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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-54A2232 Original Issue: April 15, 2010 ATA System: 5410 5451 5432 5462 1113 SUBJECT: NACELLES/PYLONS - Nacelle Strut Spring Beam - Spring Beam Mid Pivot Bolt Assembly - Access Door Inspection and Replacement, Marker Installation, and Bolt Assembly Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

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

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: April 15, 2010 747-54A2232 1 of 99

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Original Issue: April 15, 2010 747-54A2232 2 of 99 BOEING SERVICE BULLETIN 747-54A2232

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Table of Contents

Summary5

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 7 G. Manpower .............................................. 1 7 H. Weight and Balance Changes .................................... 1 9 I. Electrical Load Data ......................................... 2 0 J. References .............................................. 2 0

1. Existing Data .......................................... 2 0

2. Data supplied with this Service Bulletin ............................ 2 0

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 0 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 1

2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary For Each Airplane ................................. 2 3

1. Kits/Parts ............................................ 2 3

2. Parts and Materials Supplied by the Operator ........................ 2 5

3. Parts Modified and Reidentified ................................ 2 6

4. Parts Removed and Not Replaced .............................. 2 6 D. Parts Necessary to Change Spares ................................. 2 6 E. Special Tooling - Price and Availability ............................... 2 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 6

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 8 FIGURE 1: STRUT NO. 1 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - INSPECTION .... 3 4 FIGURE 2: STRUT NO. 1 - INBOARD SIDE - MID PIVOT ACCESS DOOR - INSPECTION ...... 3 6 FIGURE 3: STRUT NO. 4 - INBOARD SIDE - MID PIVOT ACCESS DOOR - INSPECTION ...... 3 8 FIGURE 4: STRUT NO. 4 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - INSPECTION .... 4 0 FIGURE 5: STRUT NO. 1 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 1] ............................................ 4 2 FIGURE 6: STRUT NO. 1 - INBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 1] ............................................ 4 4 FIGURE 7: STRUT NO. 4 - INBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 1] ............................................ 4 6 FIGURE 8: STRUT NO. 4 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 1] ............................................ 4 8

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FIGURE 9: STRUT NO. 1 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 2] ............................................ 5 0 FIGURE 10: STRUT NO. 1 - INBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 2] ............................................ 5 2 FIGURE 11: STRUT NO. 4 - INBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 2] ............................................ 5 4 FIGURE 12: STRUT NO. 4 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 2] ............................................ 5 6 FIGURE 13: STRUT NO. 1 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 3] ............................................ 5 8 FIGURE 14: STRUT NO. 1 - INBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 3] ............................................ 6 0 FIGURE 15: STRUT NO. 4 - INBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 3] ............................................ 6 2 FIGURE 16: STRUT NO. 4 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - MARKER INSTALLATION [Group 3] ............................................ 6 4 FIGURE 17: STRUT NO. 1 - OUTBOARD SIDE - MID PIVOT BOLT ASSEMBLY - REPLACEMENT . 66 FIGURE 18: STRUT NO. 1 - INBOARD SIDE - MID PIVOT BOLT ASSEMBLY - REPLACEMENT . . . 68 FIGURE 19: STRUT NO. 4 - INBOARD SIDE - MID PIVOT BOLT ASSEMBLY - REPLACEMENT . . . 70 FIGURE 20: STRUT NO. 4 - OUTBOARD SIDE - MID PIVOT BOLT ASSEMBLY - REPLACEMENT . 72 FIGURE 21: STRUT NO. 1 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - REPLACEMENT . . . 74 FIGURE 22: STRUT NO. 1 - INBOARD SIDE - MID PIVOT ACCESS DOOR - REPLACEMENT .... 7 6 FIGURE 23: STRUT NO. 4 - INBOARD SIDE - MID PIVOT ACCESS DOOR - REPLACEMENT .... 7 8 FIGURE 24: STRUT NO. 4 - OUTBOARD SIDE - MID PIVOT ACCESS DOOR - REPLACEMENT . . . 80 FIGURE 25: STRUT NO. 1 - OUTBOARD SIDE - MID PIVOT BOLT ASSEMBLY - INSPECTION . . . 82 FIGURE 26: STRUT NO. 1 - INBOARD SIDE - MID PIVOT BOLT ASSEMBLY - INSPECTION ..... 8 4 FIGURE 27: STRUT NO. 4 - INBOARD SIDE - MID PIVOT BOLT ASSEMBLY - INSPECTION ..... 8 6 FIGURE 28: STRUT NO. 4 - OUTBOARD SIDE - MID PIVOT BOLT ASSEMBLY - INSPECTION . . . 88 APPENDIX A: MID PIVOT ACCESS DOOR IDENTIFICATION ....................... 9 0 APPENDIX B: MID PIVOT BOLT ASSEMBLY ULTRASONIC INSPECTION ................ 9 1 APPENDIX C: SCOPE OF CHANGE ..................................... 9 9

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-54A2232Original Issue: April 15, 2010 ATA System: 5410 5451 5432 5462 1113 SUBJECT: NACELLES/PYLONS - Nacelle Strut Spring Beam - Spring Beam Mid Pivot Bolt Assembly - Access Door Inspection and Replacement, Marker Installation, and Bolt Assembly Inspection and 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 Accomplishment of this service bulletin will make sure both spring beam mid pivot bolt assemblies on the outboard struts are correctly installed. If the mid pivot bolt assembly is not correctly installed the internal lubrication channel of the bolt assembly will not be in the correct orientation. When the lubrication channel is not in the correct orientation, the mid pivot bolt assembly could fatigue and eventually crack or fracture. A cracked or fractured mid pivot bolt assembly could result in the loss of the spring beam load path. Loss of the spring beam load path could result in the separation of a strut and engine from the airplane during flight.

An operator reported that the left and right spring beam mid pivot bolt assembly access doors for the no. 1 strut were inadvertently installed in the incorrect position. It is believed that the doors were installed on the wrong side of the strut during strut modification. The design of the access doors can allow the doors to be installed on either side of the strut. The mid pivot access door has machined tabs that fit the slots in the head of the mid pivot bolt assembly. The machined tabs correctly orient the mid pivot bolt assembly and prevent the mid pivot bolt from rotating in the spring beam. The correct orientation of the mid pivot bolt is necessary to reduce the fatigue on the cross-drilled lubrication channel. If the incorrect access door is installed, the lubrication channel will not be in the correct orientation. If the lubrication channel is not in the correct orientation, fatigue cracks could develop in the mid pivot bolt assembly. The fatigue cracks may result in the fracture of the mid pivot bolt assembly. Fracture of the mid pivot bolt assembly could result in the loss of the spring beam load path. Loss of the spring beam load path could result in the separation of a strut and engine from the airplane during flight.

Inspection of the access door assembly part numbers on each side of struts no. 1 and 4 will determine if the correct door is installed. Installation of markers on the doors will help prevent the inadvertent installation of the doors on the wrong side of the strut. Inspection and replacement of the mid pivot bolt assemblies at the locations where the incorrect access doors were installed will help prevent fatigue fracture of the mid pivot bolt assemblies due to the incorrect orientation. Rotating the mid pivot bolt assembly to the correct orientation, and replacing the access doors at the locations where the incorrect access doors were installed will ensure the mid pivot bolt assemblies are properly oriented.

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Boeing Service Related Problem (SRP) 747-SRP-54-0121 is related to this service bulletin.

ACTION (PRR 85901-92S) Part 1 - Access Door Inspection Remove the spring beam mid pivot bolt assembly access door from each side of the no. 1 and 4 struts. Do an inspection to determine the part number. Install the spring beam mid pivot bolt assembly access door on each side of the no. 1 and 4 struts.

Part 2 - Marker Installation Install markers on the inside surface of mid pivot bolt assembly access doors on each side of the no. 1 and 4 struts.

Part 3 - Mid Pivot Bolt Assembly Replacement At locations where the incorrect access door was installed, remove and discard the spring beam mid pivot bolt assembly. Install new spring beam mid pivot bolt assembly.

Part 4 - Access Door Replacement At locations where the incorrect access door was installed, rotate the mid pivot bolt assembly to the correct orientation, if required, and replace the access door with an access door with the correct part number Part 5 - Mid Pivot Bolt Assembly Inspection Remove the spring beam mid pivot bolt assembly access door from each side of the no. 1 and 4 struts, if required.

Do an Ultrasonic Inspection (UT) of the mid pivot bolt assembly for cracks. Install the spring beam mid pivot bolt assembly access door on each side of the no. 1 and 4 struts.

EFFECTIVITY 747-200B, -300, -400, -400D, -400F airplanes powered by Pratt and Whitney 4000 series engines or General Electric CF6-80C2 series engines. Refer to Paragraph 1.A., Effectivity

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 not available for the configuration changes, inspections, ,and/or repair procedures given in this service bulletin.

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MANPOWER Elapsed Hours Total Task Hours Task

2.003.00Part 1 - Access Door Inspection

0.400.40Part 2 - Marker Installation

50.50362.00Part 3 - Mid Pivot Bolt Assembly Replacement

4.604.60Part 4 - Access Door Replacement

3.004.00Part 5 - Mid Pivot Bolt Assembly Inspection

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN 747-54A2232

ALERT ALERT ENGINE NO. 1 (LEFT SIDE) PART 4:

AT LOCATION WHERE

INCORRECT ACCESS DOOR

WAS INSTALLED, REPLACE

THE ACCESS DOOR WITH AN

ACCESS DOOR WITH THE

CORRECT PART NUMBER PART 2:

INSTALL MARKER PART 1: DO AN INSPECTION TO DETERMINE IF THE (LEFT SIDE SHOWN, STRUT NO. 1 RIGHT SIDE, STRUT NO. 4 LEFT SIDE, AND STRUT NO. 4 RIGHT SIDE SIMILAR) STRUT NO. 1

CORRECT ACCESS DOOR

IS INSTALLED MID PIVOT

BOLT ASSEMBLY PART 3:

AT LOCATION WHERE

INCORRECT ACCESS DOOR

WAS INSTALLED, REPLACE

MID PIVOT BOLT ASSEMBLY PART 5:

ACCESS DO AN ULTRASONIC INSPECTION (UT) OF THE MID PIVOT BOLT

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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 This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 85901-92S for data about this change.

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

DESCRIPTIONCONFIGURATIONGROUP 747-400, -400F airplanes powered by PW4000 series engines, line numbers 696 through 1375.

-1 747-200B, -300 airplanes powered by GE CF6-80C2 series engines, line numbers 679 through 719.

-2 747-400, -400D, -400F airplanes powered by GE CF6-80C2 series engines, line numbers 700 through 1400.

-3 Airplane Models:

747-200B, 747-300, 747-400, 747-400D, 747-400F GroupVariable Number 2RD166 - RD167

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GroupVariable Number 3RF001 - RF006 3RL401 - RL403 3RL411 - RL430 1RL431 - RL436 1RL451 - RL456 3RL461 - RL462 3RL471 - RL476 3RL481 1RL491 - RL492 1RL501 - RL502 3RL511 - RL516 3RL521 - RL522 3RL531 - RL534 3RL561 - RL563 3RL576 - RL577 3RL651 - RL655 3RL671 - RL675 3RL681 - RL684 1RL751 - RL752 3RM001 - RM007 3RM010 1RM011 - RM013 1RM021 - RM024 3RM026 - RM030 1RM036 - RM045 3RM051 - RM053 3RM071 3RM081 - RM084 1RM091 3RM116 - RM117 3RM126 - RM132 3RM156 - RM158 1RM166 - RM177

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GroupVariable Number 3RM191 - RM192 3RM231 - RM233 1RM241 - RM246 3RM316 - RM318 1RM341 3RM351 - RM355 1RM366 - RM367 3RM401 - RM403 3RM426 3RM431 3RM441 - RM443 3RM445 3RM801 - RM803 1RM811 - RM813 1RM851 - RM855 3RM861 - RM863 1RM871 - RM880 3RM891 - RM899 3RM901 - RM906 3RM911 3RR701 3RR721 - RR724 3RR746 - RR748 1RR851 - RR856 1RR861 - RR862 2RS331 - RS333 2RS341 - RS342 2RS781 - RS782 3RT001 - RT014 3RT021 - RT022 1RT031 - RT035 3RT041 - RT047 1RT061

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GroupVariable Number 3RT071 - RT075 1RT101 - RT103 3RT121 3RT131 - RT137 3RT151 - RT152 3RT161 - RT168 1RT401 - RT412 3RT431 - RT447 1RT501 - RT530 3RT531 - RT535 1RT571 - RT590 3RT591 1RT601 - RT640 3RT641 - RT657 3RT681 - RT682 3RT691 - RT699 3RT701 - RT704 3RT711 - RT717 3RT741 - RT742 1RT743 - RT750 3RT751 - RT757 3RT776 - RT777 3RT801 - RT803 1RT811 - RT814 1RT831 - RT837 3RT861 - RT864 1RT876 - RT880 3RT931 - RT932 3RT945 - RT949 3RT951 - RT955 3RT966 - RT967 1RU001 - RU006 1RU016 - RU017

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