### 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. October 16, 2008 747-53A2696 1 of 62 4.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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**

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### 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 Elapsed Hours**  **Total Task Hours Airplanes**  135.25 541.00 Group 1
**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**

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### 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.
**DESCRIPTION CONFIGURATION**  **GROUP** All 747-200C/200F Series Airplanes.

- 1

Airplane Models: 747-200C, 747-200F **Group Variable Number**  1 RJ131 - RJ133 1 RJ151 - RJ152 1 RJ301 - RJ303 1 RJ321 - RJ322 1 RJ331 - RJ333 1 RR001 - RR005 1 RR021 - RR025

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. October 16, 2008 747-53A2696 9 of 62**Group Variable Number**  1 RR031 1 RR201 - RR206 1 RR221 - RR226 1 RR261 - RR267 1 RR301 - RR310 1 RR331 - RR332 1 RR336 1 RR341 - RR345 1 RR361 - RR362 1 RR421 - RR422 1 RR431 - RR432 1 RR441 - RR442 1 RR451 1 RR501 - RR504 1 RR521 - RR522 1 RR526 1 RR531 1 RR551 - RR556 1 RR561 1 RR566 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 Zone**  **Model** 221, 222, 223, 224 747-200C, 747-200F **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. **T**

**ab le 1:** **Upper Dec k Floor beam - Upper Chor** **d Replacement Modification Compliance Time (Whichever Occurs Later)**  **Action Condition**  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

- Before Further Flight Contact Boeing for repair information and 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 T**  **ab le 1:** **Upper Dec k Floor beam - Upper Chor** **d Replacement Modification Compliance Time (Whichever Occurs Later)**  **Action Condition** 

- 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.
**T**

**ab le 2:** **P ost-Upper Chor** **d Replacement Modification Actions Compliance Time**  **Action Condition**  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

Before further flight. Do repair. Contact Boeing for repair 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. **Elapsed Hours Task Hours**  **Number of Persons**  **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 (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 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**
-1063.3 lb-in -2.8 lbs 747-200C -1063.3 lb-in -2.8 lbs 747-200F
**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:
**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 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 Dec k Floor Beam Station (ST**  **A) 340**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10927-16 Chord-Upper (STA 340) 1 65B10927-101 (b) (c) 65B10927-19 Radius Filler L/H (STA 340) 1 65B10927-102 (b) (c) 65B10927-20 Radius Filler R/H (STA 340) 1 65B10927-103 (d) (e)

- Bolt 2 BACB30FM6A3 Or BACB30MC6A3 (d) (e)

- Bolt 15 BACB30FM6A4 Or BACB30MC6A4 (d) (e)

- Bolt 35 BACB30FM6A5 Or BACB30MC6A5 (d) (e)

- Bolt 15 BACB30FM6A6 Or BACB30MC6A6 (d) (e)

- Bolt 4 BACB30FM6A7 Or BACB30MC6A7 (d) (e)

- Bolt 2 BACB30FM6A9 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 Dec** **k Floor Beam Station (ST A) 340** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 1 BACB30FN6A3 Or BACB30FQ6A3 (d) (e)

- Bolt 1 BACB30FN6A9 Or BACB30FQ6A9 (d)

- Collar 73 BACC30M6 (d) (e)

- Rivet 4 BACR15BA6D5C 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

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 Dec** **k Floor Beam Station (ST A) 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 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 Dec k Floor Beam Station (ST**  **A) 360**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10928-40 Chord-Upper (STA 360) 1 65B10928-148 (b) (c) 65B10928-42 Radius Filler L/H (STA 360) 1 65B10928-149 (b) (c) 65B10928-43 Radius Filler R/H (STA 360) 1 65B10928-150 (d) (e)

- Bolt 2 BACB30FM6A3 Or 6BACB30MC6A3 (d) (e)

- Bolt 3 BACB30FM6A4 Or BACB30MC6A4 (d) (e)

- Bolt 12 BACB30FM6A5 Or BACB30MC6A5 (d) (e)

- Bolt 4 BACB30FM6A6 Or BACB30MC6A6 (d) (e)

- Bolt 2 BACB30FM6A7 Or BACB30MC6A7 (d) (e)

- Bolt 4 BACB30FM6A8 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 Dec** **k Floor Beam Station (ST A) 360** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 2 BACB30FM6A10 Or BACB30MC6A10 (d) (e)

- Bolt 2 BACB30FM6A12 Or BACB30MC6A12 (d) (e)

- Bolt 8 BACB30MY6K5 Or BACB30NX6K5X (d) (e)

- Bolt 12 BACB30MY6K6 Or BACB30NX6K6X (d) (e)

- Bolt 6 BACB30MY6K7 Or BACB30NX6K7X (d) (e)

- Bolt 14 BACB30MY6K8 Or BACB30NX6K8X (d) (e)

- Bolt 6 BACB30MY6K9 Or BACB30NX6K9X (d)

- Collar 81 BACC30M6 (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

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 Dec** **k Floor Beam Station (ST A) 360** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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 Dec k Floor Beam Station (ST**  **A) 380**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10929-518 Chord-Upper (STA 380) 1 65B10929-167 (b) (c) 65B10929-537 Radius Filler L/H (STA 380) 1 65B10929-168 (b) (c) 65B10929-566 Radius Filler R/H (STA 380) 1 65B10929-169 (d) (e)

- Bolt 1 BACB30FM5A7 Or BACB30FM6A7 (d) (e)

- Bolt 2 BACB30FM6A3 Or BACB30MC6A3 (d) (e)

- Bolt 16 BACB30FM6A4 Or BACB30MC6A4 (d) (e)

- Bolt 18 BACB30FM6A5 Or BACB30MC6A5 (d) (e)

- Bolt 3 BACB30FM6A6 Or BACB30MC6A6 (d) (e)

- Bolt 7 BACB30FM6A7 Or BACB30MC6A7 (d) (e)

- Bolt 1 BACB30FM6A8 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 Dec** **k Floor Beam Station (ST A) 380** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 2 BACB30MY6K8 Or BACB30NX6K8X (d)

- Collar 1 BACC30M5 (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 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 Dec** **k Floor Beam Station (ST A) 380** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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 Dec k Floor Beam Station (ST**  **A) 400**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10930-65 Or 65B10930-509 Chord-Upper 1 65B10930-213 Or 65B10930-216 (b) (c) 65B10930-66 Or 65B10930-525 Radius Filler L/H 1 65B10930-215 Or 65B10930-217 (b) (c) 65B10930-156 Or 65B10930-528 Radius Filler R/H 1 65B10930-214 Or 65B10930-218 (d) (e)

- Bolt 11 BACB30FM6A4 Or BACB30MC6A4 (d) (e)

- Bolt 14 BACB30FM6A5 Or BACB30MC6A5 (d) (e)

- Bolt 5 BACB30FM6A6 Or BACB30MC6A6 (d) (e)

- Bolt 2 BACB30FM6A7 Or BACB30MC6A7 (d) (e)

- Bolt 1 BACB30MY5K6 Or BACB30MY6K6 (d) (e)

- Bolt 14 BACB30MY6K5 Or BACB30NX6K5X (d) (e)

- Bolt 3 BACB30MY6K6 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 Dec** **k Floor Beam Station (ST A) 400** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 2 BACB30MY6K7 Or BACB30NX6K7X (d) (e)

- Bolt 9 BACB30MY8K4 Or BACB30MY8K4X (d) (e)

- Bolt 8 BACB30MY8K5 Or BACB30MY8K5X (d) (e)

- Bolt 2 BACB30MY8K7 Or BACB30NX8K7X (d)

- Collar 1 BACC30M5 (d) Collar 43 BACC30M6 (d)

- Collar 13 BACC30M8 (d) (e)

- Rivet 6 BACR15BA5D6C Or BACR15BA6D6C (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

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 Dec** **k Floor Beam Station (ST A) 400** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (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 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 Dec k Floor Beam Station (ST**  **A) 420**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (b) 65B10931-64 Or 65B10931-508 Chord-Upper 1 65B10931-265 Or 65B10931-268 (a) (b) 65B10931-65 Or 65B10931-531 Radius Filler L/H 1 65B10931-266 Or 65B10931-269 (a) (b) 65B10931-511 Radius Filler R/H 1 65B10931-267 (c) (d)

- Bolt 6 BACB30MY6K3 Or BACB30NX6K3X (c) (d)

- Bolt 25 BACB30MY6K4 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 Dec** **k Floor Beam Station (ST A) 420** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (c) (d)

- Bolt 20 BACB30MY6K5 Or BACB30NX6K5X (c) (d)

- Bolt 5 BACB30MY6K6 Or BACB30NX6K6X (c) (d)

- Bolt 1 BACB30MY6K7 Or BACB30NX6K7X (c) (d)

- Bolt 1 BACB30MY8K5 Or BACB30MY8K5X (c) (d)

- Bolt 2 BACB30MY8K6 Or BACB30MY8K6X (c) (d)

- Bolt 16 BACB30MY8K7 Or BACB30MY8K7X (c) (d)

- Bolt 1 BACB30MY8K10 Or BACB30MY8K10X (c) (d)

- Bolt 11 BACB30NW6K3 Or 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 (c) (d)

- Rivet 9 BACR15BB8D6C 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 Dec** **k Floor Beam Station (ST A) 420** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (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 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 Dec k Floor Beam Station (ST**  **A) 440**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10932-508 Or 65B10932-541 Chord-Upper 1 65B10932-211 Or 65B10932-216 (b) (c) 65B10932-513 Radius Filler L/H 1 65B10932-212 (b) (c) 65B10932-514 Radius Filler R/H 1 65B10932-213 (a) (c) 65B10932-516 Radius Filler 1 65B10932-214 (a) (c) 65B10932-515 Radius Filler 1 65B10932-215 (d) (e)

- Bolt 2 BACB30FM6A6 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 Dec** **k Floor Beam Station (ST A) 440** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 2 BACB30FM6A7 Or BACB30MC6A7 (d) (e)

- Bolt 1 BACB30FM6A6 Or BACB30MC6A6 (d) (e)

- Bolt 1 BACB30FM6A8 Or BACB30MC6A8 (d) (e)

- Bolt 4 BACB30FN6A8 Or BACB30FQ6A8 (d) (e)

- Bolt 1 BACB30MB6A5 Or BACB30MC6A5 (d) (e)

- Bolt 4 BACB30MB6A7 Or BACB30MC6A7 (d) (e)

- Bolt 2 BACB30MB6A8 Or BACB30MC6A8 (d) (e)

- Bolt 71 BACB30MY6K5 Or BACB30NX6K5X (d) (e)

- Bolt 16 BACB30MY6K6 Or BACB30NX6K6X (d) (e)

- Bolt 21 BACB30MY6K7 Or BACB30NX6K7X (d) (e)

- Bolt 13 BACB30MY6K8 Or BACB30NX6K8X (d) (e)

- Bolt 2 BACB30MY6K10 Or BACB30NX6K10X (d) (e)

- Bolt 4 BACB30MY8K8 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 Dec** **k Floor Beam Station (ST A) 440** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 12 BACB30MY8K9 Or BACB30MY8K9X (d) (e)

- Bolt 4 BACB30MY8K10 Or BACB30MY8K10X (d) (e)

- Bolt 2 BACB30MY8K11 Or BACB30MY8K11X (d) (e)

- Bolt 2 BACB30MY8K13 Or BACB30MY8K13X (d) (e)

- Bolt 2 BACB30NW8K8 Or BACB30NW8K8X (d) (e)

- Bolt 1 BACB30VN8K6 Or BACB30VN10K6 (d) (e)

- Bolt 1 BACB30VN8K8 Or BACB30VN10K8 (d) (e)

- Bolt 2 BACB30YP8K8 Or 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 (d) (e)

- Rivet 21 BACR15BB6D8C 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 Dec** **k Floor Beam Station (ST A) 440** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (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 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 Dec k Floor Beam Station (ST**  **A) 500**
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (a) (c) 65B10935-144Or 65B10935-507 Chord-Upper R/H 1 65B10935-211 Or 65B10935-213 (a) (c) 65B10935-506 Chord-Upper L/H 1 65B10935-215 (b) (c) 65B10935-515 Or 65B10935-145 Reinforcement Angle Radius Filler L/H 1 65B10935-216 Or 65B10935-217 (b) (c) 65B10935-146 Or 65B10935-516 Reinforcement Angle Radius Filler R/H 1 65B10935-212 Or 65B10935-214 (d) (e)

- Bolt 11 BACB30FM6A4 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 Dec** **k Floor Beam Station (ST A) 500** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 19 BACB30FM6A5 Or BACB30MC6A5 (d) (e)

- Bolt 5 BACB30FM6A6 Or BACB30MC6A6 (d) (e)

- Bolt 4 BACB30FM6A7 Or BACB30MC6A7 (d) (e)

- Bolt 2 BACB30FM6A8 Or BACB30MC6A8 (d) (e)

- Bolt 1 BACB30FM6A9 Or BACB30MC6A9 (d) (e)

- Bolt 1 BACB30FM8A5 Or BACB30FP8A5 (d) (e)

- Bolt 4 BACB30FN6A7 Or BACB30FQ6A7 (d) (e)

- Bolt 20 BACB30MY8K7 Or BACB30MY8K7X (d) (e)

- Bolt 4 BACB30MY8K8 Or 8BACB30MY8K8X (d) (e)

- Bolt 4 BACB30MY8K11 Or BACB30MY8K11X (d) (e)

- Bolt 2 BACB30NW8K7 Or BACB30NW8K7X (d) (e)

- Bolt 8 BACB30VN6K4 Or BACB30VN8K4 (d) (e)

- Bolt 2 BACB30VN6K6 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 Dec** **k Floor Beam Station (ST A) 500** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 1 BACB30VN8K7 Or BACB30VN10K7 (d) (e)

- Bolt 2 BACB30YP8K7 Or 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 (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 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 Dec** **k Floor Beam Station (ST A) 500** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / 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 Dec k Floor Beam Station (ST**  **A) 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 65B10936-187 Or 65B10936-192 Or 65B10936-197 Or 65B10936-198 (b) (c) 65B10936-511 Or 65B10936-133 Radius Filler L/H 1 65B10936-188 Or 65B10936-196 (b) (c) 65B10936-512 Or 65B10936-132 Radius Filler R/H 1 65B10936-189 Or 65B10936-195 (a) (c) 65B10936-509 Or 65B10936-524 Strap 1 65B10936-190 Or 65B10936-193 (a) (c) 65B10936-508 Or 65B10936-523 Strap 1 65B10936-191 Or 65B10936-194 (d) (e)

- Bolt 145 BACB30FM6A4 Or BACB30MC6A4 (d) (e)

- Bolt 29 BACB30FM6A5 Or BACB30MC6A5 (d) (e)

- Bolt 87 BACB30FM6A6 Or BACB30MC6A6 (d) (e)

- Bolt 2 BACB30FM6A7 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 Dec** **k Floor Beam Station (ST A) 520** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (d) (e)

- Bolt 8 BACB30FM6A8 Or BACB30MC6A8 (d) (e)

- Bolt 1 BACB30FN6A4 Or BACB30FQ6A4 (d) (e)

- Bolt 4 BACB30FN6A6 Or BACB30FQ6A6 (d) (e)

- Bolt 1 BACB30MB6A7 Or BACB30MC6A7 (d) (e)

- Bolt 3 BACB30MB6A8 Or BACB30MC6A8 (d) (e)

- Bolt 8 BACB30MY10K8 Or BACB30MY10K8X (d) (e)

- Bolt 4 BACB30MY10K13 Or BACB30MY10K13X (d) (e)

- Bolt 1 BACB30NW8K8 Or BACB30NW8K8X (d) (e)

- Bolt 6 BACB30VN6K5 Or BACB30VN8K5 (d) (e)

- Bolt 2 BACB30VN6K7 Or BACB30VN8K7 (d) (e)

- Bolt 1 BACB30YP8K8 Or 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

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 Dec** **k Floor Beam Station (ST A) 520** 
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  (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 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**  **CA UTION:**  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. **NO TE:**  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 **CA UTION:**  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. **NO TE:**  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. **NO TE:**  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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) 1

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

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

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

- Lavatory Remove/Keep 4 (e)

- - Personnel Accommodations Area Floor Covering Remove/Keep 5

(f)

- - Upper Deck Floor Panel 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 (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.
**MORE DATA QTY**  **IDENTIFICATION STA**  **NAME TASK**  **STEP CA** **UTION:** 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) (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 65B10936-16 520 (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) 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) 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) 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 (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 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) 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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a)

- - Fastener Holes Inspect 1 (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.
**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 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.
**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. (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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a)

- - Upper Deck Floor Panel Install (Kept) 1 (b)

- - Personnel Accommodations 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 (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. **T**

**ABLE 1: ST**  **A**

**TION 340 FLOORBEAM INST ALLA**  **TION - DRA WING 65B10927**  **Right Strap Left Strap**  **Upper Chord Part Usage**  **Installation Sheet**  **Airplane Effectivity (Basic Numbers)**  -20 -19 -16 Production -503 1, 4, PL, PSDL All affected airplanes. (c) (b) (a) Optional: 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.
**T**

**ABLE 2: ST**  **A**

**TION 360 FLOORBEAM INST ALLA**  **TION - DRA WING 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) Optional: 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.
**T**

**ABLE 3: ST**  **A**

**TION 380 FLOORBEAM INST ALLA**  **TION - DRA WING 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) Optional: 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 T**  **ABLE 4: ST**  **A**

**TION 400 FLOORBEAM INST ALLA**  **TION - DRA WING 65B10930**  **Right Strap/Angle**  **Left Strap/Angle**  **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) Optional: Make from

-156 -525 -509 Production -163 1, 4, 10, PL, PSDL R6144-R6153, R6155-R6156 (c) (b) (a) Optional: Make from -156 -66 -65 Production -204 1, 4, 5, PL, PSDL R4108, R6154, R6157 (c) (d) (a) Optional: Make from -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) Optional: 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.
**T**

**ABLE 5: ST**  **A**

**TION 420 FLOORBEAM INST ALLA**  **TION - DRA WING 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) Optional: 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 T**  **ABLE 5: ST**  **A**

**TION 420 FLOORBEAM INST ALLA**  **TION - DRA WING 65B10931**  **Right Strap Left Strap**  **Upper Chord**  **Parts Usage Installation**  **Sheet Airplane Effectivity (Basic**  **Numbers)** -511 -531 -508 Production -186, -503 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, R6144-R6153, R6155-R6156 (c) (b) (a) Optional: 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.
**T**

**ABLE 6: ST**  **A**

**TION 440 FLOORBEAM INST ALLA**  **TION - DRA WING 65B10932** 
**Aft Radius**  **Filler Fwd**  **Radius 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) Optional:Make from -515 -516 -514 -513 -541 Production -157, -503 1, 4, 5, 11, PL, PSDL R6001-R6016, R6101-R6157 (d) (c) (b) (b) (a) Optional:Make 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.
**T**

**ABLE 7: ST**  **A**

**TION 500 FLOORBEAM INST ALLA**  **TION - DRA WING 65B10935**  **Right Strap/Angle**  **Left Strap/Angle**  **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) Optional: 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 T**  **ABLE 7: ST**  **A**

**TION 500 FLOORBEAM INST ALLA**  **TION - DRA WING 65B10935**  **Right Strap/Angle**  **Left Strap/Angle**  **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) Optional: 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.
**T**

**ABLE 8: ST**  **A**

**TION 520 FLOORBEAM INST ALLA**  **TION - DRA WING 65B10936** 
**Aft Radius**  **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) Optional: Make from -508 -509 -132 -133 -146 Production -134 1, 4, PL, PSDL R4108 (c) (c) (b) (b) (a) Optional: Make from -508 -509 -512 -511 -507 Production -501 1, 4, 12, PL, PSDL R4001-R4107 (c) (c) (b) (b) (a) Optional: Make from -523 -524 -512 -511 -525 Production -518 1, 5, 12, PL, PSDL R6001-R6143 (c) (c) (b) (b) (d) Optional: 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**