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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-54A2238 Original Issue: January 31, 2014 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut Attach Pin - Outboard Struts Aft Upper Spar Fuse Pin 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:

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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, 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.

Original Issue: January 31, 2014 747-54A2238 1 of 56

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Original Issue: January 31, 2014 747-54A2238 2 of 56 BOEING SERVICE BULLETIN 747-54A2238

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Table of Contents

Summary5

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

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

1. Existing Data: ......................................... 1 3

2. Data Supplied with this Service Bulletin: ........................... 1 3

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 3 K. Publications Affected ........................................ 1 3 L. Interchangeability and Intermixability of Parts ........................... 1 4 M. Software Accomplishment Summary ................................ 1 4

2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 5 C. Parts Necessary for Each Airplane ................................. 1 5

1. Kits/Parts ............................................ 1 5

2. Parts and Materials Supplied by the Operator ........................ 1 6

3. Parts Modified and Reidentified ................................ 1 7

4. Parts Removed and Not Replaced .............................. 1 7 D. Parts Necessary to Change Spares ................................. 1 7 E. Special Tooling - Price and Availability ............................... 1 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 8

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 9 A. GENERAL INFORMATION ..................................... 1 9 B. WORK INSTRUCTIONS ....................................... 2 0 FIGURE 1: STRUT NO. 1 - ACCESS COVER ASSEMBLY REMOVAL ................. 2 3 FIGURE 2: STRUT NO. 4 - ACCESS COVER ASSEMBLY REMOVAL ................. 2 5 FIGURE 3: STRUT NO. 1 - OUTBOARD SIDE - AFT UPPER SPAR FUSE PIN REPLACEMENT . . 27 FIGURE 4: STRUT NO. 1 - INBOARD SIDE - AFT UPPER SPAR FUSE PIN REPLACEMENT .... 3 5 FIGURE 5: STRUT NO. 4 - INBOARD SIDE - AFT UPPER SPAR FUSE PIN REPLACEMENT .... 4 0 FIGURE 6: STRUT NO. 4 - OUTBOARD SIDE - AFT UPPER SPAR FUSE PIN REPLACEMENT . . 48 FIGURE 7: STRUT NO. 1 - ACCESS COVER ASSEMBLY INSTALLATION .............. 5 3 FIGURE 8: STRUT NO. 4 - ACCESS COVER ASSEMBLY INSTALLATION .............. 5 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 31, 2014 747-54A2238 3 of 56 BOEING SERVICE BULLETIN 747-54A2238

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Original Issue: January 31, 2014 747-54A2238 4 of 56 BOEING SERVICE BULLETIN 747-54A2238

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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-54A2238Original Issue: January 31, 2014 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut Attach Pin - Outboard Struts Aft Upper Spar Fuse Pin 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 prevent outboard migration of the outboard aft upper spar strut-to-wing attachment fuse pins on struts No. 1 and No. 4 that could result in the complete disconnect and loss of the outboard aft upper spar strut-to-wing attachment load path. The complete loss of the No. 1 or No. 4 outboard aft upper spar strut-to-wing attachment load path could result in divergent flutter in certain parts of the flight envelope, which can result in loss of control of the airplane.

Boeing analysis determined that the existing outboard aft upper spar strut-to-wing attachment fuse pins on struts No. 1 and No. 4 are susceptible to migration in the event of a failed fuse pin through bolt. To prevent the outboard aft upper spar strut-to-wing attachment fuse pins migrating outboard, the outboard aft upper spar strut-to-wing attachment fuse pin design was changed to add a flange. The outboard fuse pin access cover assemblies were changed to add interference ribs to only allow the fuse pin to be installed with the flanged end of the fuse pin on the inboard side of the outboard aft upper spar fitting. To prevent incorrect installation of the outboard aft upper spar strut-to-wing attachment fuse pins, the inboard aft upper spar strut-to-wing attachment fuse pin incorporated the same flanged fuse pin design.

This service bulletin provides instructions to replace the outboard aft upper spar strut-to-wing attachment fuse pins and access covers on struts No. 1 and No. 4 with the new flanged fuse pins and ribbed access cover assemblies. Installation of the new flanged fuse pins at the outboard aft upper spar strut-to-wing attachment will prevent outboard migration of the fuse pins and possible loss of the outboard aft upper spar strut-to-wing attach load path. Installation of the new ribbed fuse pin access cover assembly will prevent incorrect installation of the outboard aft upper spar strut-to-wing attachment fuse pins.

This service bulletin also provides instructions to replace the inboard aft upper spar strut-to-wing attachment fuse pins on struts No. 1 and No. 4 with the new flanged fuse pins. Installation of the new flanged fuse pins at the inboard aft upper spar strut-to-wing attachment will prevent incorrect installation of the non-flanged fuse pins at the outboard and inboard aft upper spar strut-to-wing attachment.

Original Issue: January 31, 2014 747-54A2238 5 of 56

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Boeing Service Related Problem (SRP) 747-8-SRP-51-0016 is related to this service bulletin.

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., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION (PRR 86601-4) Get access to the Aft Upper Spar Fuse Pins and remove Access Cover Assemblies. Depressurize hydraulic system. Remove Air Drive Units and replace Fuse Pins. Install Air Drive Units and pressurize hydraulic system.

Install new Access Cover Assemblies and close access to the Aft Upper Spar Fuse Pins.

EFFECTIVITY 747-8 and 747-8F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(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.

Boeing recommends that the change given in this service bulletin be done within 48 months after the Original Issue date of this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of July 25, 2012. Please refer to Paragraph

2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.

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MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Original Issue: January 31, 2014 747-54A2238 7 of 56 BOEING SERVICE BULLETIN 747-54A2238

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BOEING SERVICE BULLETIN 747-54A2238

ALERT ALERT NO. 1 OUTBOARD STRUT

GET ACCESS TO THE AFT UPPER SPAR FUSE PINS AND REMOVE ACCESS COVER ASSEMBLIES.

DEPRESSURIZE HYDRAULIC SYSTEM.

REMOVE AIR DRIVE UNITS AND REPLACE FUSE PINS

INSTALL AIR DRIVE UNITS AND PRESSURIZE HYDRAULIC SYSTEM. INSTALL NEW ACCESS COVER

ASSEMBLIES AND CLOSE ACCESS TO THE AFT UPPER SPAR FUSE PINS.

UPPER LINK

AFT UPPER

SPAR FITTINGS

SIDE LINKS

DIAGONAL

DIAGONAL BRACE BRACE NO. 1 OUTBOARD STRUT SHOWN (NO. 4 OUTBOARD STRUT IS SIMILAR) Original Issue: January 31, 2014 Export Controlled ECCN: 9E991 - BOEING 747-54A2238 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 56

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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 airplane(s) shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 86601-4 for data about this change.

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

NOTE: Variable numbers for airplanes scheduled to be delivered more than a year after the Original Issue date of this service bulletin are not listed in the table below. MyBoeingFleet (MBF) will show current listing of the affected airplanes.

NOTE: This service bulletin is for the airplanes shown in the effectivity list below. The effectivity list includes all affected airplanes scheduled to be delivered before DEC 02, 2014. In addition, at least one airplane scheduled to be delivered after DEC 02, 2014 is affected by this service bulletin and is in Group(s) 1 as described in the Group Configuration table.

Affected airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page.

DESCRIPTIONCONFIGURATIONGROUP 747-8 and 747-8F Airplanes line number 1420 through 1434, 1436 through 1491 -1 Airplane Models:

Original Issue: January 31, 2014 747-54A2238 9 of 56

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GroupVariable Number 1RC001 - RC008 1RC022 - RC030 1RC501 - RC511 1RC521 - RC528 1RC541 1RC546 - RC549 1RC551 - RC563 1RC571 - RC572 1RC574 - RC582 1RC601 - RC605

2. Spares Affected None.

B. Concurrent Requirements None.

C. Reason Accomplishment of this service bulletin will prevent outboard migration of the outboard aft upper spar strut-to-wing attachment fuse pins on struts No. 1 and No. 4 that could result in the complete disconnect and loss of the outboard aft upper spar strut-to-wing attachment load path. The complete loss of the No. 1 or No. 4 outboard aft upper spar strut-to-wing attachment load path could result in divergent flutter in certain parts of the flight envelope, which can result in loss of control of the airplane.

To prevent the outboard aft upper spar strut-to-wing attachment fuse pins migrating outboard, the outboard aft upper spar strut-to-wing attachment fuse pin design was changed to add a flange. The outboard fuse pin access cover assemblies were changed to add interference ribs to only allow the fuse pin to be installed with the flanged end of the fuse pin on the inboard side of the outboard aft upper spar fitting. To prevent incorrect installation of the outboard aft upper spar strut-to-wing attachment fuse pins, the inboard aft upper spar strut-to-wing attachment fuse pin incorporated the same flanged fuse pin design.

Original Issue: January 31, 2014 747-54A2238 10 of 56 BOEING SERVICE BULLETIN 747-54A2238

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Boeing Service Related Problem (SRP) 747-8-SRP-51-0016 is related to this service bulletin.

D. Description Get access to the Aft Upper Spar Fuse Pins and remove Access Cover Assemblies. Depressurize hydraulic system. Remove Air Drive Units and replace Fuse Pins. Install Air Drive Units and pressurize hydraulic system. Install new Access Cover Assemblies and close access to the Aft Upper Spar Fuse Pins.

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

Affected Maintenance Zones ZoneModel 451, 452, 481, 482747-8, 747-8F E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Boeing recommends that the change given in this service bulletin be done within 48 months after the Original Issue date of this service bulletin.

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.

G. Manpower The table below shows an estimate of the task hours necessary to do this replacement 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:

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Time to inspect the work Time to cure the materials Time to make the parts Time to find the tools.

Elapsed Hours Task HoursNumber of Persons Task

3.2513.004Open Access Remove Access Panels

1.001.001...FIGURE 1: Strut No. 1

1.001.001...FIGURE 2: Strut No. 4

0.150.151Depressurize hydraulic system

4.5018.004Remove Air Drive Unit Replace Fuse Pins

4.008.002...FIGURE 3: Strut No. 1, Outboard Side

2.755.502...FIGURE 4: Strut No. 1, Inboard Side

2.755.502...FIGURE 5: Strut No. 4, Inboard Side

4.008.002...FIGURE 6: Strut No. 4, Outboard Side

4.5018.004Install Air Drive Unit

0.150.151Pressurize hydraulic system Install Access Panels

1.001.001...FIGURE 7: Strut No. 1

1.001.001...FIGURE 8: Strut No. 4

3.2513.004Close Access

1.004.004Test

34.3097.30TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane +8320.9 lb.-in.+5.2 lb.All I. Electrical Load Data Not changed.

Original Issue: January 31, 2014 747-54A2238 12 of 56 BOEING SERVICE BULLETIN 747-54A2238

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