# Boeing Alert Service Bulletin 747-54A2245: Revision 1

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- Document: [Boeing Alert Service Bulletin 747-54A2245](https://openairdocs.org/service-documents/boeing/747-54a2245.md)
- Title as filed: SB-747-54A2245-00 BOEING
- Pages: 114
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### Page 1

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Unpublished Work.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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Table of Contents
S u m m a r y  ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A . E f f e c t i v i t y  ................................................ 9
1. Airplanes ............................................. 9
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
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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
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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.
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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 Air-
plane 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.
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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.
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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)
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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
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
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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
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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
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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
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2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
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.
D. Description
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.
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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.
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.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
452, 482747-200B, 747-300, 747-400,
747-400D, 747-400F
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.
A logic diagram showing compliance tasks and compliance times are included as an aid in APPENDIX
A and APPENDIX B.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When
more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION
numbers for that CONDITION number or OPTION number.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
Airplanes with 9,000 total flight cycles or less at the original issue date of this service bulletin, refer to
Table 1 for compliance times.
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Airplanes with more than 9,000 total flight cycles at the original issue date of this service bulletin, refer
to Table 2 for compliance times.
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 Modi-
fication - Airplanes with 9,000 Total Flight Cycles or Less
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 12
months after the
original issue
date of this ser-
vice bulletin.
Before 9,000 to-
tal flight cycles.
PART 2: SURFACE
HFEC INSPECTION OF
STRUT SIDE SKIN for
cracks.
Airplanes with 9,000 total
flight cycles or less at the
original issue date of this
service bulletin.
500 flight cycles.(a)-OPTION 1 (ACTION 1):CONDITION 1: NO
CRACK FOUND ON
STRUT SIDE SKIN SUR-
FACE
Repeat PART 2: SUR-
FACE HFEC INSPEC-
TION OF STRUT SIDE
SKIN for cracks.
-Within 60 months after the initial
inspection.
OPTION 1 (ACTION 2):
Do PART 3: FASTENER
HOLE OPEN HOLE
HFEC INSPECTION,
REPAIR, AND FASTEN-
ER INSTALLATION
MODIFICATION.(a)
-Before further flight.OPTION 2:
Do PART 3: FASTENER
HOLE OPEN HOLE
HFEC INSPECTION,
REPAIR, AND FASTEN-
ER INSTALLATION
MODIFICATION.(a)
-Before further flight.Do PART 3: FASTENER
HOLE OPEN HOLE
HFEC INSPECTION,
REPAIR, AND FASTEN-
ER INSTALLATION
MODIFICATION.(a)
CONDITION 2: ANY
CRACK FOUND ON
STRUT SIDE SKIN SUR-
FACE
(a) Accomplishment of PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION, REPAIR, AND
FASTENER INSTALLATION MODIFICATION is terminating action for the repeat inspections.
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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 Modi-
fication - Airplanes with More Than 9,000 Total Flight Cycles
Repeat Interval
(Not to Exceed)
Compliance TimeActionCondition
-Within 12 months after the original
issue date of this service bulletin.
Do PART 2: SURFACE
HFEC INSPECTION OF
STRUT SIDE SKIN for
cracks.
Airplanes with more than
9,000 total flight cycles at
the original issue date of
this service bulletin.
500 flight cycles.(a)-OPTION 1 (ACTION 1):CONDITION 1: NO
CRACK FOUND ON
STRUT SIDE SKIN SUR-
FACE
Repeat PART 2: SUR-
FACE HFEC INSPEC-
TION OF STRUT SIDE
SKIN for cracks.
-Within 60 months after the original
issue date of this service bulletin.
OPTION 1 (ACTION 2):
Do PART 3: FASTENER
HOLE OPEN HOLE
HFEC INSPECTION,
REPAIR, AND FASTEN-
ER INSTALLATION
MODIFICATION.(a)
-Before further flight.OPTION 2:
Do PART 3: FASTENER
HOLE OPEN HOLE
HFEC INSPECTION,
REPAIR, AND FASTEN-
ER INSTALLATION
MODIFICATION.(a)
-Before further flight.Do PART 3: FASTENER
HOLE OPEN HOLE
HFEC INSPECTION,
REPAIR, AND FASTEN-
ER INSTALLATION
MODIFICATION.(a)
CONDITION 2: ANY
CRACK FOUND ON
STRUT SIDE SKIN SUR-
FACE
(a) Accomplishment of PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION, REPAIR, AND
FASTENER INSTALLATION MODIFICATION is terminating action for the repeat inspections.
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.
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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 work for each work package.
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: Initial and Repeat Inspection of the Strut Side Skin Surface
Elapsed HoursTask HoursNumber of PersonsTask
18.0144.08OPEN ACCESS
1.51.51FIGURE 1
1.51.51FIGURE 2
18.0144.08CLOSE ACCESS
39.0291.0TOTAL FOR EACH AIRPLANE
Table 2: Fastener Hole Inspection, Repair, and Fastener Installation Modification
Elapsed HoursTask HoursNumber of PersonsTask
18.0144.08OPEN ACCESS
9.036.04FIGURE 3
9.036.04FIGURE 4
7.7531.04FIGURE 5
7.7531.04FIGURE 6
8.534.04FIGURE 7
8.534.04FIGURE 8
18.0144.08CLOSE ACCESS
86.5490.0TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
None.
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I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 85901-145RS
b. Boeing Service Related Problem (SRP) 747-SRP-54-0152
c. Service Bulletin Index D6-30300
d. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-43-03, 20-50-01,
20-50-10, 20-50-19, 20-50-20
e. 747 Fleet Team Digest (FTD) 54-15001
f. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00
g. 747-100/200/300 Aircraft Maintenance Manual (AMM) 12-09-09, 27-81-00, 54-10-01, 54-10-04,
71-00-02
h. 747-100/200/300 Structural Repair Manual (SRM) 51-10-08, 51-30-08
i. 747-400 Aircraft Maintenance Manual (AMM) 06-09-09, 27-81-00, 54-51-01, 54-51-03, 71-00-02
j. 747-400 Structural Repair Manual (SRM) 51-20-07, 51-40-08
k. 747-400F Structural Repair Manual (SRM) 51-20-07, 51-40-08
l. 747-400LCF Structural Repair Manual (SRM) 51-20-07, 51-40-08
m. 747-400SF Structural Repair Manual (SRM) 51-20-07, 51-40-08
2. Data Supplied with this Service Bulletin:
a. Drawings:
ADCNDCN/REVSheetTitleDrawing No
--1SPOT FACING KIT - OUTBOARD ENGINE
PYLON R3/R4 SPRING BEAM SUPPORT
FITTING CRACKING
MIT321U2400
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
SKIN PANEL INSTL OUTBD NACELLE STRUT, CF6-80C2321U2400
SKIN PANEL INSTL OUTBD NACELLE STRUT, PW4000321U4400
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TitleDrawing Number
FRAME, INSTL-STA 298.93, OUTBD STRUT, PW4256321U4310
SPRING BEAM SUPPORT INSTL - OUTBOARD STRUT CF6-80C2321U2140
The table above lists applicable drawings used to prepare this service bulletin. The drawings are
not necessary to make the specified changes, and are not supplied with this service bulletin. The
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 but no new DTIs are necessary.
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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### Page 21

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below.
Operators are encouraged to share schedule requirements with Boeing for incorporation of the service
bulletin. The kit is subject to the terms and conditions of the Boeing standard purchase order
acknowledgment. Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the original re-
lease date of this
Service Bulletin
(US Dollars)
ROLT as of the
original issue
date of this Ser-
vice Bulletin (Cal-
endar Days)
QTYDateNameKit Number
$53,898.00399102/03/2016TOP KIT, RETROFIT -
OUTBOARD ENGINE
PYLON R3/R4 SPRING
BEAM SUPPORT FIT-
TING
015U2157-1
404/19/2016
1005/03/2016
1005/17/2016
1006/15/2016
1007/14/2016
1008/11/2016
909/09/2016
$584.00149101/12/2016FASTENER KIT -
OUTBOARD ENGINE
PYLON R3/R4 FIT-
TING, 2ND NOMINAL,
"A" LOCATION
015U2157-2 (a)
403/24/2016
$663.00149101/12/2016FASTENER KIT -
OUTBOARD ENGINE
PYLON R3/R4 FIT-
TING, 2ND NOMINAL,
"D" LOCATION
015U2157-3 (a)
403/24/2016
$645.00149101/12/2016FASTENER KIT -
OUTBOARD ENGINE
PYLON R3/R4 FIT-
TING, 2ND NOMINAL,
"E" LOCATION
015U2157-4 (a)
403/24/2016
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REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the original re-
lease date of this
Service Bulletin
(US Dollars)
ROLT as of the
original issue
date of this Ser-
vice Bulletin (Cal-
endar Days)
QTYDateNameKit Number
$624.00149101/12/2016FASTENER KIT -
OUTBOARD ENGINE
PYLON R3/R4 FIT-
TING, 2ND NOMINAL,
"F" LOCATION
015U2157-5 (a)
403/24/2016
(a) This kit is necessary if a 2nd next nominal fastener is needed at the specified fastener location. This kit
includes necessary parts per fastener hole location and the quantity of kit will depend on number of fas-
tener holes affected.
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.
B. Industry Support Information
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this
service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit, applicable fastener kit(s), and the items shown in Paragraph 2.C.2., Parts
and Materials Supplied by the Operator, are necessary for each airplane. The Top Kit is
divided into Figure kits for each installation figure shown in the table below.
Figure Kit
87Top Kit
11015U2157-1
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ALL
KIT 015U2157-1
Notes
Existing Part
NumberName
Figure
New Part Number
87
Qty
-WASHER, OVER-
SIZED OD, COUN-
TERSUNK
44321U2400-5506
-WASHER, OVER-
SIZED OD, COUN-
TERSUNK
88321U2400-5507
-WASHER, OVER-
SIZED OD, COUN-
TERSUNK
1212321U2400-5508
-WASHER, OVER-
SIZED OD, COUN-
TERSUNK
44321U2400-5509
-SKIN PANEL IN-
STL - OUTBD NA-
CELLE STRUT,
CF6-80C2
44321U2400-5600
-SKIN PANEL IN-
STL - OUTBD NA-
CELLE STRUT,
CF6-80C2
44321U2400-5601
-SKIN PANEL IN-
STL - OUTBD NA-
CELLE STRUT,
CF6-80C2
66321U2400-5602
(b)-BOLT, 12 PT
HEAD
44BACB30US6K16
(b)-BOLT, 12 PT
HEAD
88BACB30US8K18
(b)-BOLT, 12 PT
HEAD
44BACB30US8K19
(b)-BOLT, 12 PT
HEAD
44BACB30US9K19
(b)-BOLT, 12 PT
HEAD
44BACB30UU7K17
(b)-BOLT, 12 PT
HEAD
44BACB30UU7K18
(BACB30UU7K19
optional)
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ALL
KIT 015U2157-1
Notes
Existing Part
NumberName
Figure
New Part Number
87
Qty
-SELF-LOCKING
NUT
44BACN10HR6CD
-NUT1212BACN10HR8CD
-NUT44BACN10HR9CD
-SELF-LOCKING
NUT
88BACN10JC7CD
(a)-WASHER88BACW10BP6DP
(a)-WASHER2020BACW10BP7DP
(a)-WASHER2424BACW10BP8DP
(a)-WASHER88BACW10BP9DP
(a) There are more parts than are necessary.
(b) If grip length shown is not available at Boeing, fasteners supplied in kits may
be one grip length longer than indicated. Also, if any fasteners part numbers
listed are not available or have been superseded, substitute fasteners may be
supplied in kits.
KIT 015U2157-2
NotesNameQtyNew Part Number
WASHER, OVER-
SIZED OD, COUN-
TERSUNK
1321U2400-5507
(b)BOLT, 12 PT
HEAD
1BACB30US7K16
NUT1BACN10HR7CD
(a)WASHER3BACW10BP7DP
(a) There are more parts than are necessary.
(b) If grip length shown is not available at Boeing, fas-
teners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers
listed are not available or have been superseded,
substitute fasteners may be supplied in kits.
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KIT 015U2157-3
NotesNameQtyNew Part Number
WASHER, OVER-
SIZED OD, COUN-
TERSUNK
1321U2400-5709
(b)BOLT, 12 PT
HEAD
1BACB30US9K18
NUT1BACN10HR9CD
(a)WASHER3BACW10BP9DP
(a) There are more parts than are necessary.
(b) If grip length shown is not available at Boeing, fas-
teners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers
listed are not available or have been superseded,
substitute fasteners may be supplied in kits.
KIT 015U2157-4
NotesNameQtyNew Part Number
WASHER, OVER-
SIZED OD, COUN-
TERSUNK
1321U2400-5709
(b)BOLT, 12 PT
HEAD
1BACB30US9K19
NUT1BACN10HR9CD
(a)WASHER3BACW10BP9DP
(a) There are more parts than are necessary.
(b) If grip length shown is not available at Boeing, fas-
teners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers
listed are not available or have been superseded,
substitute fasteners may be supplied in kits.
KIT 015U2157-5
NotesNameQtyNew Part Number
WASHER, OVER-
SIZED OD, COUN-
TERSUNK
1321U2400-5710
(b)BOLT, 12 PT
HEAD
1BACB30US10K19
NUT1BACN10HR10CD
(a)WASHER3BACW10BP10DP
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KIT 015U2157-5
NotesNameQtyNew Part Number
(a) There are more parts than are necessary.
(b) If grip length shown is not available at Boeing, fas-
teners supplied in kits may be one grip length longer
than indicated. Also, if any fasteners part numbers
listed are not available or have been superseded,
substitute fasteners may be supplied in kits.
2. Parts and Materials Supplied by the Operator
The following parts or materials are necessary to do the change in this service bulletin. Parts and
materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine
operator part and material supply to make sure all necessary parts and materials are available.
NotesNameQTYPart Number /
Specification
(a)CHEMICAL CONVERSION COAT-
ING
--
(b)PRIMER-BMS 10-11, TYPE
1
(b)SEALANT-BMS 5-95
(c)SHIM-1100 ALUMINUM
PER AMS-QQ-A-
250/1 OR ASTM B
209; OR 302/304
CORROSION RE-
SISTANT STEEL
(CRES) PER
AMS5516 OR
AMS5513
(d)FREEZE PLUG-7075-T6 ALU-
MINUM CLAD
PER AMS-QQ-A-
250/13
(e)REPAIR WASHER-2024-T4 OR 2024-
T351 PER AMS-
QQ-A-225/6
(a) Refer to SOPM 20-43-03 for material information.
(b) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS)
for supplier data.
(c) To maintain a maximum of 0.005 gap requirement, fabricate a shim from 1100 aluminum
per AMS-QQ-A-250/1 or ASTM B 209; or 302/304 corrosion resistant steel (CRES) per
AMS5516 or AMS551. Refer to SOPM 20-50-20 as an accepted procedure. Refer to
FIGURE 3 and FIGURE 4.
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NotesNameQTYPart Number /
Specification
(d) If a freeze plug repair is necessary in the strut side skin, fabricate a freeze plug from
7075-T6 aluminum clad per AMS-QQ-A-250/13 in accordance with 747-100/200/300
SRM 51-10-08, 747-400 SRM 51-20-07, 747-400F SRM 51-20-07, 747-400LCF SRM
51-20-07, or 747-400SF SRM 51-20-07. Refer to FIGURE 5 and FIGURE 6.
(e) If any countersink remains in the strut side skin, fabricate a repair washer from 2024-T4
OR 2024-T351 per AMS-QQ-A-225/6 in accordance with 747-100/200/300 SRM 51-30-
08, 747-400 SRM 51-40-08, 747-400F SRM 51-40-08, 747-400LCF SRM 51-40-08, or
747-400SF SRM 51-40-08. Refer to FIGURE 7 and FIGURE 8.
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
Boeing can supply the tool(s) shown in Paragraph 2.F., Special Tooling Necessary to do this Service
Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of
the service bulletin. The tool(s) are subject to the terms and conditions of the Boeing standard purchase
order acknowledgement. Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin number and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or Boeing Part Page
2. Fax to (206) 662-7145
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REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST
RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT)
AND PRICE INFORMATION
Purchase Data:
Unit Price as of
the Original Issue
date of this Ser-
vice Bulletin (US
Dollars)
NameTool Kit Number
$34,025.00SPOT FACING KIT - OUT-
BOARD ENGINE PYLON
R3/R4 SPRING BEAM SUP-
PORT FITTING CRACKING
MIT321U2400
F. Special Tooling Necessary to do this Service Bulletin
To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability.
Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be
necessary. Examine operator tool supply to make sure all necessary tools are available.
NameTool Kit Number
SPOT FACING KIT - OUT-
BOARD ENGINE PYLON R3/R4
SPRING BEAM SUPPORT FIT-
TING CRACKING
MIT321U2400
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### Page 29

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 and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque Values:
— Values for structural fasteners are given in 747 Structural Repair Manual,
Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 747
Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of
Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 747
Aircraft Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
4. Use the approved fastener, process and 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. Refer to SOPM 20-50-01 for alternate
full threaded fasteners (screws) needed for installation in this service bulletin.
6. 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.
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### Page 30

7. 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.
8. Refer to APPENDIX A and APPENDIX B for logic diagrams. Logic diagrams are
provided as an aid only. Information contained in Paragraph 1.E., Compliance is the
primary source for compliance times. Information in Paragraph 3.B., Work Instructions
is the primary source for tasks required for compliance.
9. Refer to APPENDIX C for Master Fastener Code Table.
10. Refer to APPENDIX D for Boeing Part Demand Intent.
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. Use of colors in Figures is based on guidance from the ATA e-Business Program
(ATA) iSpec 2200.
13. When more than one OPTION is given for a CONDITION, do only one of the OPTION
numbers. When more than one ACTION is given for a CONDITION number or an
OPTION number, do all of the ACTION numbers for that CONDITION number or
OPTION number.
14. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
15. Some steps in the Work Instructions are labeled as Required for Compliance (RC).
If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps
labeled as RC, including sub-steps under an RC step and any figures identified in
an RC step, must be done to comply with the AD. An Alternative Method of
Compliance (AMOC) is required for any deviations to RC steps, including sub-steps
and identified figures. Steps not labeled as RC may be deviated from using accepted
methods in accordance with the operator's maintenance or inspection program without
obtaining approval of an AMOC. This is provided that the RC steps, including
sub-steps and identified figures, can still be done as specified, and the airplane can
be put back in an airworthy condition.
16. The Work Instructions include drill/ream tasks to remove any cracking in the affected
fastener holes. It is recommended to remove the least amount of material as
necessary, within the specified allowable limits, to accomplish the crack removal
requirements.
17. The instructions in Paragraph 3.B., Work Instructions, are applicable to No. 1 and
No. 4 pylons. Accomplishment of the work instructions on each pylon can be done
independently.
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PROPRIETARY - Copyright © Unpublished
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BOEING SERVICE BULLETIN 747-54A2245
ALERTALERT

### Page 31

B. WORK INSTRUCTIONS
Initial and Repeat Inspections of Strut Side Skin Surface
1. Do PART 1: OPEN ACCESS.
2. RC - Do PART 2: SURFACE HFEC INSPECTION OF STRUT SIDE SKIN for cracks.
a. CONDITION 1: NO CRACK FOUND ON STRUT SIDE SKIN SURFACE
(1) OPTION 1 (ACTION 1): Repeat PART 2: SURFACE HFEC INSPECTION OF STRUT
SIDE SKIN for cracks.
(2) OPTION 1 (ACTION 2): Do PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION,
REPAIR, AND FASTENER INSTALLATION MODIFICATION. Refer to Fastener Hole
Inspection, Repair, and Fastener Installation Modification.
NOTE: Accomplishment of PART 3: FASTENER HOLE OPEN HOLE HFEC
INSPECTION, REPAIR, AND FASTENER INSTALLATION MODIFICATION is
terminating action for the repeat inspection.
(3) OPTION 2: Do PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION, REPAIR,
AND FASTENER INSTALLATION MODIFICATION. Refer to Fastener Hole Inspection,
Repair, and Fastener Installation Modification.
NOTE: Accomplishment of PART 3: FASTENER HOLE OPEN HOLE HFEC
INSPECTION, REPAIR, AND FASTENER INSTALLATION MODIFICATION is
terminating action for the repeat inspection.
b. CONDITION 2: ANY CRACK FOUND ON STRUT SIDE SKIN SURFACE
(1) Do PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION, REPAIR, AND
FASTENER INSTALLATION MODIFICATION. Refer to Fastener Hole Inspection, Repair,
and Fastener Installation Modification.
NOTE: Accomplishment of PART 3: FASTENER HOLE OPEN HOLE HFEC
INSPECTION, REPAIR, AND FASTENER INSTALLATION MODIFICATION is
terminating action for the repeat inspection.
3. Do PART 4: CLOSE ACCESS.
4. Put the airplane back to a serviceable condition.
Fastener Hole Inspection, Repair, and Fastener Installation Modification
1. Do PART 1: OPEN ACCESS.
2. RC - Do PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION, REPAIR, AND FASTENER
INSTALLATION MODIFICATION.
NOTE: Accomplishment of PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION,
REPAIR, AND FASTENER INSTALLATION MODIFICATION is terminating action for the
repeat inspection.
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PROPRIETARY - Copyright © Unpublished
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ALERTALERT

### Page 32

3. Do PART 4: CLOSE ACCESS.
4. Put the airplane back to a serviceable condition.
PART 1: OPEN ACCESS
1. For Initial and Repeat Inspections of Strut Side Skin Surface, do the following:
a. Retract and deactivate the leading edge flaps. Refer to 747-100/200/300 AMM 27-81-00 or
747-400 AMM 27-81-00 as an accepted procedure.
2. For Fastener Hole Inspection, Repair, and Fastener Installation Modification, do the following:
a. Remove the No.1 and No.4 engines. Refer to 747-100/200/300 AMM 71-00-02 or 747-400
AMM 71-00-02 as an accepted procedure.
b. Remove the No.1 and No.4 nacelle struts. Refer to 747-100/200/300 AMM 54-10-01 or 747-400
AMM 54-51-01 an accepted procedure.
c. Remove the left and right side spring beams of the No.1 and No.4 nacelle struts. Refer to
747-100/200/300 AMM 54-10-04 or 747-400 AMM 54-51-03 as an accepted procedure.
PART 2: SURFACE HFEC INSPECTION OF STRUT SIDE SKIN
1. Do a surface high frequency eddy current (HFEC) inspection of strut side skin for cracks in
accordance with the figures below:
No. 4 StrutNo. 1 Strut
FIGURE 2FIGURE 1
PART 3: FASTENER HOLE OPEN HOLE HFEC INSPECTION, REPAIR, AND FASTENER
INSTALLATION MODIFICATION
1. Prepare the fillers in accordance with the figures in the following table:
No. 4 StrutNo. 1 Strut
FIGURE 4FIGURE 3
2. Do an open hole high frequency eddy current (HFEC) inspection of the fastener holes for cracks
and, if any crack is found, repair, in accordance with the figures in the following table:
No. 4 StrutNo. 1 Strut
FIGURE 6FIGURE 5
3. Do a fastener installation modification in accordance with the figures in the following table:
No. 4 StrutNo. 1 Strut
FIGURE 8FIGURE 7
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ALERTALERT

### Page 33

PART 4: CLOSE ACCESS
1. For Initial and Repeat Inspections of Strut Side Skin Surface, do the following:
a. Activate the leading edge flaps. Refer to 747-100/200/300 AMM 27-81-00 or 747-400 AMM
27-81-00 as an accepted procedure.
2. For Fastener Hole Inspection, Repair, and Fastener Installation Modification, do the following:
a. Install the left and right side spring beams back in the No. 1 and No. 4 nacelle struts. Refer
to 747-100/200/300 AMM 54-10-04 or 747-400 AMM 54-51-03 as an accepted procedure.
b. Install the No. 1 and No. 4 nacelle struts. Refer to 747-100/200/300 AMM 54-10-01 or 747-400
AMM 54-51-01 an accepted procedure.
c. Install the No. 1 and No. 4 engines. Refer to 747-100/200/300 AMM 71-00-02 or 747-400
AMM 71-00-02 as an accepted procedure.
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PROPRIETARY - Copyright © Unpublished
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BOEING SERVICE BULLETIN 747-54A2245
ALERTALERT

### Page 34 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
J
GE CF6-80 SERIES  PW4000 SERIES
ENGINES  ENGINES
OUTER SPRING BEAM
SUPPORT FITTINGS
B
B
NO.1 NACELLE STRUT
(SPRING BEAMS REMOVED)
(TYPICAL)
2436912
FIGURE 1: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION OF
STRUT SIDE SKIN
(SHEET 1 OF 3)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
SPRING BEAM
BEARING/ LUBRICATION
ACCESS DOOR
FWD
SKIN
A-A
SPRING BEAM
BEARING/ LUBRICATION
ACCESS DOOR
-WD
SKIN
B-B  2436916
FIGURE 1: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION OF
STRUT SIDE SKIN
(SHEET 2 OF 3)
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### Page 36

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a) (b)--STRUT SIDE SKINInspect1
(a) Do a surface HFEC of strut side skin around fasteners for cracks in accordance with 747 NDT Manual
Part 6, 51-00-00, Procedure 4 or 23.
(b) Refer to 747-100/200/300 AMM 12-09-09 or 747-400 AMM 06-09-09 for the location of the spring beam
bearing/lubrication access door.
FIGURE 1: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION OF
STRUT SIDE SKIN
(SHEET 3 OF 3)
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PROPRIETARY - Copyright © Unpublished
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ALERTALERT

### Page 37 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
GE CF6-80 SERIES  PW4000 SERIES
ENGINES  ENGINES
OUTER SPRING BEAM
SUPPORT FITTINGS
B
NO.4 NACELLE STRUT
(SPRING BEAMS REMOVED)
(TYPICAL)
2436943
FIGURE 2: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION OF
STRUT SIDE SKIN
(SHEET 1 OF 3)
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### Page 38 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
SPRING BEAM
BEARING/LUBRICATION
ACCESS DOOR
FWD
SKIN
A-A
SPRING BEAM
BEARING/ LUBRICATION
ACCESS DOOR
SKIN
B-B  2436945
FIGURE 2: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION OF
STRUT SIDE SKIN
(SHEET 2 OF 3)
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Work - See page 1 for details.  38 of 114

### Page 39

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a) (b)--STRUT SIDE SKINInspect1
(a) Do a surface HFEC of strut side skin around fasteners for cracks in accordance with 747 NDT Manual
Part 6, 51-00-00, Procedure 4 or 23.
(b) Refer to 747-100/200/300 AMM 12-09-09 or 747-400 AMM 06-09-09 for the location of the spring beam
bearing/lubrication access door.
FIGURE 2: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - SURFACE HFEC INSPECTION OF
STRUT SIDE SKIN
(SHEET 3 OF 3)
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PROPRIETARY - Copyright © Unpublished
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ALERTALERT

### Page 40 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
J
GE CF6-80 SERIES
ENGINES  PW4000 SERIES  ENGINES
OUTER SPRING BEAM
SUPPORT FITTING
OUTER SPRING BEAM
SUPPORT FITTING
NO.1 NACELLE STRUT
(SPRING BEAMS REMOVED)
(TYPICAL)
2433043
FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 1 OF 7)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
17 LOCATIONS  NAC  STA
308.9
OUTER SPRING BEAM
SUPPORT FITTING
SKIN
1 7 LOCATIONS
FWD
A-A
NAC  STA  17 LOCATIONS
308.9
OUTER SPRING BEAM
SUPPORT FITTING
SKIN
FWD  17 LOCATIONS
B-B  2433044
FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 2 OF 7)
Original Issue: December 18, 2015
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### Page 42 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
OUTER SPRING BEAM
FILLER A  FILLER B  35 € 7 LOCATIONS  SUPPORT FITTING
CHORD  / BULKHEAD
(/ LOCATIONS)
FILLER C
BULKHEAD FACE REMOVED FOR CLARITY
C-C
OUTER SPRING BEAM  SUPPORT FITTING  BULKHEAD  15 € 7 LOCATIONS  FILLER A
CHORD  FILLER B
FWD  FILLER C (7 LOCATIONS)  PILOT HOLE
BULKHEAD FACE REMOVED FOR CLARITY  2435386
D-D
FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 3 OF 7)
Original Issue: December 18, 2015
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PROPRIETARY - Copyright © Unpublished
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### Page 43 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
SHIM  SKIN
CHORD  OUTER SPRING BEAM
SUPPORT FITTING
TYPICAL
E-E
- BULKHEAD
- OUTER SPRING BEAM
SUPPORT FITTING
SKIN -
~ SHIM
CHORD
TYPICAL  F-F  2457081
FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 4 OF 7)
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### Page 44 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
— SHIM
OUTER SPRING BEAM
SUPPORT FITTING
CHORD
SKIN
TYPICAL
G-G
2456725
FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 5 OF 7)
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### Page 45

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)28-FASTENERRemove1
Shown as FILLER A.
(b)
4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Align2
Shown as FILLER B.
(b)
4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Align
Shown as FILLER
C. (b)
6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Align
(c)4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Chamfer3
(c)4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Chamfer
(c)6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Chamfer
(d)8-SHIMMake4
(d)8-SHIMPut / Hold
4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Remove / Keep5
4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Remove / Keep
6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Remove / Keep
If previously made.--SHIMRemove / Keep
FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 6 OF 7)
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BOEING SERVICE BULLETIN 747-54A2245
ALERTALERT

### Page 46

More DataQtyIdentificationNameTaskStep
(e)4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Identify6
(e)4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Identify
(e)6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Identify
If previously made.
(e)
--SHIMIdentify
(a) For PW4000 engines there are radius fillers installed on each side at two of the fastener locations on the
top row common to the bulkhead. Remove these radius fillers.
(b) Position the filler so that the center of the filler is in line with the center of the fastener hole.
(c) It is acceptable to chamfer the edges of the fillers to prevent interference with the fillet radii of the existing
structure. Refer to SOPM 20-50-20 as an accepted procedure.
(d) If necessary, make shim to maintain a maximum of 0.005 inch gap between the outer spring beam support
fitting and filler. Make the shim from 1100 aluminum alloy foil per AMS-QQ-A-250/1 or ASTM B 209; or
302 or 304 corrosion resistant steel (CRES) per AMS5516 or AMS5513. Refer to SOPM 20-50-20 as an
accepted procedure.
(e) Mark to identify the location. Refer to SOPM 20-50-10 as an accepted procedure.
More DataQtyIdentificationName
Flag
Note
Position the edge of the filler as far
aft as possible without interfering
with the adjacent fillet radius on
the outer spring beam support fit-
ting.
--EDGE OF FILLER ALIGN-
MENT
1
FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 7 OF 7)
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ALERTALERT

### Page 47 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
GE CF6-80 SERIES
ENGINES  PW4000 SERIES
ENGINES
OUTER SPRING BEAM
SUPPORT FITTING
OUTER SPRING BEAM
SUPPORT FITTING
NO.4 NACELLE STRUT
(SPRING BEAMS REMOVED)
(TYPICAL)
2433046
FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 1 OF 7)
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### Page 48 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
NAC
) 7 LOCATIONS  STA
308.9
OUTER SPRING BEAM
SUPPORT FITTING
SKIN
FWD
1 7 LOCATIONS
A-A
NAC  STA  1 7 LOCATIONS
308.9
OUTER SPRING BEAM
SUPPORT FITTING
SKIN
17 LOCATIONS
B-B  2433047
FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 2 OF 7)
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### Page 49 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
OUTER SPRING BEAM
FILLER A  FILLER B  (3E€ 7 LOCATIONS SUPPORT FITTING
CHORD  BULKHEAD
PILOT HOLE  -WD
(7 LOCATIONS)
FILLER C
BULKHEAD FACE REMOVED FOR CLARITY
C-C
OUTER SPRING BEAM  SUPPORT FITTING  BULKHEAD  3Y5X6 7 LOCATIONS  FILLER A
CHORD  FILLER B
PILOT HOLE
FILLER C  (7 LOCATIONS)
BULKHEAD FACE REMOVED FOR CLARITY  2435397
D-D
FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 3 OF 7)
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### Page 50 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
SHIM  SKIN
CHORD  OUTER SPRING BEAM
TYPICAL  SUPPORT FITTING
E-E
- BULKHEAD
- OUTER SPRING BEAM
SUPPORT FITTING
SKIN -
SHIM
CHORD
TYPICAL  F-F  2456827
FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 4 OF 7)
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### Page 51 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
- SHIM
• OUTER SPRING BEAM
SUPPORT FITTING
CHORD
SKIN
TYPICAL
G-G
2457074
FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 5 OF 7)
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### Page 52

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
More DataQtyIdentificationNameTaskStep
(a)28-FASTENERRemove1
Shown as FILLER A.
(b)
4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Align2
Shown as FILLER B.
(b)
4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Align
Shown as FILLER
C. (b)
6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Align
(c)4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Chamfer3
(c)4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Chamfer
(c)6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Chamfer
(d)8-SHIMMake4
(d)8-SHIMPut / Hold
4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Remove / Keep5
4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Remove / Keep
6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Remove / Keep
If previously made.--SHIMRemove / Keep
FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 6 OF 7)
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BOEING SERVICE BULLETIN 747-54A2245
ALERTALERT

### Page 53

More DataQtyIdentificationNameTaskStep
(e)4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Identify6
(e)4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Identify
(e)6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Identify
If previously made.
(e)
--SHIMIdentify
(a) For PW4000 engines there are radius fillers installed on each side at two of the fastener locations on the
top row common to the bulkhead. Remove these radius fillers.
(b) Position the filler so that the center of the filler is in line with the center of the fastener hole.
(c) It is acceptable to chamfer the edges of the fillers to prevent interference with the fillet radii of the existing
structure. Refer to SOPM 20-50-20 as an accepted procedure.
(d) If necessary, make shim to maintain a maximum of 0.005 inch gap between the outer spring beam support
fitting and filler. Make the shim from 1100 aluminum alloy foil per AMS-QQ-A-250/1 or ASTM B 209; or
302 or 304 corrosion resistant steel (CRES) per AMS5516 or AMS5513. Refer to SOPM 20-50-20 as an
accepted procedure.
(e) Mark to identify the location. Refer to SOPM 20-50-10 as an accepted procedure.
More DataQtyIdentificationName
Flag
Note
Position the edge of the filler as far
aft as possible without interfering
with the adjacent fillet radius on
the outer spring beam support fit-
ting.
--EDGE OF FILLER ALIGN-
MENT
1
FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION
(SHEET 7 OF 7)
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Original Issue: December 18, 2015
747-54A2245
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BOEING SERVICE BULLETIN 747-54A2245
ALERTALERT

### Page 54 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
GE CF6-80 SERIES
ENGINES  PW4000 SERIES  ENGINES
OUTER SPRING BEAM
SUPPORT FITTING
OUTER SPRING BEAM
SUPPORT FITTING
NO.1 NACELLE STRUT
(SPRING BEAMS REMOVED)
(TYPICAL)
2433055
FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE
HFEC INSPECTION AND REPAIR
(SHEET 1 OF 10)
Original Issue: December 18, 2015
PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  747-54A2245
Work - See page 1 for details.  54 of 114

### Page 55 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
OUTER SPRING BEAM
1) 7 LOCATIONS  ) 14 LOCATIONS  CHORD SUPPORT FITTING
BULKHEAD
FWD
BULKHEAD FACE REMOVED FOR CLARITY
A-A
OUTER SPRING BEAM  17 LOCATIONS
SUPPORT FITTING  CHORD  2) 14 LOCATIONS
BULKHEAD
FWD
BULKHEAD FACE REMOVED FOR CLARITY  2450231
B-B
FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE
HFEC INSPECTION AND REPAIR
(SHEET 2 OF 10)
Original Issue: December 18, 2015
Export Controlled ECCN: 9E991 - BOEING  747-54A2245
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  55 of 114

### Page 56 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
NAC
STA
308.9
BULKHEAD  OUTER SPRING BEAM
SUPPORT FITTING
SKIN
1 THROUGH ® 14 LOCATIONS  FWD
C-C
NAC
STA
308.9  BULKHEAD
OUTER SPRING BEAM
SUPPORT FITTING
SKIN
1 THROUGH ® 14 LOCATIONS
D-D  2457930
FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE
HFEC INSPECTION AND REPAIR
(SHEET 3 OF 10)
Original Issue: December 18, 2015
Export Controlled ECCN: 9E991 - BOEING  PROPRIETARY - Copyright © Unpublished  747-54A2245
Work - See page 1 for details.  56 of 114

### Page 57 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
BULKHEAD  OUTER SPRING BEAM
SUPPORT FITTING
CHORD
SKIN
3 THROUGH 8 7 LOCATIONS
FWD
FREEZE PLUG IN SKIN NOT SHOWN FOR CLARITY
(TYPICAL)
E-E
BULKHEAD  OUTER SPRING BEAM
SUPPORT FITTING
CHORD
SKIN
THROUGH ® 7 LOCATIONS
FREEZE PLUG IN SKIN NOT SHOWN FOR CLARITY
(TYPICAL)  F-F  2450984
FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE
HFEC INSPECTION AND REPAIR
(SHEET 4 OF 10)
Original Issue: December 18, 2015
Export Controlled ECCN: 9E991 - BOEING  747-54A2245
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  57 of 114

### Page 58 (OCR)

BOEING SERVICE BULLETIN 747-54A2245
ALERT  ALERT
OUTER SPRING
BEAM SUPPORT
FITTING
~SHIM
• CHORD
- SKIN
FREEZE PLUG WITH COUNTER SINK IN SKIN AT
APPLICABLE FASTENER HOLE LOCATIONS
BULKHEAD AND FILLER NOT SHOWN FOR CLARITY
(TYPICAL)
OUTER SPRING
BEAM SUPPORT
FITTING
SHIM
• CHORD
- SKIN
FREEZE PLUG WITHOUT COUNTER SINK IN SKIN AT
APPLICABLE FASTENER HOLE LOCATIONS
BULKHEAD AND FILLER NOT SHOWN FOR CLARITY
(TYPICAL)
B  2450991
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE
HFEC INSPECTION AND REPAIR
(SHEET 5 OF 10)
Original Issue: December 18, 2015
PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  747-54A2245
Work - See page 1 for details.  58 of 114

### Page 59

NOTE: Boeing Tool MIT321U2400 includes various sized reamers to meet the requirements of fastener hole
sizes given in Table 1 and Table 3 of this figure. It is acceptable to use operator's equivalent tool to
meet the requirements of fastener hole sizes given in Table 1 and Table 3 of this figure.
Accomplishment of the steps shown in this figure are necessary on fastener holes shown (total of 28
locations). It is acceptable to accomplish the sequence of Steps 2 through 8 shown on each fastener
hole location independently.
More DataQtyIdentificationNameTaskStep
(a)4321U2400-5600SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Put / Hold1
(a)4321U2400-5601SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Put / Hold
(a)6321U2400-5602SKIN PANEL INSTL -
OUTBD NACELLE
STRUT, CF6-80C2
Put / Hold
If previously made.
Not shown. This part
is located between
the filler and outer
spring beam support
fitting. (a)
--SHIMPut / Hold
(b)14-TEMPORARY FASTEN-
ER
Install (Temporary)
Match drill fillers to
the existing hole size
in the structure.
28-FASTENER HOLEDrill / Ream2
Holes common to
the bulkhead
area.(c) (e)
8-FASTENER HOLEInspect3
Holes not common
to the bulkhead
area.(d) (e)
20-FASTENER HOLEInspect
FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE
HFEC INSPECTION AND REPAIR
(SHEET 6 OF 10)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 2015
747-54A2245
59 of 114
BOEING SERVICE BULLETIN 747-54A2245
ALERTALERT

### Page 60

More DataQtyIdentificationNameTaskStep
Bulkhead area.8-FASTENER HOLEDrill / Ream4
Refer to Table 1 for
fastener hole size
limits.(f) (g)
Bulkhead area.(c)
(h) (i)
8-FASTENER HOLEInspect
Non-bulkhead area.20-FASTENER HOLEDrill / Ream
Refer to Table 1 for
fastener hole size
limits.(f) (j)
Non-bulkhead
area.(d) (h) (k)
20-FASTENER HOLEInspect
Refer to Table 2 for
strut side skin freeze
plug hole size lim-
its.(l) (m) (n)
28-FASTENER HOLE
(SKIN)
Drill / Ream5
(l) (o)28-FASTENER HOLE
(SKIN)
Inspect
(l) (p)28-FREEZE PLUG HOLE
(SKIN)
Measure6
(l) (p)28-FREEZE PLUG (SKIN)Make
(l) (q)28-FREEZE PLUG (SKIN)Install (New)7
Drill final hole size.
Refer to Table 3. (n)
28-FASTENER HOLEDrill / Ream8
(a) Put/hold the part according to the part mark location information.
(b) Hold the filler/shim together with the existing structure with one temporary fastener on each filler during
drill/ream steps. Remove and install a temporary fastener from one fastener hole location (initial pilot hole
location) to the adjacent location (final sized hole) on a filler to accomplish the drill/ream steps at all the
fastener hole locations.
(c) Do an open hole HFEC inspection for cracks in accordance with 747 NDT Manual Part 6, 51-00-00, Pro-
cedure 1, 11, or 16 for the aluminum strut side skin, chord, and bulkhead; and 747 NDT Manual Part 6,
51-00-00, Procedure 2 or 19 for the CRES outer spring beam support fitting.
(d) Do an open hole HFEC inspection for cracks in accordance with 747 NDT Manual Part 6, 51-00-00, Pro-
cedure 1, 11, or 16 for the aluminum strut side skin and chord; and 747 NDT Manual Part 6, 51-00-00,
Procedure 2 or 19 for the CRES outer spring beam support fitting.
FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE
HFEC INSPECTION AND REPAIR
(SHEET 7 OF 10)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 18, 2015
747-54A2245
60 of 114
BOEING SERVICE BULLETIN 747-54A2245
ALERTALERT

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