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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-54A2245 Original Issue: December 18, 2015 ATA System: 5451 5410 SUBJECT: NACELLES / PYLONS - Nacelle Strut - PW4000 and GE CF6-80 Series Engines - No.
1 and No. 4 Outer Spring Beam Support Fitting Fastener Holes - Inspection, Repair, and Fastener Installation Change 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 © 2015 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Unpublished Work.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, 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.
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3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BLANK PAGE
Table of Contents
S u m m a r y5
1. PLANNING INFORMATION9
A . E f f e c t i v i t y9
1. Airplanes9
2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 3 E. Compliance .............................................. 1 4 F . A p p r o v a l ............................................... 1 6 G. Manpower .............................................. 1 7 H. Weight and Balance Changes .................................... 1 7 I. Electrical Load Data ......................................... 1 8 J . R e f e r e n c e s .............................................. 1 8
1. Existing Data: ......................................... 1 8
2. Data Supplied with this Service Bulletin: ........................... 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8 K. Publications Affected ........................................ 1 9 L. Interchangeability and Intermixability of Parts ........................... 1 9 M. Software Accomplishment Summary ................................ 1 9
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 2 C. Parts Necessary for Each Airplane ................................. 2 2 1 . K i t s / P a r t s ............................................ 2 2
2. Parts and Materials Supplied by the Operator ........................ 2 6
3. Parts Modified and Reidentified ................................ 2 7
4. Parts Removed and Not Replaced .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 1 FIGURE 1: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION O F S T R U T S I D E S K I N ..................................... 3 4 FIGURE 2: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION O F S T R U T S I D E S K I N ..................................... 3 7 FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION . 40 FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION . 47 FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE HFEC INSPECTION AND REPAIR .............................. 5 4 FIGURE 6: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE HFEC INSPECTION AND REPAIR .............................. 6 4 FIGURE 7: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER INSTALLATION MODIFICATION ........................................ 7 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 8: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER INSTALLATION MODIFICATION ........................................ 9 0 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: NO. 1 AND NO. 4 OUTER
SPRING BEAM SUPPORT FITTING FASTENER HOLES - STRUT SIDE SKIN, CHORD, OUTER
SPRING BEAM SUPPORT FITTING, AND BULKHEAD - INSPECTION, REPAIR, AND FASTENER INSTALLATION MODIFICATION - AIRPLANES WITH 9,000 TOTAL FLIGHT C Y C L E S O R L E S S ...................................... 1 0 6 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: NO. 1 AND NO. 4 OUTER
SPRING BEAM SUPPORT FITTING FASTENER HOLES - STRUT SIDE SKIN, CHORD, OUTER
SPRING BEAM SUPPORT FITTING, AND BULKHEAD - INSPECTION, REPAIR, AND FASTENER INSTALLATION MODIFICATION - AIRPLANES WITH MORE THAN 9,000 TOTAL F L I G H T C Y C L E S....................................... 1 0 8 APPENDIX C: MASTER FASTENER CODE TABLE ............................ 1 1 0 APPENDIX D: PART DEMAND INTENT ................................... 1 1 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-54A2245Original Issue: December 18, 2015 ATA System: 5451 5410 SUBJECT: NACELLES / PYLONS - Nacelle Strut - PW4000 and GE CF6-80 Series Engines - No.
1 and No. 4 Outer Spring Beam Support Fitting Fastener Holes - Inspection, Repair, and Fastener Installation Change
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 find and repair cracks in the fastener holes on the horizontal tang of the outer spring beam support fittings of the No. 1 and No. 4 pylons. If any crack is not found and repaired, a complete failure of the outer spring beam support fitting for any of the spring beams installed on the No.1 and No. 4 pylons can occur. A complete failure of the outer spring beam support fitting on the No. 1 and No. 4 pylons could result in possible separation of a strut and engine from the airplane during flight.
During an open hole high frequency eddy current (HFEC) inspection while accomplishing SB 747-54-2233, an operator found cracks in both the aluminum strut side skin and corrosion resistant steel (CRES) outer spring beam support fitting. Both fittings on the right and left side of the No.4 outboard pylon of the airplane were reported to have cracks. The cracking of the strut side skin was also visible upon detailed inspection with magnifying optics. On the left side of the pylon, on the horizontal tang of the fitting, 6 out of 14 fastener holes were reported to have cracks. On the right side, on the same horizontal tang, 4 out of 14 fasteners holes were reported with cracks. Boeing has done a detailed analysis of the cracking reports and has found that the fastener hole cracking is due to fatigue of the strut side skin and outer spring beam support fitting joint.
This service bulletin gives instructions to inspect for cracks in the strut side skin, chord, outer spring beam support fitting, and bulkhead, and necessary repairs for the fastener holes in the affected area of the outer spring beam support fitting. Also, this service bulletin gives modification instructions to install protruding head fasteners in the affected area of the outer spring beam support fitting, which terminates repeat inspections given in this service bulletin.
Boeing Service Related Problem (SRP) 747-SRP-54-0152 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 747 FTD 54-15001 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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 ChangesNoWeight 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 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 85901-145RS) Initial and Repeat Inspection of the Strut Side Skin Surface
1. Get access to left and right sides of the No. 1 and No. 4 struts.
2. Do a surface high frequency eddy current (HFEC) inspection for cracking of the strut side skin on the left and right sides of the No. 1 and No. 4 strut.
a. If no crack is found, repeat surface HFEC inspections of the strut side skin for cracking until the Fastener Hole Inspection, Repair, and Fastener Installation Modification is accomplished.
NOTE: Accomplishment of the Fastener Hole Inspection, Repair, and Fastener Installation Modification is terminating action for the repeat inspection.
b. If any crack is found, do the Fastener Hole Inspection, Repair, and Fastener Installation Modification.
NOTE: Accomplishment of the Fastener Hole Inspection, Repair, and Fastener Installation Modification is terminating action for the repeat inspection.
3. Close access to left and right sides of the No. 1 and No. 4 strut.
4. Put the airplane back to a serviceable condition.
Fastener Hole Inspection, Repair, and Fastener Installation Modification
1. Remove No. 1 and No. 4 engines, struts, and spring beams.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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2. Prepare fillers, do an open hole HFEC inspection of the fastener holes for cracks and complete necessary repairs, and do the fastener installation modification in accordance with this service bulletin.
NOTE: Accomplishment of the Fastener Hole Inspection, Repair, and Fastener Installation Modification is terminating action for the repeat inspection.
3. Install No.1 and No. 4 spring beams, struts, and engines.
4. Put the airplane back to a serviceable condition.
EFFECTIVITY 747-200B, 747-300, 747-400, 747-400D, 747-400F Airplane(s) with GE CF6-80 series engines and PW4000 series engines. 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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.
MANPOWER Table 1: Initial and Repeat Inspection of the Strut Side Skin Surface Elapsed HoursTotal Task HoursAirplanes
39.0291.0All Airplanes Table 2: Fastener Hole Inspection, Repair, and Fastener Installation Modification Elapsed HoursTotal Task HoursAirplanes
86.5490.0All Airplanes Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX D of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 747-54A2245
ALERT ALERT Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
DO A SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE STRUT SIDE SKIN FOR CRACKS.
GE CF6-80 SERIES ENGINES SHOWN IF ANY CRACK IS FOUND, DO THE FASTENER HOLE INSPECTION, REPAIR, AND FASTENER INSTALLATION MODIFICATION IF NO CRACKING IS FOUND. , REPEAT THE INSPECTIONS UNTIL THE ENGINES SIMILAR) _(PW4000 SERIES INSTALLATIO FASTENER HOLE INSPE ON, REPAIR AND FASTENER IS ACCOMPLISHED.
NO.1 AND NO.4 NACELLE STRUTS 2433039 (TYPICAL) Original Issue: December 18, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-54A2245 Work - See page 1 for details. 8 of 114
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-54A2245 Original Issue: December 18, 2015 ATA System: 5451 5410 SUBJECT: NACELLES / PYLONS - Nacelle Strut - PW4000 and GE CF6-80 Series Engines - No.
1 and No. 4 Outer Spring Beam Support Fitting Fastener Holes - Inspection, Repair, and Fastener Installation Change
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 applicable to 747-200B, 747-300, 747-400, 747-400D, and 747-400F Airplane(s) with GE CF6-80 series engines and PW4000 series engines installed, line numbers 679-1419 in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below. Refer to PRR 85901-145RS for data about this change.
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 747-200B/300/400/400D/400F airplanes with Pratt & Whitney PW4000 series engines or General Electric CF6-80 series engines.
-1 Airplane Models:
747-200B, 747-300, 747-400, 747-400D, 747-400F GroupVariable Number 1RD166 - RD167 1RF001 - RF006 1RL401 - RL403 1RL411 - RL436 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1RL451 - RL456 1RL461 - RL462 1RL471 - RL481 1RL491 - RL492 1RL501 - RL502 1RL511 - RL516 1RL521 - RL522 1RL531 - RL534 1RL561 - RL568 1RL571 - RL572 1RL576 - RL577 1RL579 1RL581 - RL586 1RL651 - RL655 1RL671 - RL675 1RL681 - RL684 1RL751 - RL752 1RM001 - RM007 1RM010 - RM013 1RM021 - RM024 1RM026 - RM030 1RM036 - RM045 1RM051 - RM053 1RM071 1RM081 - RM084 1RM091 1RM116 - RM117 1RM126 - RM132 1RM156 - RM158 1RM166 - RM177 1RM191 - RM192 1RM231 - RM233 1RM241 - RM246 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1RM316 - RM318 1RM341 1RM351 - RM355 1RM366 - RM367 1RM401 - RM403 1RM426 1RM431 1RM441 - RM443 1RM445 1RM801 - RM803 1RM811 - RM813 1RM851 - RM855 1RM861 - RM863 1RM871 - RM880 1RM891 - RM899 1RM901 - RM906 1RM911 1RR701 1RR721 - RR724 1RR746 - RR748 1RR851 - RR856 1RR861 - RR862 1RS331 - RS333 1RS341 - RS342 1RS781 - RS782 1RT001 - RT014 1RT021 - RT022 1RT031 - RT035 1RT041 - RT047 1RT061 1RT071 - RT075 1RT101 - RT103 1RT121 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1RT131 - RT137 1RT151 - RT152 1RT161 - RT168 1RT401 - RT412 1RT431 - RT447 1RT501 - RT535 1RT571 - RT591 1RT601 - RT657 1RT681 - RT682 1RT691 - RT699 1RT701 - RT704 1RT711 - RT717 1RT741 - RT757 1RT776 - RT777 1RT801 - RT803 1RT811 - RT814 1RT831 - RT837 1RT861 - RT864 1RT876 - RT880 1RT931 - RT932 1RT945 - RT949 1RT951 - RT955 1RT966 - RT967 1RU001 - RU006 1RU016 - RU017 1RU031 - RU032 1RU051 - RU052 1RU059 - RU062 1RU081 - RU083 1RU101 - RU102 1RU801 - RU809 1RU831 - RU841 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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