# Boeing Alert Service Bulletin 747-53A2696: Revision 1

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- Document: [Boeing Alert Service Bulletin 747-53A2696](https://openairdocs.org/service-documents/boeing/747-53a2696.md)
- Title as filed: U.S. DOT/FAA - SB 747-53A2696R1
- Pages: 101
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## Text

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### Page 1

Commercial 
Airplanes
747
Service Bulletin
ALERT
Number: 747-53A2696
Original Issue: October 16, 2008
Revision 1: April 12, 2012
ATA System: 5321
SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor
Beam Upper Chord and Strap Replacement
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 300-774). An export license may be required before it is used for development, production or use by foreign
persons from specific countries. The controller of this data has the individual responsibility to abide by all export
laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 2008 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner™,
BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and Boeing
liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection
with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management
Company.
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1 of 101
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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 9
1. PLANNING INFORMATION ........................................ 1 3
A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 4
B. Concurrent Requirements ...................................... 1 4
C. Reason ................................................ 1 4
D. Description .............................................. 1 5
E. Compliance .............................................. 1 6
F. Approval ............................................... 1 9
G. Manpower .............................................. 2 0
H. Weight and Balance Changes .................................... 2 2
I. Electrical Load Data ......................................... 2 2
J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data Supplied with this Service Bulletin: ........................... 2 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3
K. Publications Affected ........................................ 2 4
L. Interchangeability and Intermixability of Parts ........................... 2 4
M. Software Accomplishment Summary ................................ 2 4
2. MATERIAL INFORMATION ........................................ 2 5
A. Material - Price and Availability ................................... 2 5
B. Industry Support Information .................................... 2 5
C. Parts Necessary for Each Airplane ................................. 2 5
1. Kits/Parts: ........................................... 2 5
2. Parts and Materials Supplied by the Operator: ........................ 2 5
3. Parts Modified and Reidentified: ............................... 5 8
4. Parts Removed and Not Replaced: .............................. 5 8
D. Parts Necessary to Change Spares ................................. 5 8
E. Special Tooling - Price and Availability ............................... 5 8
F. Special Tooling Necessary to do this Service Bulletin ....................... 5 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 9
A. GENERAL INFORMATION ..................................... 5 9
B. WORK INSTRUCTIONS ....................................... 6 0
FIGURE 1: UPPER DECK FLOOR BEAM - UPPER CHORDS - ACCESS (STA 340 - STA 440, STA 500,
STA 520) ............................................ 6 5
FIGURE 2: UPPER DECK FLOOR BEAM - UPPER CHORD REMOVAL (STA 340 - STA 440, STA 500,
STA 520) ............................................ 6 7
FIGURE 3: INSPECTION OF HOLES IN STRUCTURE WHERE UPPER CHORDS WERE REMOVED (STA
340 - STA 440, STA 500, STA 520) ............................. 7 2
FIGURE 4: UPPER DECK FLOOR BEAM - UPPER CHORD FABRICATION (STA 340 - STA 440, STA
500, STA 520) ......................................... 7 4
FIGURE 5: UPPER DECK FLOOR BEAM - UPPER CHORD INSTALLATION (STA 340 - STA 440, STA
500, STA 520) ......................................... 7 7
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FIGURE 6: UPPER DECK FLOOR BEAM - UPPER CHORDS - CLOSE ACCESS (STA 340 - STA 440,
STA 500, STA 520) ...................................... 8 1
FIGURE 7: UPPER DECK FLOOR BEAM - UPPER CHORDS - REMOVAL (STA 540 - STA 780) . . 83
FIGURE 8: UPPER DECK FLOOR BEAMS - HOLE INSPECTION ................... 8 6
FIGURE 9: UPPER DECK FLOOR BEAM - UPPER CHORDS - FABRICATION (STA 540 - STA 780) . 88
FIGURE 10: UPPER DECK FLOOR BEAM - UPPER CHORDS - INSTALLATION (STA 540 - STA 780) . 90
Appendix A: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 340 - STA 440, STA 500, STA
520) ............................................... 9 2
APPENDIX B: UPPER DECK FLOOR BEAM - UPPER CHORD DATA (STA 540 - STA 780) ...... 9 6
APPENDIX C: SECTION 42 - FASTENER REPLACEMENT GUIDE .................... 1 0 0
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Commercial 
Airplanes
747
Service Bulletin
ALERT
Revision Transmittal SheetNumber: 747-53A2696Original Issue: October 16, 2008
Revision 1: April 12, 2012
ATA System: 5321
SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor
Beam Upper Chord and Strap Replacement
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. Do
the upper chord replacement at body stations 540 through 780 at the compliance time specified in Paragraph
1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2005-07-21, AD 2010-03-05
and AD 2010-07-03 are related to this service bulletin.
REASON FOR REVISION
This revision is sent to add replacement instructions for upper deck floor beam upper chords at body stations
540 through 780. Several other changes have also been made.
These sections were changed:
1. Throughout the service bulletin, the words "as given in" have been changed to "in accordance with".
However, this is not considered an important change, therefore, vertical lines have not been added to
the left side of the page at locations where only this change was made.
2. In Summary: Updated the Background and Action sections to reflect new work requirements. Also,
updated Compliance section with new AD numbers, updated Manpower estimates, and updated
Summary illustration.
3. In Paragraph 1.C., Reason: Added reason for new replacement requirements aft of station (STA) 520,
and added reference to service letter for Widespread Fatigue Damage (WFD).
4. In Paragraph 1.D., Description: Added summary of new replacement requirements aft of STA 520.
5. In Paragraph 1.E., Compliance: Updated titles of Tables 1 and 2. In Table 2, corrected the "Part" callout
in the "Action" column for the "no crack found" condition, and clarified repetitive post-replacement
inspection action. Added compliance Tables 3, 4, and 5 for replacement and post-replacement
requirements of STA 540 through STA 780. Revised grace period for the initial action in compliance
Table 1 to match the grace period given in AD 2010-03-05.
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6. In Paragraph 1.F., Approval: Removed Alternative Method of Compliance (AMOC) statement for
Airworthiness Directive (AD) 2006-08-02 that has been superseded. Added AMOC statements for AD
2010-07-03 and AD 2010-03-05. Updated AMOC statements for AD 2005-07-21 and AD 2004-07-22
R1.
7. In Paragraph 1.G., Manpower: Added manpower estimates for replacement of upper deck floor beam
upper chords for STA 540 through STA 780.
8. In Paragraph 1.H., Weight and Balance Changes: Removed previous weight and balance information
that was entered for Section 41 upper chord replacement. Although the previous revision specified
weight and balance changes, it has been determined that accomplishment of this service bulletin will
not result in a significant change to the airplane weight and balance.
9. In Paragraph 1.J., References: Updated existing data references and added Section 42 drawings used
to prepare the service bulletin.
10. In Paragraph 1.K., Damage Tolerance Based Structural Inspections: Added damage tolerance statement
appropriate for this service bulletin.
11. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added parts and materials needed
for replacement of upper deck floor beam upper chords at STA 540 through STA 780. Also, revised
the upper chord, radius filler, and strap part numbers for stations 340 through 520. Also, removed
original size bolt part numbers for stations 340 through 520. Boeing recommends installation of oversize
fasteners at all bolt locations.
12. In Paragraph 3.A., General Information: Updated existing general notes and added new general notes.
13. In Paragraph 3.B., Work Instructions: Added "Section 41" to Part 1 through Part 5 and designated these
Parts as "Work Package 1: Section 41 Replacement". Clarified post replacement inspection actions
and repetitive requirement in Part 4. Added new Part 6 through Part 10 as "Work Package 2: Section
42 Replacement".
14. In Figures 1 through 6: Updated figure titles to reflect the stations where each figure is applicable. Also,
clarified/corrected the illustrations in these figures and clarified the instructions and footnotes where
necessary.
15. In Figure 2: Upper chord part number for STA 520 has been corrected. Footnote (a) has been revised
to clarify to remove/discard any repair, modification, or splice parts that were previously installed on
the upper chord as part of a Service Bulletin 747-53A2429 repair or modification. Footnote (d) has
been added.
16. In Figure 3: Added step 2 and footnote (b) to clarify requirement to inspect frame where fasteners were
removed.
17. In Figure 5: Revised footnote (a) to clarify requirements at existing fastener locations in frames that
were previously oversized during accomplishment of Section 41 modification Service Bulletin
747-53-2272. Revised footnote (g) to clarify oversize allowances, and revised footnote (i) to clarify
requirement for wet installation of bolts.
18. Figures 7 through 10: Added these new figures for replacement of upper deck floor beam upper chords
at STA 540 through STA 780.
19. In Appendix A: Revised the title to reflect the stations where this appendix is applicable.
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20. Appendix B: Added this new appendix to identify the parts to be replaced and the material used to
make replacement parts for STA 540 through STA 780.
21. Appendix C: Added this new appendix as a cross-reference between the production drawing fastener
codes and the replacement fasteners shown for Section 42 in Paragraph 2.C.2., Parts and Materials
Supplied by the Operator.
The data given in Information Notice 747-53A2696 IN01 is included in this revision. Information Notice
747-53A2696 IN01 was issued to inform operators that the upper chord, radius filler, and strap part numbers
shown in "Part Number / Specification" column of the material tables in paragraph 2.C.2., Parts Necessary For
Each Airplane of the original issue of the service bulletin are incorrect. The part numbers have been corrected
in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location
of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY
October 16, 2008Original Issue:
April 12, 2012Revision 1:
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Commercial 
Airplanes
747
Service Bulletin
ALERT
SummaryNumber: 747-53A2696Original Issue: October 16, 2008
Revision 1: April 12, 2012
ATA System: 5321
SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor
Beam Upper Chord and Strap Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
This service bulletin gives instructions to replace the upper chords and straps on the upper deck floor beams
at STA 340, STA 360, STA 380, STA 400, STA 420, STA 440, STA 500, and STA 520. Analysis by Boeing
indicates that accomplishment of the inspections, repairs, and modifications currently in Service Bulletins
747-53A2420, 747-53A2429, and 747-53A2439 are not adequate to ensure the structural integrity of the affected
7075 aluminum upper deck floor beam upper chords on airplanes that are operated beyond 21,000 total
flight-cycles. On these airplanes, Boeing recommends that the affected upper deck floor beam upper chords be
replaced as shown in this service bulletin. Cracks in the floor beam upper chords that are not found and repaired
could become large and fully sever the floor beam. A severed floor beam can lead to large deflection or
deformation of the floor and of the body skin, frames, and stringers and could result in damage to the wire
bundles and unintended inputs to the flight control cables which could affect airplane controllability. Adjacent
severed floor beams could result in rapid decompression of the airplane, and the loss of structural integrity.
Flight critical wire bundles and control cables are routed through cut outs in the upper deck floor beams.
The affected upper deck floor beam upper chords are made from 7075 aluminum. Boeing has received many
reports from operators of upper chord cracks that have been found on the affected upper deck floor beams.
Cracks were found in the floor beam upper chords and straps common to floor panel fastener locations. The
airplanes had flown between 16,264 and 23,561 total flight cycles. As a result of these crack reports, Boeing
issued Service Bulletin 747-53A2439, "Fuselage Floors Upper Deck Floor Beam Upper Chord Inspection at
Floor Panel Attachment Fastener Holes". In addition, Boeing has received many reports of cracks in the affected
floor beam upper chords at the fastener locations where the upper chords attach to the body frames. As a result
of these crack reports, Boeing issued Service Bulletins 747-53A2420, "Fuselage Floors Upper Deck Floor Beam
Web and Chord Crack Inspection" and 747-53A2429, "Fuselage Floors Upper Deck Floor Beam Modification
and Repair".
Boeing Service Related Problem (SRP) 747OP-SRP-53-0238 is related to this service bulletin.
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Subsequent to the original issue of this service bulletin, Boeing has determined that upper deck floor beam
upper chord replacement is required at body stations aft of station (STA) 520. Upper deck floor beam upper
chords aft of STA 520 are made from 2024 aluminum. These upper chords have been determined to be structure
that is susceptible to Widespread Fatigue Damage (WFD). Ongoing inspection of this structure is not sufficient
to maintain an acceptable level of safety, and replacement of the structure is required.
For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
Paragraph 1.E., ComplianceYesAD Related
Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedNoPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsNoBoeing supplied Kits/Parts
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
YesOperator Supplied Parts and Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
Get access to upper deck floor beams from STA 340 to STA 440, and at STA 500 and STA 520 from the upper
deck. Remove the floor beam upper chords, angles, straps and radius fillers. Do an open hole High Frequency
Eddy Current (HFEC) inspection at all accessed holes and repair if any crack is found. Fabricate new upper
chords, straps, angles and radius fillers. Install the new floor beam upper chords, angles, straps and radius
fillers. Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin 747-53A2429
should not be re-installed. Install all equipment and panels removed for access.
Group 1:
Get access to upper deck floor beams from STA 540 to STA 740 from the upper deck. Remove the floor beam
upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and do
a repair if any crack is found. Fabricate and install new floor beam upper chords. Re-install any repairs or parts
that are not replaced, except parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install
all equipment and panels removed for access.
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Group 2:
Get access to upper deck floor beams from STA 540 to STA 780 from the upper deck. Remove the floor beam
upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and do
a repair if any crack is found. Fabricate and install new floor beam upper chords. Re-install any repairs or parts
that are not replaced, except parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install
all equipment and panels removed for access.
EFFECTIVITY
All 747-200C/200F airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directives 2004-07-22 R1, 2005-07-21, 2010-03-05 and
2010-07-03 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER
Work Package 1
Elapsed HoursTotal Task HoursAirplanes
135.25541.00Group 1 and 2
Work Package 2
Elapsed HoursTotal Task HoursAirplanes
100.00400.00Group 1
115.81463.25Group 2
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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### Page 12 (OCR)

BOEING SERVICE BULLETIN 747-53A2696
ALERT  ALERT
SEE
GROUP1 AND 2: REMOVE AND DISCARD
EXISTING UPPER CHORDS AND STRAPS AT
STATION 340 THRU 440, AND AT
STATIONS 500 AND 520. MAKE AND
INSTALL NEW UPPER CHORDS AND STRAPS
GROUP1: REMOVE AND DISCARD EXISTING
UPPER CHORDS AT STATION 540 THRU
740. MAKE AND INSTALL NEW UPPER
CHORDS
FLOOR PANEL  GROUP2: REMOVE AND DISCARD EXISTING
UPPER CHORDS AT STATION 540 THRU
780. MAKE AND INSTALL NEW UPPER
CHORDS
UPPER CHORD
WEB -  DO HFEC OPEN HOLE INSPECTIONS
OF ALL ACCESSED HOLES IN THE
WEB AND FRAMES.
LOWER CHORD
UP
TYPICAL UPPER
DECK FLOOR BEAMS  DINBD
1423286
Original Issue: October 16, 2008
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### Page 13

Commercial 
Airplanes
747
Service Bulletin
ALERT
Number: 747-53A2696
Original Issue: October 16, 2008
Revision 1: April 12, 2012
ATA System: 5321
SUBJECT: FUSELAGE - Auxiliary Structure - Main and Upper Deck Floor - Upper Deck Floor
Beam Upper Chord and Strap Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP
All 747-200F airplanes.-1
All 747-200C airplanes.-2
Airplane Models:
747-200C, 747-200F
GroupVariable Number
2RJ131 - RJ133
2RJ151 - RJ152
2RJ301 - RJ303
2RJ321 - RJ322
2RJ331 - RJ333
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GroupVariable Number
1RR001 - RR005
1RR021 - RR025
1RR031
1RR201 - RR206
1RR221 - RR226
1RR261 - RR267
1RR301 - RR310
1RR331 - RR332
1RR336
1RR341 - RR345
1RR361 - RR362
1RR421 - RR422
1RR431 - RR432
1RR441 - RR442
1RR451
1RR501 - RR504
1RR521 - RR522
1RR526
1RR531
1RR551 - RR556
1RR561
1RR566
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
This service bulletin gives instructions to replace the upper chords and straps on the upper deck floor
beams at STA 340, STA 360, STA 380, STA 400, STA 420, STA 440, STA 500, and STA 520. Analysis
by Boeing indicates that accomplishment of the inspections, repairs, and modifications currently in
Service Bulletins 747-53A2420, 747-53A2429, and 747-53A2439 are not adequate to ensure the
structural integrity of the affected 7075 aluminum upper deck floor beam upper chords on airplanes
that are operated beyond 21,000 total flight-cycles. On these airplanes, Boeing recommends that the
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ALERTALERT

### Page 15

affected upper deck floor beam upper chords be replaced as shown in this service bulletin. Cracks in
the floor beam upper chords that are not found and repaired could become large and fully sever the
floor beam. A severed floor beam can lead to large deflection or deformation of the floor and of the
body skin, frames, and stringers and could result in damage to the wire bundles and unintended inputs
to the flight control cables which could affect airplane controllability. Adjacent severed floor beams
could result in rapid decompression of the airplane, and the loss of structural integrity.
Flight critical wire bundles and control cables are routed through cut outs in the upper deck floor beams.
The affected upper deck floor beam upper chords are made from 7075 aluminum. Boeing has received
many reports from operators of upper chord cracks that have been found on the affected upper deck
floor beams. Cracks were found in the floor beam upper chords and straps common to floor panel
fastener locations. The airplanes had flown between 16,264 and 23,561 total flight cycles. As a result
of these crack reports, Boeing issued Service Bulletin 747-53A2439, "Fuselage Floors Upper Deck
Floor Beam Upper Chord Inspection at Floor Panel Attachment Fastener Holes". In addition, Boeing
has received many reports of cracks in the affected floor beam upper chords at the fastener locations
where the upper chords attach to the body frames. As a result of these crack reports, Boeing issued
Service Bulletins 747-53A2420, "Fuselage Floors Upper Deck Floor Beam Web and Chord Crack
Inspection" and 747-53A2429, "Fuselage Floors Upper Deck Floor Beam Modification and Repair".
Boeing Service Related Problem (SRP) 747OP-SRP-53-0238 is related to this service bulletin.
Subsequent to the original issue of this service bulletin, Boeing has determined that upper deck floor
beam upper chord replacement is required at body stations aft of station (STA) 520. Upper deck floor
beam upper chords aft of STA 520 are made from 2024 aluminum. These upper chords have been
determined to be structure that is susceptible to Widespread Fatigue Damage (WFD). Ongoing inspection
of this structure is not sufficient to maintain an acceptable level of safety, and replacement of the
structure is required.
For more information about WFD, refer to Boeing Service Letter 747-SL-53-088A.
Revision 1 is sent to add replacement instructions for upper deck floor beam upper chords at body
stations 540 through 780. Other changes have also been made. A list of Revision 1 changes can be
found in the Revision Transmittal Sheet section of Revision 1.
D. Description
Get access to upper deck floor beams from STA 340 to STA 440, and at STA 500 and STA 520 from
the upper deck. Remove the floor beam upper chords, angles, straps and radius fillers. Do an open
hole High Frequency Eddy Current (HFEC) inspection at all accessed holes and repair if any crack is
found. Fabricate new upper chords, straps, angles and radius fillers. Install the new floor beam upper
chords, angles, straps and radius fillers. Re-install any repairs or parts that are not replaced, except
parts installed by Service Bulletin 747-53A2429 should not be re-installed. Install all equipment and
panels removed for access.
Group 1:
Get access to upper deck floor beams from STA 540 to STA 740 from the upper deck. Remove the
floor beam upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all
accessed holes and do a repair if any crack is found. Fabricate and install new floor beam upper chords.
Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin
747-53A2429 should not be re-installed. Install all equipment and panels removed for access.
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Group 2:
Get access to upper deck floor beams from STA 540 to STA 780 from the upper deck. Remove the
floor beam upper chords. Do an open hole High Frequency Eddy Current (HFEC) inspection at all
accessed holes and do a repair if any crack is found. Fabricate and install new floor beam upper chords.
Re-install any repairs or parts that are not replaced, except parts installed by Service Bulletin
747-53A2429 should not be re-installed. Install all equipment and panels removed for access.
Revision 1 - More work is necessary on airplanes changed in accordance with the original issue of this
service bulletin. Do the upper chord replacement at body stations 540 through 780 at the compliance
time specified in Paragraph 1.E., Compliance.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
221, 222, 223, 224, 225, 226, 233, 234747-200F
Group 2:
Affected Maintenance Zones
ZoneModel
221, 222, 223, 224, 225, 226, 233, 234747-200C
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directives AD 2004-07-22 R1, AD 2005-07-21,
AD 2010-03-05 and AD 2010-07-03 are related to this service bulletin.
Table 1: Upper Deck Floor beam - Upper Chord Replacement - Section 41
Compliance Time (Whichever Occurs Later)ActionCondition
Within 1,500 flight cycles
after March 11, 2010 (the
effective date of AD
2010-03-05).
Before 21,000 total flight
cycles. (a)
Do an open hole HFEC inspection at all
accessed fastener holes at STA 340
through STA 440, STA 500 and STA 520
for cracks in accordance with the Accom-
plishment Instructions, Paragraph 3.B,
Part 2.
All airplanes
-Before further flightContact Boeing for repair instructions
and do the repair.
Any crack
found
-Immediately after the in-
spection in accordance
with the Accomplishment
Instructions, Paragraph
3.B, Part 2 is accom-
plished.
Install new upper deck floor beam upper
chords, straps, angles and radius fillers
at STA 340 through STA 440, STA 500
and STA 520 in accordance with the
Accomplishment Instructions, Paragraph
3.B, Part 3.
All airplanes
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Table 1: Upper Deck Floor beam - Upper Chord Replacement - Section 41
Compliance Time (Whichever Occurs Later)ActionCondition
(a) Due to the post-replacement requirements, and the possibility that it will be necessary to replace the upper
chords again, Boeing does not recommend upper chord replacement prior to 15,000 total flight-cycles.
Table 2: Post-Upper Chord Replacement Actions - Section 41
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
-Within 15,000 flight cycles after
upper chord replacement in accor-
dance with this service bulletin.
Do detailed and HFEC inspections
of the replaced upper deck floor
beam chords for cracks in accor-
dance with the Accomplishment In-
structions, paragraph 3.B, Part 4.
Upper chord re-
placement has
been accom-
plished
-Before further flight.Contact Boeing for repair instruc-
tions and do the repair.
Any crack is
found.
3,000 flight cycles.-Repeat the detailed and HFEC in-
spections of the replaced upper
deck floor beam chords for cracks
in accordance with the Accomplish-
ment Instructions, paragraph 3.B,
Part 4.
No crack is
found.
-Within 5,000 flight cycles after the
initial detailed and HFEC inspec-
tion was done in accordance with
the Accomplishment Instructions,
paragraph 3.B, Part 4.
Do the inspection and chord replace-
ment actions again, in accordance
with the Accomplishment Instruc-
tions, paragraph 3.B, Part 2 and
paragraph 3.B, Part 3.
Group 1:
Table 3: Upper Deck Floor beam - Upper Chord Replacement - Section 42
Compliance Time (Whichever Occurs Later)ActionCondition
Within 1,500 flight cycles
after the Revision 1 date
on this service bulletin.
Before 30,000 total flight
cycles. (a)
Do an open hole HFEC inspection at all
accessed fastener holes at STA 540
through STA 740 for cracks in accor-
dance with the Accomplishment Instruc-
tions, paragraph 3.B, Part 7.
All airplanes
-Before further flightContact Boeing for repair instructions
and do the repair.
Any crack
found
-Immediately after the in-
spection in accordance
with the Accomplishment
Instructions paragraph
3.B, Part 7 is accom-
plished.
Install new upper deck floor beam upper
chords at STA 540 through STA 740 in
accordance with the Accomplishment
Instructions paragraph 3.B, Part 8.
All airplanes
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Group 1:
Table 3: Upper Deck Floor beam - Upper Chord Replacement - Section 42
Compliance Time (Whichever Occurs Later)ActionCondition
(a) Due to the post-replacement requirements, and the possibility that it will be necessary to replace the upper
chords again, Boeing does not recommend upper chord replacement prior to 15,000 total flight-cycles.
Group 2:
Table 4: Upper Deck Floor beam - Upper Chord Replacement - Section 42
Compliance Time (Whichever Occurs Later)ActionCondition
Within 1,500 flight cycles
after the Revision 1 date
on this service bulletin.
Before 30,000 total flight
cycles. (a)
Do an open hole HFEC inspection at all
accessed fastener holes at STA 540
through STA 780 for cracks in accor-
dance with the Accomplishment Instruc-
tions, paragraph 3.B, Part 7.
All airplanes
-Before further flightContact Boeing for repair instructions
and do the repair.
Any crack
found
-Immediately after the in-
spection in accordance
with the Accomplishment
Instructions, paragraph
3.B, Part 7 is accom-
plished.
Install new upper deck floor beam upper
chords at STA 540 through STA 780 in
accordance with the Accomplishment
Instructions, paragraph 3.B, Part 8.
All airplanes
(a) Due to the post-replacement requirements, and the possibility that it will be necessary to replace the upper
chords again, Boeing does not recommend upper chord replacement prior to 15,000 total flight-cycles.
Table 5: Post-Upper Chord Replacement Actions - Section 42
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
-Within 20,000 flight cycles after
upper chord replacement in accor-
dance with this service bulletin.
Do HFEC inspections of the re-
placed upper deck floor beam
chords for cracks in accordance with
the Accomplishment Instructions,
paragraph 3.B, Part 9.
Upper chord re-
placement has
been accom-
plished
-Before further flight.Contact Boeing for repair instruc-
tions and do the repair.
Any crack is
found.
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Table 5: Post-Upper Chord Replacement Actions - Section 42
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
6,000 flight cycles.-Repeat the HFEC inspections of the
replaced upper deck floor beam
chords for cracks in accordance with
the Accomplishment Instructions,
paragraph 3.B, Part 9.
No crack is
found.
-Within 10,000 flight cycles after
the initial detailed and HFEC in-
spection was done in accordance
with the Accomplishment Instruc-
tions, paragraph 3.B, Part 9.
Do the inspection and chord replace-
ment actions again, in accordance
with the Accomplishment Instruc-
tions, paragraph 3.B, Part 7 and
paragraph 3.B, Part 8.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
This service bulletin has been approved by the FAA. In addition, the Manager of the Seattle Aircraft
Certification Office (ACO) approves the replacement and post replacement inspection actions with the
corresponding compliance times specified in Tables 1, 2, 3, 4, and 5 under paragraph 1.E., "Compliance",
of Service Bulletin 747-53A2696, Revision 1, as an Alternative Method of Compliance (AMOC) to the
inspection, repair, and modification actions with corresponding compliance times required by paragraphs
(g), (h), (i), (k), (l), and (m) of AD 2010-07-03. This AMOC is only for areas where upper deck floor
beam upper chords have been replaced in accordance with this service bulletin. When this service
bulletin specifies contacting Boeing for repair instructions, the repair instructions must be approved by
the FAA in accordance with paragraph (o) of the AD. All provisions of AD 2010-07-03 that are not
specifically referenced in this paragraph remain fully applicable and must be complied with.
In addition, the Manager of the Seattle ACO approves the accomplishment of the applicable inspection,
repair, and modification procedures in this service bulletin, as an AMOC to the inspection, repair and
modification requirements of paragraphs (a), (b), (c), (e) and (i) of AD 2005-07-21. The Manager of the
Seattle ACO also approves the accomplishment of the applicable inspection, repair and modification
procedures in this service bulletin, as a method of compliance (MOC) to the inspection, repair, and
modification requirements of paragraphs (g)(1), (h)(2), (j), (k) and (l) of AD 2005-07-21. All provisions
of AD 2005-07-21 that are not specifically referenced in the preceding statement remain fully applicable
and must be complied with accordingly.
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In addition, the Manager of the Seattle ACO approves the accomplishment of the replacement and
post replacement inspection actions with corresponding compliance times listed in Tables 1 and 2
under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, Revision 1, as an AMOC to the
replacement and post replacement inspection actions with corresponding compliance times specified
in Tables 1 and 2 under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, original issue,
dated October 16, 2008, required by paragraphs (g) and (h) of AD 2010-03-05. The Manager of the
Seattle ACO also approves the accomplishment of the replacement and post replacement inspection
actions with corresponding compliance times listed in Tables 1 and 2 under paragraph 1.E.,
"Compliance", of Service Bulletin 747-53A2696, Revision 1, as a MOC to the replacement and post
replacement inspection actions with corresponding compliance times specified in Tables 1 and 2 under
paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, original issue, dated October 16, 2008,
required by paragraph (i) of AD 2010-03-05. All provisions of AD 2010-03-05 that are not specifically
referenced in the preceding statement remain fully applicable and must be complied with accordingly.
In addition, the Manager of the Seattle ACO approves the accomplishment of the replacement and
post replacement inspection actions with corresponding compliance times specified in Tables 1, 2, 3,
4, and 5 under paragraph 1.E., "Compliance", of Service Bulletin 747-53A2696, Revision 1, as an
AMOC to the corresponding inspection and repair requirements of paragraphs (h), (i), and (j) of AD
2004-07-22 R1, for the inspection of Structural Significant Items (SSI) F-19B, F-19C, F-19D, F-19E,
F-20A, and F-20G of Supplemental Structural Inspection Document (SSID) D6-35022, Revision G,
dated December 2000. This AMOC only applies to the areas where upper deck floor beam upper chords
were replaced in accordance with this service bulletin. When this service bulletin specifies contacting
Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with
paragraph (l) of the AD. All provisions of AD 2004-07-22 R1 that are not specifically reference in this
paragraph, including the initial inspection threshold per paragraph (i) of AD 2004-07-22 R1, remain
fully applicable and must be complied with.
G. Manpower
The table below shows an estimate of the task hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to inspect the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Table 1: Upper Deck Floor Beam Upper Chord Replacement at STA 340 - STA 440, STA
500, and STA 520 (Work Package 1)
Elapsed HoursTask HoursNumber of Per-
sons
Task
15.0060.004Open Access
7.7531.004Figure 1
27.75111.004Figure 2
10.5042.004Figure 3
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Table 1: Upper Deck Floor Beam Upper Chord Replacement at STA 340 - STA 440, STA
500, and STA 520 (Work Package 1)
Elapsed HoursTask HoursNumber of Per-
sons
Task
(a)(a)-Figure 4
51.50206.004Figure 5
7.7531.004Figure 6
15.0060.004Close Access
(b)(b)-Test
135.25541.00TOTAL 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 ac-
cess or chord replacement in accordance with this service bulletin.
Group 1:
Table 2: Upper Deck Floor Beam Upper Chord Replacement at STA 540 - STA 740 (Work
Package 2)
Elapsed HoursTask HoursNumber of Per-
sons
Task
6.3125.254Access
35.75143.004Figure 7 - Removal
14.5058.004Figure 8 - Inspec-
tion
(a)(a)-Figure 9 - Fabrica-
tion
37.13148.504Figure 10 - Installa-
tion
6.3125.254Close Access
100.00400.00TOTAL FOR EACH AIRPLANE
(a) Time to manufacture parts is not included in this estimate.
Group 2:
Table 3: Upper Deck Floor Beam Upper Chord Replacement at STA 540 - STA 780 (Work
Package 2)
Elapsed HoursTask HoursNumber of Per-
sons
Task
6.3125.254Access
42.25169.004Figure 7 - Removal
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Group 2:
Table 3: Upper Deck Floor Beam Upper Chord Replacement at STA 540 - STA 780 (Work
Package 2)
Elapsed HoursTask HoursNumber of Per-
sons
Task
17.0668.254Figure 8 - Inspec-
tion
(a)(a)-Figure 9 - Fabrica-
tion
43.88175.504Figure 10 - Installa-
tion
6.3125.254Close Access
115.81463.25TOTAL FOR EACH AIRPLANE
(a) Time to manufacture parts is not included in this estimate.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. 747-100/200/300 Aircraft Maintenance Manual (AMM) 25-11-02, 25-11-03, 25-16-01, 25-16-02,
25-25-01 , 25-27-05 , 25-40-03, 53-21-02
b. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00
c. Boeing Service Bulletin 747-53A2429, "FUSELAGE - Floors - Upper Deck Floor Beam
Modification And Repair"
d. Boeing Service Bulletin 747-53A2439, FUSELAGE - Floors - Upper Deck Floor Beam Upper
Chord Inspection at Floor Panel Attachment Fastener Holes"
e. Boeing Service Bulletin 747-53A2420, FUSELAGE - Floors - Upper Deck Floor Beam Web
Chord Crack Inspection
f. Boeing Service Bulletin 747-53-2272, FUSELAGE-Nose Section 41 Body Frame Structure
Replacement and Reinforcement
g. Service Related Problem (SRP) 747OP-SRP-53-0238.
h. Standard Overhaul Practices Manual (SOPM) 20-43-03, 20-50-03.
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i. Boeing Drawing 012W6100.
j. Boeing Parts Standards Document D-590.
k. Supplemental Structural Inspection Document (SSID) D6-35022, Revision G.
l. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2004-07-22 R1, 2005-07-21,
2010-03-05, 2010-07-03
m. Boeing Service Letter 747-SL-53-088A
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
SHEAR TIE INSTL - CREW FLOOR, STA 330 TO STA 52065B07966
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 34065B10927
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 36065B10928
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 38065B10929
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 40065B10930
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 42065B10931
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 44065B10932
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 50065B10935
FLOOR BEAM INSTL - CREW COMPARTMENT, STA 52065B10936
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 54065B38517
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 56065B38518
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 58065B38519
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 60065B38520
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 62065B38521
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 64065B38522
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 66065B38523
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 68065B38524
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 70065B38525
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 72065B38526
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 74065B38527
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 76065B17358
FLOOR BEAM INSTL - STATEROOM, FUSELAGE STATION 78065B17359
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These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected
are contained in Paragraph 1.E., Compliance of this service bulletin.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary For Each
Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin
does not show the Boeing price and supply data.
B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts:
None.
2. Parts and Materials Supplied by the Operator:
NOTE: For Section 41 (STA 340 - 520), if frames have previously been replaced in accordance
with Section 41 modification Service Bulletin 747-53-2272, then additional oversize
fasteners will be needed where holes have already been oversized in the frames.
NOTE: For Section 41 (STA 340 - 520), the replacement fasteners listed are based on original
production drawings and have not been updated to current specifications. Any fasteners
and their associated oversizes equivalent to the original production fasteners, as outlined
in the D-590 substitution document are acceptable.
NOTE: For Section 42 (STA 540 - 780), the replacement fasteners listed in this revision are
current specifications. Any fasteners and their associated oversizes equivalent to the
original production fasteners, as outlined in the D-590 substitution document are
acceptable. Also, replacement fasteners listed for Section 42 are based on Appendix C
- Fastener Replacement Guide.
Upper Deck Floor Beam Station (STA) 340
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10927-16Chord-Upper (STA 340)165B10927-16
(b) (c)65B10927-19Radius Filler L/H (STA 340)165B10927-19
(b) (c)65B10927-20Radius Filler R/H (STA 340)165B10927-20
(d) (e)-Bolt2BACB30MC6A3
(d) (e)-Bolt15BACB30MC6A4
(d) (e)-Bolt35BACB30MC6A5
(d) (e)-Bolt15BACB30MC6A6
(d) (e)-Bolt4BACB30MC6A7
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Upper Deck Floor Beam Station (STA) 340
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Bolt2BACB30MC6A9
(d) (e)-Bolt1BACB30FQ6A3
(d) (e)-Bolt1BACB30FQ6A9
(d)-Collar73BACC30M6
(d) (e)-Rivet4BACR15BA6D5C
or
BACR15BA7D5C
(d) (e)-Rivet88BACR15BB5D5C
or
BACR15BB6D5C
(d) (e)-Rivet20BACR15BB5D6C
or
BACR15BB6D6C
(d) (e)-Rivet7BACR15BB6D6C
or
BACR15BB7D6C
(d) (e)-Rivet44BACR15BB6D7C
or
BACR15BB7D7C
(d) (e)-Rivet4BACR15BB6D8C
or
BACR15BB7D8C
(d) (e)-Rivet2BACR15BB8D6C
or
BACR15BB9D6C
(d) (e)-Rivet2BACR15BB8D7C
or
BACR15BB9D7C
(d) (e)-Rivet2BACR15BB8D8C
or
BACR15BB9D8C
(d) (e)-Rivet4BACR15GF6D8C
or
BACR15GF61D8C
(d) (e)-Rivet4BACR15GF6D8C
or
BACR15GF61D8C
(f)-Chemical Conversion Coating4 OuncesType 2, Class A
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Upper Deck Floor Beam Station (STA) 340
NotesExisting Part NumberNameQTYPart Number /
Specification
(g)-Primer1/4 PintBMS 10-11,
Type I
(g)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.
(b) Fabricate from 2024-T3511 in accordance with APPENDIX A.
(c) Discard the existing part.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
(f) Refer to SOPM 20-43-03 for supplier data.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 360
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10928-40Chord-Upper (STA 360)165B10928-40
(b) (c)65B10928-42Radius Filler L/H (STA 360)165B10928-42
(b) (c)65B10928-43Radius Filler R/H (STA 360)165B10928-43
(d) (e)-Bolt2BACB30MC6A3
(d) (e)-Bolt3BACB30MC6A4
(d) (e)-Bolt12BACB30MC6A5
(d) (e)-Bolt4BACB30MC6A6
(d) (e)-Bolt2BACB30MC6A7
(d) (e)-Bolt4BACB30MC6A8
(d) (e)-Bolt2BACB30MC6A10
(d) (e)-Bolt2BACB30MC6A12
(d) (e)-Bolt8BACB30NX6K5X
(d) (e)-Bolt12BACB30NX6K6X
(d) (e)-Bolt6BACB30NX6K7X
(d) (e)-Bolt14BACB30NX6K8X
(d) (e)-Bolt6BACB30NX6K9X
(d)-Collar81BACC30M6
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### Page 28

Upper Deck Floor Beam Station (STA) 360
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Rivet70BACR15BB5D5C
or
BACR15BB6D5C
(d) (e)-Rivet70BACR15BB5D6C
or
BACR15BB6D6C
(d) (e)-Rivet9BACR15BB5D7C
or
BACR15BB6D7C
(d) (e)-Rivet6BACR15GF6D8C
or
BACR15GF61D8C
(f)-Chemical Conversion Coating4 OuncesType 2, Class A
(g)-Primer1/4 pintBMS 10-11,
Type I
(g)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.
(b) Fabricate from 2024-T3511 in accordance with APPENDIX A .
(c) Discard the existing part.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
(f) Refer to SOPM 20-43-03 for supplier data.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 380
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10929-518Chord-Upper (STA 380)165B10929-518
(b) (c)65B10929-537Radius Filler L/H (STA 380)165B10929-537
(b) (c)65B10929-566Radius Filler R/H (STA 380)165B10929-566
(d) (e)-Bolt1BACB30FM6A7
(d) (e)-Bolt2BACB30MC6A3
(d) (e)-Bolt16BACB30MC6A4
Export Controlled ECCN: 9E991 - BOEING
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### Page 29

Upper Deck Floor Beam Station (STA) 380
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Bolt18BACB30MC6A5
(d) (e)-Bolt3BACB30MC6A6
(d) (e)-Bolt7BACB30MC6A7
(d) (e)-Bolt1BACB30MC6A8
(d) (e)-Bolt2BACB30NX6K8X
(d)-Collar50BACC30M6
(d) (e)-Rivet138BACR15BB5D6C
or
BACR15BB6D6C
(d) (e)-Rivet161BACR15BB5D7C
or
BACR15BB6D7C
(d) (e)-Rivet42BACR15BB5D8C
or
BACR15BB6D8C
(d) (e)-Rivet10BACR15BB6D7C
or
BACR15BB7D7C
(d) (e)-Rivet9BACR15BB6D8C
or
BACR15BB7D8C
(d) (e)-Rivet20BACR15BB8D8C
or
BACR15BB9D8C
(d) (e)-Rivet2BACR15GF6D8C
or
BACR15GF61D8C
(d) (e)-Rivet4BACR15GF6D9C
or
BACR15GF61D9C
(f)-Chemical Conversion Coating4 OuncesType 2, Class A
(g)-Primer1/4 PintBMS 10-11,
Type I
(g)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A .
(b) Fabricate from 7075-T6 in accordance with APPENDIX A .
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### Page 30

Upper Deck Floor Beam Station (STA) 380
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) Discard the existing part.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
(f) Refer to SOPM 20-43-03 for supplier data.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 400
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10930-65 or
65B10930-509
Chord-Upper165B10930-65 or
65B10930-509
(b) (c)65B10930-66 or
65B10930-525
Radius Filler L/H165B10930-66 or
65B10930-525
(b) (c)65B10930-156 or
65B10930-528
Radius Filler R/H165B10930-156
or
65B10930-528
(d) (e)-Bolt11BACB30MC6A4
(d) (e)-Bolt14BACB30MC6A5
(d) (e)-Bolt5BACB30MC6A6
(d) (e)-Bolt2BACB30MC6A7
(d) (e)-Bolt1BACB30MY6K6
(d) (e)-Bolt14BACB30NX6K5X
(d) (e)-Bolt3BACB30NX6K6X
(d) (e)-Bolt2BACB30NX6K7X
(d) (e)-Bolt9BACB30MY8K4X
(d) (e)-Bolt8BACB30MY8K5X
(d) (e)-Bolt2BACB30NX8K7X
(d)Collar43BACC30M6
(d)-Collar13BACC30M8
(d) (e)-Rivet6BACR15BA5D6C
or
BACR15BA6D6C
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### Page 31

Upper Deck Floor Beam Station (STA) 400
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Rivet1BACR15BA6D7C
or
BACR15BA7D7C
(d) (e)-Rivet134BACR15BB5D5C
or
BACR15BB6D5C
(d) (e)-Rivet14BACR15BB5D6C
or
BACR15BB6D6C
(d) (e)-Rivet2BACR15BB5D7C
or
BACR15BB6D7C
(d) (e)-Rivet35BACR15BB6D7C
or
BACR15BB7D7C
(d) (e)-Rivet8BACR15BB8D6C
or
BACR15BB9D6C
(d) (e)-Rivet2BACR15BB8D8C
or
BACR15BB9D8C
(d) (e)-Rivet18BACR15BB8D9C
or
BACR15BB9D9C
(d) (e)-Rivet6BACR15GF6D8C
or
BACR15GF61D8C
(f)-Chemical Conversion Coating4 OuncesType 2, Class A
(g)-Primer1/4 PintBMS 10-11,
Type I
(g)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A .
(b) Fabricate from 7075-T6 in accordance with APPENDIX A .
(c) Discard the existing part.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
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### Page 32

Upper Deck Floor Beam Station (STA) 400
NotesExisting Part NumberNameQTYPart Number /
Specification
(f) Refer to SOPM 20-43-03 for supplier data.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 420
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B10931-64 or
65B10931-508
Chord-Upper165B10931-64 or
65B10931-508
(a) (b)65B10931-65 or
65B10931-531
Radius Filler L/H165B10931-65 or
65B10931-531
(a) (b)65B10931-511Radius Filler R/H165B10931-511
(c) (d)-Bolt6BACB30NX6K3X
(c) (d)-Bolt25BACB30NX6K4X
(c) (d)-Bolt20BACB30NX6K5X
(c) (d)-Bolt5BACB30NX6K6X
(c) (d)-Bolt1BACB30NX6K7X
(c) (d)-Bolt1BACB30MY8K5X
(c) (d)-Bolt2BACB30MY8K6X
(c) (d)-Bolt16BACB30MY8K7X
(c) (d)-Bolt1BACB30MY8K10X
(c) (d)-Bolt11BACB30NW6K3X
(c)-Collar2BACC30BL8
(c)-Collar68BACC30M6
(c)-Collar20BACC30M8
(c) (d)-Rivet7BACR15BB5D6C
or
BACR15BB6D6C
(c) (d)-Rivet3BACR15BB5D7C
or
BACR15BB6D7C
(c) (d)-Rivet148BACR15BB6D6C
or
BACR15BB7D6C
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### Page 33

Upper Deck Floor Beam Station (STA) 420
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)-Rivet9BACR15BB8D6C
or
BACR15BB9D6C
(c) (d)-Rivet1BACR15BB8D7C
or
BACR15BB9D7C
(c) (d)-Rivet50BACR15BB6D7C
or
BACR15BB7D7C
(c) (d)-Rivet4BACR15GF6D8C
or
BACR15GF61D8C
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 440
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10932-508 or
65B10932-541
Chord-Upper165B10932-508
or
65B10932-541
(b) (c)65B10932-513Radius Filler L/H165B10932-513
(b) (c)65B10932-514Radius Filler R/H165B10932-514
(a) (c)65B10932-516Radius Filler165B10932-516
(a) (c)65B10932-515Radius Filler165B10932-515
(d) (e)-Bolt2BACB30MC6A6
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### Page 34

Upper Deck Floor Beam Station (STA) 440
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Bolt2BACB30MC6A7
(d) (e)-Bolt1BACB30MC6A6
(d) (e)-Bolt1BACB30MC6A8
(d) (e)-Bolt4BACB30FQ6A8
(d) (e)-Bolt1BACB30MC6A5
(d) (e)-Bolt4BACB30MC6A7
(d) (e)-Bolt2BACB30MC6A8
(d) (e)-Bolt71BACB30NX6K5X
(d) (e)-Bolt16BACB30NX6K6X
(d) (e)-Bolt21BACB30NX6K7X
(d) (e)-Bolt13BACB30NX6K8X
(d) (e)-Bolt2BACB30NX6K10X
(d) (e)-Bolt4BACB30MY8K8X
(d) (e)-Bolt12BACB30MY8K9X
(d) (e)-Bolt4BACB30MY8K10X
(d) (e)-Bolt2BACB30MY8K11X
(d) (e)-Bolt2BACB30MY8K13X
(d) (e)-Bolt2BACB30NW8K8X
(d) (e)-Bolt1BACB30VN10K6
(d) (e)-Bolt1BACB30VN10K8
(d) (e)-Bolt2BACB30NW8K8X
(d)-Collar7BACC30BH6
(d)-Collar2BACC30BK8
(d)-Collar2BACC30BL8
(d)-Collar131BACC30M6
(d)-Collar28BACC30M8
(d) (e)-Rivet4BACR15BB6D6C
or
BACR15BB7D6C
(d) (e)-Rivet87BACR15BB6D7C
or
BACR15BB7D7C
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
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### Page 35

Upper Deck Floor Beam Station (STA) 440
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Rivet21BACR15BB6D8C
or
BACR15BB7D8C
(d) (e)-Rivet4BACR15BB6D9C
or
BACR15BB7D9C
(d) (e)-Rivet1BACR15BB6D10C
or
BACR15BB7D10C
(f)-Chemical Conversion Coating4 OuncesType 2, Class A
(g)-Primer1/4 PintBMS 10-11,
Type I
(g)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A .
(b) Fabricate from 7075-T6 in accordance with APPENDIX A.
(c) Discard the existing part.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
(f) Refer to SOPM 20-43-03 for supplier data.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 500
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10935-144 or
65B10935-507
Chord-Upper R/H165B10935-144
or
65B10935-507
(a) (c)65B10935-506Chord-Upper L/H165B10935-506
(b) (c)65B10935-515 or
65B10935-145
Reinforcement Angle Radius Filler
L/H
165B10935-515
or
65B10935-145
(b) (c)65B10935-146 or
65B10935-516
Reinforcement Angle Radius Filler
R/H
165B10935-146
or
65B10935-516
(d) (e)-Bolt11BACB30MC6A4
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### Page 36

Upper Deck Floor Beam Station (STA) 500
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Bolt19BACB30MC6A5
(d) (e)-Bolt5BACB30MC6A6
(d) (e)-Bolt4BACB30MC6A7
(d) (e)-Bolt2BACB30MC6A8
(d) (e)-Bolt1BACB30MC6A9
(d) (e)-Bolt1BACB30FP8A5
(d) (e)-Bolt4BACB30FQ6A7
(d) (e)-Bolt20BACB30MY8K7X
(d) (e)-Bolt48BACB30MY8K8X
(d) (e)-Bolt4BACB30MY8K11X
(d) (e)-Bolt2BACB30NW8K7X
(d) (e)-Bolt8BACB30VN8K4
(d) (e)-Bolt2BACB30VN8K6
(d) (e)-Bolt1BACB30VN10K7
(d) (e)-Bolt2BACB30NW8K7X
(d)-Collar10BACC30BK6
(d)-Collar1BACC30BK8
(d)-Collar2BACC30BL8
(d)-Collar46BACC30M6
(d)-Collar31BACC30M8
(d) (e)-Rivet2BACR15BB5D6C
or
BACR15BB6D6C
(d) (e)-Rivet42BACR15BB5D7C
or
BACR15BB6D7C
(d) (e)-Rivet24BACR15BB5D8C
or
BACR15BB6D8C
(d) (e)-Rivet42BACR15BB6D8C
or
BACR15BB7D8C
(d) (e)-Rivet5BACR15BB6D10C
or
BACR15BB7D10C
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
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### Page 37

Upper Deck Floor Beam Station (STA) 500
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) (e)-Rivet38BACR15BB6D11C
or
BACR15BB7D11C
(f)-Chemical Conversion Coating4 OuncesType 2, Class A
(g)-Primer1/4 PintBMS 10-11,
Type I
(g)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.
(b) Fabricate from 7075-T73511 or 7075-T6 in accordance with APPENDIX A.
(c) Discard the existing part.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
(f) Refer to SOPM 20-43-03 for supplier data.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 520
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10936-507 or
65B10936-525 or
65B10936-146 or
65B10936-147
Chord-Upper165B10936-507
or
65B10936-525
or
65B10936-146
or
65B10936-147
(b) (c)65B10936-511 or
65B10936-133
Radius Filler L/H165B10936-511
or
65B10936-133
(b) (c)65B10936-512 or
65B10936-132
Radius Filler R/H165B10936-512
or
65B10936-132
(a) (c)65B10936-509 or
65B10936-524
Strap165B10936-509
or
65B10936-524
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### Page 38

Upper Deck Floor Beam Station (STA) 520
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (c)65B10936-508 or
65B10936-523
Strap165B10936-508
or
65B10936-523
(d) (e)-Bolt145BACB30MC6A4
(d) (e)-Bolt29BACB30MC6A5
(d) (e)-Bolt87BACB30MC6A6
(d) (e)-Bolt2BACB30MC6A7
(d) (e)-Bolt8BACB30MC6A8
(d) (e)-Bolt1BACB30FQ6A4
(d) (e)-Bolt4BACB30FQ6A6
(d) (e)-Bolt1BACB30MC6A7
(d) (e)-Bolt3BACB30MC6A8
(d) (e)-Bolt8BACB30MY10K8X
(d) (e)-Bolt4BACB30MY10K13X
(d) (e)-Bolt1BACB30NW8K8X
(d) (e)-Bolt6BACB30VN8K5
(d) (e)-Bolt2BACB30VN8K7
(d) (e)-Bolt1BACB30NW8K8X
(d)-Collar4BACC30BH6
(d)-Collar8BACC30BK6
(d)-Collar1BACC30BL8
(d)-Collar276BACC30M6
(d)-Collar1BACC30M8
(d)-Collar12BACC30M10
(d) (e)-Rivet1BACR15BB6D7C
or
BACR15BB7D7C
(f)-Chemical Conversion Coating4 OuncesType 2, Class A
(g)-Primer1/4 PintBMS 10-11,
Type I
(g)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 7075-T6511 in accordance with APPENDIX A.
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### Page 39

Upper Deck Floor Beam Station (STA) 520
NotesExisting Part NumberNameQTYPart Number /
Specification
(b) Fabricate from 7075-T6 in accordance with APPENDIX A .
(c) Discard the existing part.
(d) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(e) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment.
(f) Refer to SOPM 20-43-03 for supplier data.
(g) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Upper Deck Floor Beam Station (STA) 540
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38517-3Chord-Upper165B38517-3
(c) (d)BACB30FM5*Bolt5BACB30VT6K4
(c) (d)BACB30FM5*Bolt14BACB30VT6K5
(c) (d)BACB30FM5*Bolt3BACB30VT6K6
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt28BACB30NX6K5X
(c) (d)BACB30FM6*Bolt12BACB30NX6K6X
(c) (d)BACB30DX6*Bolt1BACB30NX6K5X
(c) (d)BACB30DX6*Bolt1BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt4BACB30MY8K7X
(c) (d)BACB30MY8C*Bolt4BACB30MY8K9X
(c) (d)BACR15BB5D*Rivet124BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet153BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet18BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D8C
or
BACR15BB7D*C
(c) (d)BACB30MY8C*Bolt10BACB30MY8K6X
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 40

Upper Deck Floor Beam Station (STA) 540
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D6C
(c) (d)BACR15BA3D*Rivet10BACR15BA3D6C
or
BACR15BA4D7C
(c) (g)-Collar66BACC30BL6
(c) (g)-Collar46BACC30BH6
(c)-Collar18BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 560
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38518-3Chord-Upper165B38518-3
(c) (d)BACB30FM5*Bolt6BACB30VT6K4
(c) (d)BACB30FM5*Bolt26BACB30VT6K5
(c) (d)BACB30FM5*Bolt3BACB30VT6K6
(c) (d)BACB30FM6*Bolt2BACB30NX6K4X
(c) (d)BACB30FM6*Bolt20BACB30NX6K5X
(c) (d)BACB30FM6*Bolt8BACB30NX6K6X
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
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ALERTALERT

### Page 41

Upper Deck Floor Beam Station (STA) 560
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACB30FM6Bolt4BACB30NX6K7X
(c) (d)BACB30MY8C*Bolt8BACB30MY8K6X
(c) (d)BACR15BB5D*Rivet119BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet137BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet16BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D8C
or
BACR15BB7D*C
(c) (d)BACB30MY8*Bolt10BACB30MY8K5X
(c) (d)BACR15BA3D*Rivet8BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet4BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar69BACC30BL6
(c) (g)-Collar34BACC30BH6
(c)-Collar18BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 42

Upper Deck Floor Beam Station (STA) 560
NotesExisting Part NumberNameQTYPart Number /
Specification
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 580
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38519-3Chord-Upper165B38519-3
(c) (d)BACB30FM5*Bolt7BACB30VT6K4
(c) (d)BACB30FM5*Bolt25BACB30VT6K5
(c) (d)BACB30FM5*Bolt4BACB30VT6K6
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt20BACB30NX6K5X
(c) (d)BACB30FM6*Bolt10BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt16BACB30MY8K6X
(c) (d)BACR15BB5D*Rivet125BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet136BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet15BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D8C
or
BACR15BB7D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar70BACC30BL6
(c) (g)-Collar34BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
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Original Issue: October 16, 2008
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ALERTALERT

### Page 43

Upper Deck Floor Beam Station (STA) 580
NotesExisting Part NumberNameQTYPart Number /
Specification
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 600
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38520-3Chord-Upper165B38520-3
(c) (d)BACB30FM5*Bolt19BACB30VT6K5
(c) (d)BACB30FM6*Bolt38BACB30NX6K5X
(c) (d)BACB30FM6*Bolt14BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt12BACB30MY8K6X
(c) (d)BACB30MY8C*Bolt4BACB30MY8K7X
(c) (d)BACR15BB5D*Rivet141BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet89BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet13BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 44

Upper Deck Floor Beam Station (STA) 600
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar71BACC30BL6
(c) (g)-Collar52BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 620
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38521-3Chord-Upper165B38521-3
(c) (d)BACB30FM5*Bolt11BACB30VT6K4
(c) (d)BACB30FM5*Bolt18BACB30VT6K5
(c) (d)BACB30FM5*Bolt1BACB30VT6K6
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt16BACB30NX6K5X
(c) (d)BACB30FM6*Bolt14BACB30NX6K6X
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 45

Upper Deck Floor Beam Station (STA) 620
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACB30MY8C*Bolt16BACB30MY8K6X
(c) (d)BACR15BB5D*Rivet126BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet136BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet16BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D6C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D7C
(c) (g)-Collar64BACC30BL6
(c) (g)-Collar34BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: October 16, 2008
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45 of 101
BOEING SERVICE BULLETIN 747-53A2696
ALERTALERT

### Page 46

Upper Deck Floor Beam Station (STA) 640
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38522-3Chord-Upper165B38522-3
(c) (d)BACB30FM5*Bolt11BACB30VT6K4
(c) (d)BACB30FM5*Bolt17BACB30VT6K5
(c) (d)BACB30FM5*Bolt1BACB30VT6K6
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt16BACB30NX6K5X
(c) (d)BACB30FM6*Bolt14BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt10BACB30MY8K6X
(c) (d)BACB30MY8C*Bolt4BACB30MY8K7X
(c) (d)BACB30MY8C*Bolt2BACB30MY8K8X
(c) (d)BACR15BB5D*Rivet123BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet129BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet17BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACR15GF5D*Rivet1BACR15GF5D7
or
BACR15GF6D*
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar63BACC30BL6
(c) (g)-Collar34BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 47

Upper Deck Floor Beam Station (STA) 640
NotesExisting Part NumberNameQTYPart Number /
Specification
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 660
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38523-3Chord-Upper165B38523-3
(c) (d)BACB30FM5*Bolt6BACB30VT6K4
(c) (d)BACB30FM5*Bolt17BACB30VT6K5
(c) (d)BACB30FM5*Bolt4BACB30VT6K6
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt16BACB30NX6K5X
(c) (d)BACB30FM6*Bolt14BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt16BACB30MY8K6X
(c) (d)BACR15BA5D*Rivet1BACR15BA5D6C
or
BACR15BA6D*C
(c) (d)BACR15BB5D*Rivet125BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet149BACR15BB5D7C
or
BACR15BB6D*C
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 48

Upper Deck Floor Beam Station (STA) 660
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACR15BB5D*Rivet17BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar61BACC30BL6
(c) (g)-Collar34BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 680
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38524-3Chord-Upper165B38524-3
(c) (d)BACB30FM5*Bolt7BACB30VT6K4
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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### Page 49

Upper Deck Floor Beam Station (STA) 680
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACB30FM5*Bolt24BACB30VT6K5
(c) (d)BACB30FM5*Bolt4BACB30VT6K6
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt20BACB30NX6K5X
(c) (d)BACB30FM6*Bolt10BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt12BACB30MY8K6X
(c) (d)BACB30MY8C*Bolt4BACB30MY8K7X
(c) (d)BACR15BB5D*Rivet126BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet135BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet16BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar69BACC30BL6
(c) (g)-Collar34BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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ALERTALERT

### Page 50

Upper Deck Floor Beam Station (STA) 680
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 700
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38525-3Chord-Upper165B38525-3
(c) (d)BACB30FM5*Bolt6BACB30VT6K4
(c) (d)BACB30FM5*Bolt17BACB30VT6K5
(c) (d)BACB30FM5*Bolt16BACB30VT6K6
(c) (d)BACB30FM6*Bolt6BACB30NX6K4X
(c) (d)BACB30FM6*Bolt20BACB30NX6K5X
(c) (d)BACB30FM6*Bolt16BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt8BACB30MY8K6X
(c) (d)BACR15BB5D*Rivet122BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet136BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet17BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACB30MY8C*Bolt8BACB30MY8K5X
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
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### Page 51

Upper Deck Floor Beam Station (STA) 700
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar81BACC30BL6
(c) (g)-Collar42BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Upper Deck Floor Beam Station (STA) 720
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38526-3Chord-Upper165B38526-3
(c) (d)BACB30FM5*Bolt11BACB30VT6K4
(c) (d)BACB30FM5*Bolt18BACB30VT6K5
(c) (d)BACB30FM5*Bolt1BACB30VT6K6
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt16BACB30NX6K5X
(c) (d)BACB30FM6*Bolt14BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt4BACB30MY8K6X
(c) (d)BACB30MY8C*Bolt4BACB30MY8K7X
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### Page 52

Upper Deck Floor Beam Station (STA) 720
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACR15BB5D*Rivet122BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet136BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet16BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACB30MY8C*Bolt8BACB30MY8K5X
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar64BACC30BL6
(c) (g)-Collar34BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
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### Page 53

Upper Deck Floor Beam Station (STA) 740
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B38527-3 or
65B38527-603
Chord-Upper165B38527-3 or
65B38527-603
(c) (d)BACB30FM5*Bolt6BACB30VT6K4
(c) (d)BACB30FM5*Bolt18BACB30VT6K5
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
(c) (d)BACB30FM6*Bolt16BACB30NX6K5X
(c) (d)BACB30FM6*Bolt6BACB30NX6K6X
(c) (d)BACB30DX6*Bolt2BACB30NX6K4X
(c) (d)BACB30DX6*Bolt10BACB30NX6K5X
(c) (d)BACB30DX6*Bolt2BACB30NX6K6X
(c) (d)BACR15CE5D*Rivet2BACR15GF5D7
or
BACR15GF6D7
(c) (d)BACR15CE5D*Rivet2BACR15GF5D8
or
BACR15GF6D8
(c) (d)BACB30MB6*Bolt2BACB30NX6K6X
(c) (d)BACB30MB6*Bolt2BACB30NX6K7X
(c) (d)BACB30MY8C*Bolt16BACB30MY8K6X
(c) (d)BACR15BA5D*Rivet4BACR15BA5D6C
or
BACR15BA6D*C
(c) (d)BACR15BA5D*Rivet5BACR15BA5D7C
or
BACR15BA6D*C
(c) (d)BACR15BB5D*Rivet171BACR15BB5D6C
or
BACR15BA6D*C
(c) (d)BACR15BB5D*Rivet112BACR15BB5D7C
or
BACR15BA6D*C
(c) (d)BACR15BB5D*Rivet13BACR15BB5D8C
or
BACR15BA6D*C
(c) (d)BACR15BB6D*Rivet3BACR15BB6D8C
or
BACR15BB7D*C
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### Page 54

Upper Deck Floor Beam Station (STA) 740
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar50BACC30BL6
(c) (g)-Collar44BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Group 2:
Upper Deck Floor Beam Station (STA) 760
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B17358-3Chord-Upper165B17358-3
(c) (d)BACB30FM5*Bolt6BACB30VT6K4
(c) (d)BACB30FM5*Bolt18BACB30VT6K5
(c) (d)BACB30FM6*Bolt4BACB30NX6K4X
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### Page 55

Group 2:
Upper Deck Floor Beam Station (STA) 760
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACB30FM6*Bolt16BACB30NX6K5X
(c) (d)BACB30FM6*Bolt4BACB30NX6K6X
(c) (d)BACB30MY8C*Bolt8BACB30MY8K6X
(c) (d)BACR15BB5D*Rivet120BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet109BACR15BB5D7C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet11BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet1BACR15BB6D8C
or
BACR15BB7D*C
(c) (d)BACR15BB6D*Rivet2BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACB30MY8C*Bolt8BACB30MY8K5X
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar48BACC30BL6
(c) (g)-Collar24BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
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### Page 56

Group 2:
Upper Deck Floor Beam Station (STA) 760
NotesExisting Part NumberNameQTYPart Number /
Specification
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
Group 2:
Upper Deck Floor Beam Station (STA) 780
NotesExisting Part NumberNameQTYPart Number /
Specification
(a) (b)65B17359-3Chord-Upper165B17359-3
(c) (d)BACB30FM5*Bolt1BACB30VT6K5
(c) (d)BACB30FM5*Bolt4BACB30VT6K6
(c) (d)BACB30FM6*Bolt14BACB30NX6K5X
(c) (d)BACB30FM6*Bolt5BACB30NX6K6X
(c) (d)BACB30FN6*Bolt1BACB30NW6K6
(c) (d)BACB30DX5*Bolt2BACB30NX6K5
(c) (d)BACB30DX5*Bolt14BACB30NX6K5X
(c) (d)BACB30DX5*Bolt3BACB30NX6K6X
(c) (d)BACR15CE5D*Rivet2BACR15GF5D7
or
BACR15GF6D7
(c) (d)BACR15CE5D*Rivet3BACR15GF5D8
or
BACR15GF6D8
(c) (d)BACB30MY8C*Bolt8BACB30MY8K6X
(c) (d)BACR15BB5D*Rivet74BACR15BB5D6C
or
BACR15BB6D*C
(c) (d)BACR15BB5D*Rivet118BACR15BB5D7C
or
BACR15BB6D*C
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### Page 57

Group 2:
Upper Deck Floor Beam Station (STA) 780
NotesExisting Part NumberNameQTYPart Number /
Specification
(c) (d)BACR15BB5D*Rivet15BACR15BB5D8C
or
BACR15BB6D*C
(c) (d)BACR15BB6D*Rivet7BACR15BB6D7C
or
BACR15BB7D*C
(c) (d)BACR15BB6D*Rivet18BACR15BB6D8C
or
BACR15BB7D*C
(c) (d)BACR15BB6D*Rivet5BACR15BB6D9C
or
BACR15BB7D*C
(c) (d)BACB30MY8C*Bolt8BACB30MY8K5X
(c) (d)BACR15BA3D*Rivet6BACR15BA3D5C
or
BACR15BA4D*C
(c) (d)BACR15BA3D*Rivet6BACR15BA3D6C
or
BACR15BA4D*C
(c) (g)-Collar24BACC30BL6
(c) (g)-Collar38BACC30BH6
(c)-Collar16BACC30M8
(e)-Chemical Conversion Coating4 OuncesType 2, Class A
(f)-Primer1/4 PintBMS 10-11,
Type I
(f)-Sealant4 OuncesBMS 5-95, Class
B-1/2, -2, -4
(a) Fabricate from 2024-T3511 in accordance with APPENDIX B.
(b) Discard the existing part.
(c) Refer to 747 Structural Repair Manual Chapter 51 for alternative fasteners.
(d) Use oversize bolts. Use oversize rivets when the existing rivet hole in the web or the frame must be
oversized to correct damage or misalignment. At locations where an oversize rivet will be installed, deter-
mine grip length on installation.
(e) Refer to SOPM 20-43-03 for supplier data.
(f) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
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### Page 58

Group 2:
Upper Deck Floor Beam Station (STA) 780
NotesExisting Part NumberNameQTYPart Number /
Specification
(g) The actual quantity required will depend on the number of oversize fasteners installed. The quantity
shown is the maximum number that could be needed.
3. Parts Modified and Reidentified:
None.
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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### Page 59

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
— Linear dimensions are in inches
— Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch.
— Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
— Angular tolerance is plus or minus 2 degrees
— Hole dimensions for standard solid rivets are given in 747 SRM, Chapter 51
— Torque limits to tighten nuts and bolts are given in 747 SRM, Chapter 51.
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
6. A Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate procedures may be required.
7. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
8. Refer to Appendix A to identify the parts to be replaced and the material used to
make replacement parts for STA 340 - STA 440, STA 500, and STA 520 . The
appendix lists the drawing numbers for the fabrication, installation and fastener
requirements.
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### Page 60

9. Fasteners may be oversized 1/64 or 1/32 inch as needed. Maintain 1.7D edge margin
on the upper chord and all adjacent parts. Edge margin is defined as the distance
from the edge of the part to the center of the hole, and "D" is the hole diameter.
10. The instructions in Paragraph 3.B., Work Instructions and the figures can include
operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated
Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing
Index contain data on versions of the tools or test equipment that you can use. It is
permitted to use replaced tools. It is not permitted to use superseded tools.
11. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
12. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
13. Boeing Service Letter 747-SL-51-048, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
14. The work instructions are divided into work packages. Task Hours and Elapsed Hours
for each package are given in Paragraph 1.G., Manpower. You can do each work
package independently.
15. Shaded areas in Figures are reference only. Shaded areas in Figures may look
different than your airplane.
16. Refer to Appendix B to identify the parts to be replaced and the material used to
make replacement parts for STA 540 through STA 780. The appendix lists the drawing
numbers for the fabrication, installation and fastener requirements.
17. Install all bolts in transition fit holes. Transition fit hole sizes are given in 747 SRM,
Chapter 51.
18. Boeing recommends installation of oversize fasteners at all bolt locations. At rivet
locations, install the original size rivet provided the hole meets the acceptable surface
defect criteria for fastener holes given in SRM, Chapter 51.
19. Do a detailed inspection of any parts that are removed and re-installed during upper
chord replacement. Replace any parts that are found damaged.
20. Refer to Appendix C for Section 42 Fastener Replacement Guide.
B. WORK INSTRUCTIONS
Work Package 1: Section 41 Upper Deck Floor Beam Upper Chord Replacement
1. PART 1 - ACCESS - Section 41
a. Remove electrical power and place the battery switch in the off position.
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