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August 31, 2000 Revision 2: July 09, 2009 747-54A2203 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 102
ALERT ALERT Commercial Airplane Group 747
ALERTALERT Service Bulletin Number: 747-54A2203 Date: August 31, 2000 Revision 2: July 09, 2009 ATA System: 5441 SUBJECT: NACELLES/PYLONS - Strut Forward Engine Mount - Inspection/Rework
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2000 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.
BLANK PAGE August 31, 2000 Revision 2: July 09, 2009 747-54A2203 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 102 BOEING SERVICE BULLETIN 747-54A2203
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Table of Contents August 31, 2000 Revision 2: July 09, 2009 747-54A2203 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 102 BOEING SERVICE BULLETIN 747-54A2203
ALERT ALERT
Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 31
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 31 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 31
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 33
3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 35
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 1: LOGIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 FIGURE 2: FORWARD ENGINE MOUNT FITTING - DETAILED INSPECTION . . . . . . . . . . . 47 FIGURE 3: FORWARD ENGINE MOUNT FITTING - TORQUE CHECK . . . . . . . . . . . . . . . 50 FIGURE 4: FORWARD ENGINE MOUNT FITTING - ANY FASTENER FOUND UNDER-TORQUED OR LOOSE - FASTENER RE-TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . 57 FIGURE 5: THIS FIGURE HAS BEEN DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FIGURE 6: FORWARD ENGINE MOUNT FITTING REWORK . . . . . . . . . . . . . . . . . . . . 65 FIGURE 7: FORWARD ENGINE MOUNT FITTING REPLACEMENT . . . . . . . . . . . . . . . . . 76 FIGURE 8: FORWARD ENGINE MOUNT - FASTENER REPLACEMENT . . . . . . . . . . . . . . 86 FIGURE 9: FORWARD ENGINE MOUNT - CHORD AND INTERNAL ANGLE INSPECTION . . . . . 96 FIGURE 10: FORWARD ENGINE MOUNT BULKHEAD - INTERNAL BACK-UP STRUCTURE - ANGLE -
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DET AND HFEC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Original Issue: August 31, 2000 Revision 2: July 09, 2009 747-54A2203 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 102
ALERT ALERT Commercial Airplanes 747
ALERTALERT Service Bulletin Number: 747-54A2203 Revision Transmittal Sheet Original Issue: August 31, 2000 Revision 2: July 09, 2009 ATA System: 5441 SUBJECT: NACELLES/PYLONS - Strut Forward Engine Mount - Inspection/Rework This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes which were not affected by the Original Issue or Revision 1 of this service bulletin. These airplanes have hi-lok bolts and collars at all of the Group B fastener locations, except fastener no.13. These airplanes need to be inspected in accordance with Part 2 - Detailed Inspection, Torque Stripe Inspection, and Torque Check within 90 days after the date of Revision 2 of this service bulletin. In addition, the fasteners on these airplanes need to be replaced in accordance with Part 6 - Fastener Replacement within 18 months after the date of Revision 2 of this service bulletin.
NOTE: Terminating Action was removed from the service bulletin in revision 1.
REASON FOR REVISION This revision is sent to do the following:
1. Add instructions for airplanes which were not affected by the Original Issue or Revision 1 of the service bulletin. The inspections and fastener replacement in the Original Issue of this service bulletin were not required if two washers were installed under the nuts of the Group A fasteners or the pin protrusion was per the SRM. When terminating action was removed from the service bulletin in revision 1, some operators reported that the fasteners types specified in Revision 1 did not match the fasteners on the airplane. For airplanes not affected by the Original Issue, all of the Group B fasteners, except fastener no. 13, would have hi-lok bolts and collars installed and not the fasteners specified in Revision 1, as these airplanes were not required to replace the fasteners in the Original Issue. The Group A and B fasteners on airplanes not affected by the Original Issue should be removed and replaced with the fasteners given in Revision 1 or Revision 2.
2. Clarify the requirements in the torque stripe not applied and no under-torqued or loose fastener found action requirements by reordering the steps.
3. Added option to support engine weight instead of engine removal in Part 7 - HFEC Internal Angle Inspection.
The following sections were changed as follows:
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1. Planning - Paragraph 1.E., Compliance. Add requirements for airplanes not affected by the original release: See note (h). Revise order of steps in the torque stripe not applied and no under-torqued or loose fastener found action requirements.
2. Accomplishment Instructions. Revised Part 2 - Detailed Inspection, Torque Stripe Inspection, and Torque Check, Step 4., to add the requirements for airplanes which were not affected by the Original Issue or Revision 1 of this service bulletin and have hi-lok bolts and collars at all of the Group B fastener locations, except fastener no. 13.
3. Accomplishment Instructions. Revised Part 7 - HFEC Internal Angle Inspection to add option to support engine weight instead of engine removal.
4. Figure 3. Revised Table 2 - Torque Stripe not applied fastener looseness Inspection, Steps 7 and 8, to add the requirements for airplanes which were not affected by the Original Issue or Revision 1 of this service bulletin and have hi-lok bolts and collars at all of the Group B fastener locations, except fastener no. 13.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
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 Original Issue: August 31, 2000 Revision 1: August 9, 2007 Revision 2: July 9, 2009
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ALERT ALERT Commercial Airplane Group 747
ALERTALERT Service Bulletin Number: 747-54A2203 Summary Date: August 31, 2000 Revision 2: July 09, 2009 ATA System: 5441 SUBJECT: NACELLES/PYLONS - Strut Forward Engine Mount - Inspection/Rework
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 inspection, when completed, will help detect loose fasteners and/or damaged forward engine mount hanger fittings and bulkhead. Loose fasteners and/or damaged or cracked forward engine mount hanger fittings could lead to failure of the hanger fitting and bulkhead and the subsequent separation of the engine.
Three operators have reported many instances where the fasteners common to the forward engine mount hanger fitting and strut forward bulkhead have been found loose. There was also one report of hanger fitting damage. In the reports where loose fasteners were found, the fasteners were removed, the holes inspected and repaired and new fasteners installed. The damaged hanger fitting was replaced.
Hanger fitting looseness has been attributed to loose fasteners common to the strut forward engine mount bulkhead. These fasteners were replaced on airplanes during incorporation of Boeing service bulletin 747- 54A2159. These fasteners may not have been fully torqued or the nuts may have bottomed out on the bolt threads prior to full clamp-up or "shanked", during fastener torque. In addition, certain tolerance build-up conditions during production at Boeing may also cause the nuts to 'shank' during installation. This condition could lead to the loss of fastener clamp up capability, hanger fitting movement and reduced attachment capability.
Inspection and replacement of these fasteners will maintain clamp-up of the fasteners and help to prevent damage to the forward engine mount hanger fittings and bulkhead.
After release of the original issue of this service bulletin, several operators have reported finding under-torqued or loose fasteners after accomplishment of Part 6 Terminating Action. In addition, one operator reported finding an approximately 1.5 inch crack in the bulkhead chord adjacent to the upper Group B fastener on a no. 2 strut with approximately 20,050 flight-cycles and 110,000 flight-hours. Further investigation revealed that the backup angle inside the strut adjacent to the crack had fractured.
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Boeing Service Related Problem (SRP) 747-SRP-54-0068 is related to this service bulletin.
Boeing Service Related Problem (SRP) 747OP-SRP-54-0114 is related to this service bulletin.
ACTION Do a DET and torque check of the forward engine mount fittings and the adjacent support structure on the inboard and outboard struts for loose fasteners and/or damage to the hanger fitting and bulkhead. Repair or replace damaged hanger fittings. Contact The Boeing Company for repair instructions for damage found on adjacent support structure.
Do a High Frequency Eddy Current (HFEC) Inspection or Fluorescent Penetrant Inspection (FPI) of the forward engine mount bulkhead chords for cracks. Do a DET and HFEC inspection of the internal angle and stiffener for cracks or fracture.
EFFECTIVITY 747 airplanes line numbers 1 through 814 powered by Pratt and Whitney JT9D -3 or -7 series engines, except JT9D-70's.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in on which the Core Strut Mod Service Bulletin has been incorporated since May 26, 1997. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Refer to Paragraph 1.G. Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials
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AND LOOSE FASTENERS
CHORDS FOR CRACKS
INSPECT BULKHEAD
AND/OR LOOSE FASTENERS
INSPECT FITTINGS FOR DAMAGE
INSPECT BULKHEAD
FOR CRACKS
INSPECT LOWER
WEB FOR CRACKS
INSPECT CRACKS
CHANNEL FOR
BULKHEAD-TO-
FIREWALL
LOCATION
EPR TRANSMITTER
ACCESS DOOR
STRUT FWD
INSPECT INTERNAL ANGLE
AND STIFFENER FOR CRACKS
OR FRACTURE (BOTH SIDES OF STRUT).
FWD FWD V32231
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BLANK PAGE
August 31, 2000 Revision 2: July 09, 2009 747-54A2203 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 102
ALERT ALERT Commercial Airplane Group 747
ALERTALERT Service Bulletin Number: 747-54A2203 Date: August 31, 2000 Revision 2: July 09, 2009 ATA System: 5441 SUBJECT: NACELLES/PYLONS - Strut Forward Engine Mount - Inspection/Rework
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.
Airplane models:
747-100 747-100B 747-100B SUD 747-200B 747-200C 747-200F 747-300 747SP 747SR
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
AERO CONTROLS (AEO) 1 RA722–RA723
AEROLINEAS ARGENTINAS (ARG) 1 RD122–RD127 AFRICA UNITED HOLDING CO. (UHD) 1 RB010 RD513
GROUP CONFIGURATION DESCRIPTION 1 - 747 airplanes with JT9D-3/7 struts (except JT9D-70).
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AFX (AXL) 1 RD201
AGES AIRCRAFT SALES & LEASING (AGJ) 1R B 0 0 4
AIR ATLANTA ICELANDIC (AID) 1 RB421 RS211 RS233 RS235 RS237
AIR CANADA (ACN) 1 RA749–RA750 RD531
AIR CHINA (BEJ) 1 RD782–RD783 RR451
AIR GULF FALCON (GFG) 1R A 5 3 5 R A 5 3 7
AIR INDIA (AIN) 1R A 7 2 9 R A 7 3 1
ALBARAKA (AAB) 1R B 1 0 2
AMERICAN AIRLINES (AAL) 1R A 2 6 6
ARKIA ISRAELI AIRLINES (ARK) 1R A 2 5 3
BAHRAIN ROYAL FLIGHT (BHR) 1 RG009
BANC OF AMERICA LEASING (SBC) 1 RA106 RD001–RD002 BOEING AIRCRAFT HOLDING CO. (BHC) 1R J 1 3 2 C.I.T. LEASING CORPORATION (TCI) 1 RB011 RD047
CAPITAL ASSET MANAGEMENT (CPG) 1 RD053
CARGAIR (CGL) 1 RD203
CORSAIR (COR) 1 RS239–RS240