Bolt - (d) (e)

Or

BACB30MC6A8

BACB30MY10K8 8 Bolt - (d) (e)

Or

BACB30MY10K8X

BACB30MY10K13 4 Bolt - (d) (e)

Or

BACB30MY10K13X

BACB30NW8K8 1 Bolt - (d) (e)

Or

BACB30NW8K8X

BACB30VN6K5 6 Bolt - (d) (e)

Or

BACB30VN8K5

BACB30VN6K7 2 Bolt - (d) (e)

Or

BACB30VN8K7

BACB30YP8K8 1 Bolt - (d) (e)

Or

BACB30NW8K8X

BACC30BH6 4 Collar - (d)

BACC30BK6 8 Collar - (d)

BACC30BL8 1 Collar - (d)

BACC30M6 276 Collar - (d)

BACC30M8 1 Collar - (d)

BACC30M10 12 Collar - (d)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

34 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
Upper Deck Floor Beam Station (STA) 520

Part Number / QTY Name Existing Part Number Notes

Specification

BACR15BB6D7C 1 Rivet - (d) (e)

Or

BACR15BB7D7C

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

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

Type I

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

B-1/2, -2, -4

(a) Fabricate from 7075-T6511 as given in APPENDIX A.

(b) Fabricate from 7075-T6 as given in APPENDIX A .

(c) Discard the existing part.

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

(e) Use oversize bolts or rivets when the existing 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.

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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

35 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

36 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT

BLANK PAGE
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. For approved fastener and process material substitutions, refer to 747 SRM, Chapter

51, Alternate fasteners are given in 747 SRM Chapter 51 and Boeing Drawing

012W6100.

5. Refer to SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures.

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

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.

7. A Special Detailed Inspection is defined as: An intensive examination of a specific

item, installation, or assembly to detect damage, failure, or irregularity. The

examination is likely to make extensive use of specialized Inspection techniques

and/or equipment. Intricate cleaning and substantial access or disassembly procedure

may be required.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

37 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
8. These work instructions refer to procedures included on other Boeing documents.

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

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

given in" are included in the instruction, the procedure in the Boeing document must

be used.

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

make replacement parts. Appendix lists the drawing numbers for the fabrication,

installation and fastener requirements.

10. Fasteners may be oversized by 0.0156 inch or 0.0312 inch, provided a minimum

edge margin of 1.7D is maintained.

B. WORK INSTRUCTIONS

1. PART 1 - ACCESS

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

b. For access to the right side of the station (STA) 340, STA 360, STA 380, and STA 400 floor

beams only, remove the P4 flight engineers panel and the P6 main circuit breaker panel as

given in Boeing Service Bulletin 747-53-2272.

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

given in FIGURE 1.

2. PART 2 - CHORD REMOVAL AND INSPECTION

CAUTION: DO NOT REMOVE ADJACENT FLOORBEAM UPPER CHORDS AT THE SAME

TIME. IF ADJACENT FLOORBEAM UPPER CHORDS ARE REMOVED AT THE

SAME TIME, DAMAGE TO THE AIRPLANE STRUCTURE MAY OCCUR.

a. Remove the upper chord from the upper deck floor beam at STA 340 - STA 440, STA 500

and STA 520 as given in FIGURE 2.

b. Do an open hole High Frequency Eddy Current (HFEC) Inspection at all accessed holes for

the upper chord removal at STA 340 - STA 440, STA 500 and STA 520 for any crack as given

in FIGURE 3.

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

3. PART 3 - CHORD FABRICATION AND INSTALLATION

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 as given in 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 as given in FIGURE 5.

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

141U0044 as given in service bulletin 747-53A2429 Revision 1.

4. PART 4 - Post-Upper Chord Replacement Modification Actions

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

38 of 62

BOEING SERVICE BULLETIN 747-53A2696

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

open hole HFEC inspection of the modified upper deck floor beams for cracks as given in

Figure 1 and Figure 2 of Service Bulletin 747-53A2429, Revision 2.

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

of the modified upper deck floor beams for cracks as given in Service Bulletin 747-53A2439,

Revision 2. Repeat the inspection at the time as given in paragraph 1.E., Compliance, of the

service bulletin, until the upper chord replacement modification given in this service bulletin

is repeated.

c. If any crack is found, do repair at the time as given in Paragraph 1.E., Compliance. Contact

Boeing for repair instructions.

d. If no crack is found or crack has been repaired, repeat the upper chord replacement

modification given in PART 2 and PART 3 at the time as given in Paragraph 1.E., Compliance.

5. PART 5 - CLOSE ACCESS

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

given in 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 as given in Boeing Service Bulletin 747-53-2272 to verify satisfactory systems

operation.

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

require testing.

c. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

39 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS

(SHEET 1 OF 2)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

40 of 62

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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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

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

Flight Compartment - - (c)

Floor Covering

3 Remove/Keep

4 Remove/Keep Lavatory - 1 (d)

Personnel - - (e)

Accommodations Area

Floor Covering

5 Remove/Keep

Upper Deck Floor - - (f)

Panel

6 Remove/Keep

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

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

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

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

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

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

FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS

(SHEET 2 OF 2)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

41 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL

(SHEET 1 OF 5)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

42 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL

(SHEET 2 OF 5)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

43 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL

(SHEET 3 OF 5)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

44 of 62

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.

STEP TASK NAME STA IDENTIFICATION QTY MORE DATA

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

ADJACENT FLOORBEAM UPPER CHORDS ARE REMOVED AT THE SAME TIME, DAMAGE

TO THE AIRPLANE STRUCTURE MAY OCCUR.

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

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

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

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

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

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

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

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

520 65B10936-16 1 (a) (b) (c)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL

(SHEET 4 OF 5)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

45 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
STEP TASK NAME STA IDENTIFICATION QTY MORE DATA

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

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

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

(a) If a splice repair of the upper chord has been installed as given in service bulletin 747-53A2429 then

remove the splice with the upper chord.

(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 parts not listed that are removed during the chord removal should be kept for re-installation.

FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL

(SHEET 5 OF 5)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

46 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 3: UPPER DECK FLOOR BEAMS - HOLE INSPECTION

(SHEET 1 OF 2)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

47 of 62

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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Fastener Holes - - (a)

(a) Do a High Frequency Eddy Current (HFEC) open hole inspection of all accessed fastener holes in the

frame and floor beam web for cracks as given in 747 NDT, Part 6, 51-00-00 Figure16.

FIGURE 3: UPPER DECK FLOOR BEAMS - HOLE INSPECTION

(SHEET 2 OF 2)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

48 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION

(SHEET 1 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

49 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION

(SHEET 2 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

50 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION

(SHEET 3 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

51 of 62

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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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

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

Right Strap or Angle - 8

Radius Filler - 4 (c) (d)

Chemical Conversion Type 2, Class A - (e)

Coating

2 Apply

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

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

(b) Some airplanes have angles at STA 400 and STA 500.

(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

(SHEET 4 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

52 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION

(SHEET 1 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

53 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION

(SHEET 2 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

54 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION

(SHEET 3 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

55 of 62

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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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

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

Right Strap or Angle - 8

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

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

as applicable.

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

(c) Some airplanes have angles at STA 400 and STA 500.

(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 as given in Service Bulletin 747-53A2429 Revision 1 or later.

(g) Use oversize bolts or rivets when the hole for the standard size must be made oversize to correct damage

or misalignment.

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

(i) Install wet using BMS 5-95 sealant. Refer to SOPM 20-50-03 as an accepted procedure.

FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION

(SHEET 4 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

56 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS

(SHEET 1 OF 2)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

57 of 62

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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Upper Deck Floor - - (a)

Panel

1 Install (Kept)

Personnel - - (b)

Accommodations Area

Floor Covering

2 Install (Kept)

3 Install (Kept) Lavatory - 1 (c)

Flight Compartment - - (d)

Floor Covering

4 Install (Kept)

5 Install (Kept) Observer's Seat - 2 (e)

6 Install (Kept) Flight Engineer's Seat - 1 (f)

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

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

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

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

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

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

FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS

(SHEET 2 OF 2)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

58 of 62

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 FLOORBEAM INSTALLATION - DRAWING 65B10927

Airplane Effectivity Sheet Installation Part Usage Upper Chord Left Strap Right Strap

(Basic Numbers)

1, 4, PL, -503 Production -16 -19 -20

PSDL

All affected airplanes.

Optional: (a) (b) (c)

Make from

(a) Make from AND10136-2006 x 152.9 inches 7075-T6511.

(b) Make from BAC1512-3341 x 22.3 inches 2024-T3511.

(c) Make from BAC1512-3341 x 23.1 inches 2024-T3511.

TABLE 2: STATION 360 FLOORBEAM INSTALLATION - DRAWING 65B10928

Airplane Effectivity (Basic Sheet Installation Part Usage Upper Chord Left Strap Right Strap

Numbers)

1, 4, 7, -511, -97 Production -40 -42 -43

PL,

PSDL

All affected airplanes.

Optional: (a) (b) (c)

Make from

(a) Make from AND10136-2402 x 163.7 inches 7075-T6511.

(b) Make from BAC1512-3361 x 26.0 inches 2024-T3511.

(c) Make from BAC1512-3361 x 29.5 inches 2024-T3511.

TABLE 3: STATION 380 FLOORBEAM INSTALLATION - DRAWING 65B10929

Upper Left Strap Right Strap

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

-65, -109, Production -518 -537 -566

-158, -514

1, 4, 5,

9 PL,

PSDL

All affected airplanes.

Optional: (a) (b) (c)

Make from

(a) Make from AND10136-2408 x 178.9 inches 7075-T6511.

(b) Make from 0.063 x 1.7 x 19.2 inches 7075-T6.

(c) Make from 0.063 x 1.7 x 20.3 inches 7075-T6.

Appendix A: UPPER DECK FLOORBEAM - UPPER CHORD DATA

(SHEET 1 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

59 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
TABLE 4: STATION 400 FLOORBEAM INSTALLATION - DRAWING 65B10930

Right

Strap/Angle

Left

Strap/Angle

Upper

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

1, 3, 4, -61 Production -65 -66 -528

5, PL,

PSDL

R4103-R4105, R4107,

R6002-R6004, R6009-R6012,

R6015, R6101,R6106,

R6110-R6111, R6113-R6114,

R6118-R6119, R6122-R6123,

R6125, R6133-R6135, R6143

Optional: (a) (d) (d)

Make from

1, 4, 10, -163 Production -509 -525 -156

PL,

PSDL

R6144-R6153, R6155-R6156

Optional: (a) (b) (c)

Make from

1, 4, 5, -204 Production -65 -66 -156

PL,

PSDL

R4108, R6154, R6157

Optional: (a) (d) (c)

Make from

1, 4, 10, -504 Production -509 -525 -528

PL,

PSDL

R4005-R4102, R4106, R6001,

R6005-R6008, R6013-R6014,

R6016, R6102-R6105,

R6107-R6109, R6112,

R6115-R6117, R6120-R6121,

R6124, R6126-R6132,

R6136-R6142

Optional: (a) (b) (d)

Make from

(a) Make from BAC1505-100365 x 180.5 inches 7075-T6511.

(b) Make from BAC1512-3341 x 18 inches 7075-T6511.

(c) Make from BAC1490-2570 x 22.5 inches 7075-T6.

(d) Make from BAC1490-2570 x 18.0 inches 7075-T6.

TABLE 5: STATION 420 FLOORBEAM INSTALLATION - DRAWING 65B10931

Upper Left Strap Right Strap

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

1, 3, 4, -60, -238 Production -64 -65 -511

5 PL,

PSDL

R4103-R4105, R4107- R4108,

R6002-R6004, R6009-R6012,

R6015, R6101, R6106,

R6110-R6111, R6113-R6114,

R6118-R6119, R6122-R6123,

R6125, R6133-R6135,

R6143,R6154, R6157

Optional: (a) (b) (c)

Make from

Appendix A: UPPER DECK FLOORBEAM - UPPER CHORD DATA

(SHEET 2 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

60 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
TABLE 5: STATION 420 FLOORBEAM INSTALLATION - DRAWING 65B10931

Upper Left Strap Right Strap

Chord

Airplane Effectivity (Basic Sheet Installation Parts Usage

Numbers)

1, 4, 10 -186, -503 Production -508 -531 -511

PL,

PSDL

R4005-R4102, R4106, R6001,

R6005-R6008, R6013-R6014,

R6016, R6102-R6105,

R6107-R6109, R6112,

R6115-R6117, R6120-R6121,

R6124, R6126-R6132,

R6136-R6142, R6144-R6153,

R6155-R6156

Optional: (a) (b) (c)

Make from

(a) Make from AND10136-2008 x 185.3 inches 7075-T6511.

(b) Make from BAC1512-335 x 18.3 inches 7075-T6511.

(c) Make from BAC1512-3341 x 15.7 inches 7075-T6511.

TABLE 6: STATION 440 FLOORBEAM INSTALLATION - DRAWING 65B10932

Aft

Radius

Filler

Fwd

Radius

Filler

Right

Strap

Left

Strap

Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

1, 4, 5, -157, -503 Production -508 -513 -514 -516 -515

PL,

PSDL

R4005-R4009,

R4101-R4108 Optional:Make (a) (b) (b) (c) (d)

from

1, 4, 5, -157, -503 Production -541 -513 -514 -516 -515

11,

PL,

PSDL

R6001-R6016,

R6101-R6157 Optional:Make (a) (b) (b) (c) (d)

from

(a) Make from AND10136-3006 x 191.5 inches 7075-T6511.

(b) Make from 0.156 x 2.2 x 17.4 inches 7075-T6.

(c) Make from BAC1511-1618 x 191.5 inches 7075-T6.

(d) Make from BAC1511-1618 x 178.7 inches 7075-T6.

TABLE 7: STATION 500 FLOORBEAM INSTALLATION - DRAWING 65B10935

Right

Strap/Angle

Left

Strap/Angle

Right

Upper

Chord

Left Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

-140, -142, Production -506 -144 -145 -146

-191, -195

1, 3,

4, 10,

PL,

PSDL

R4108,

R6144-R6157 Optional: (a) (a) (b) (c)

Make from

Appendix A: UPPER DECK FLOORBEAM - UPPER CHORD DATA

(SHEET 3 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

61 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT
TABLE 7: STATION 500 FLOORBEAM INSTALLATION - DRAWING 65B10935

Right

Strap/Angle

Left

Strap/Angle

Right

Upper

Chord

Left Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

-115, -502, Production -506 -507 -515 -516

-503, -65

3, 4,

PL,

PSDL

R4005-R4107,

R6001-R6143 Optional: (a) (a) (d) (d)

Make from

(a) Make from BAC1505-100300 x 66.0 inches 7075-T6511.

(b) Make from BAC1503-100333 x 33.3 inches 7075-T73511.

(c) Make from BAC1503-100133 x 30.6 inches 7075-T73511.

(d) Make from 0.125 x 2.0 x 18.3 inches 7075-T6.

TABLE 8: STATION 520 FLOORBEAM INSTALLATION - DRAWING 65B10936

Aft

Radius

Filler

Fwd

Radius

Filler

Right

Strap

Left

Strap

Upper

Chord

Airplane Effectivity Sheet Installation Parts Usage

(Basic Numbers)

1, 5, -131 Production -147 -133 -132 -524 -523

PL,

PSDL

R6144-R6157

Optional: (d) (b) (b) (c) (c)

Make from

1, 4, -134 Production -146 -133 -132 -509 -508

PL,

PSDL

R4108

Optional: (a) (b) (b) (c) (c)

Make from

1, 4, -501 Production -507 -511 -512 -509 -508

12,

PL,

PSDL

R4001-R4107

Optional: (a) (b) (b) (c) (c)

Make from

1, 5, -518 Production -525 -511 -512 -524 -523

12,

PL,

PSDL

R6001-R6143

Optional: (d) (b) (b) (c) (c)

Make from

(a) Make from AND10136-3005 x 203.0 inches 7075-T6511.

(b) Make from 0.125 x 2.1 x 15.5 inches 7075-T6.

(c) Make from BAC1512-3410 x 203.0 inches 7075-T6511.

(d) Make from AND10136-3005 x 203.9 inches 7075-T6511.

Appendix A: UPPER DECK FLOORBEAM - UPPER CHORD DATA

(SHEET 4 OF 4)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

October 16, 2008

747-53A2696

62 of 62

BOEING SERVICE BULLETIN 747-53A2696

ALERT ALERT