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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-54A2245 Original Issue: December 18, 2015 Revision 1: September 20, 2016 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Unpublished Work.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.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 1 of 132
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 2 of 132 BOEING SERVICE BULLETIN 747-54A2245
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3
1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F . A p p r o v a l ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J . R e f e r e n c e s .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data Supplied with this Service Bulletin: ........................... 2 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 3 K. Publications Affected ........................................ 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 4 M. Software Accomplishment Summary ................................ 2 4
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 6 C. Parts Necessary for Each Airplane ................................. 2 6 1 . K i t s / P a r t s ............................................ 2 6
2. Parts and Materials Supplied by the Operator ........................ 3 0
3. Parts Modified and Reidentified ................................ 3 1
4. Parts Removed and Not Replaced .............................. 3 1 D. Parts Necessary to Change Spares ................................. 3 1 E. Special Tooling - Price and Availability ............................... 3 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 5 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 8 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 ..................................... 4 1 FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION . 44 FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION . 52 FIGURE 5: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE HFEC INSPECTION AND REPAIR .............................. 6 0 FIGURE 6: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER HOLE OPEN HOLE HFEC INSPECTION AND REPAIR .............................. 7 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 3 of 132 BOEING SERVICE BULLETIN 747-54A2245
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FIGURE 7: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER INSTALLATION MODIFICATION ........................................ 8 0 FIGURE 8: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FASTENER INSTALLATION MODIFICATION ........................................ 9 6 FIGURE 9: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - BEAM COVER REMOVAL FOR A C C E S S ............................................ 1 1 2 FIGURE 10: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - BEAM COVER REMOVAL FOR A C C E S S ............................................ 1 1 5 FIGURE 11: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - BEAM COVER INSTALLATION ................................................. 1 1 8 FIGURE 12: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - BEAM COVER INSTALLATION ................................................. 1 2 1 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 2 4 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 2 6 APPENDIX C: MASTER FASTENER CODE TABLE ............................ 1 2 8 APPENDIX D: PART DEMAND INTENT ................................... 1 3 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 4 of 132 BOEING SERVICE BULLETIN 747-54A2245
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Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-54A2245Original Issue: December 18, 2015 Revision 1: September 20, 2016 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 revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2016-NM-004-AD, is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue was previously done:
None.
REASON FOR REVISION This revision is sent to add FAA NPRM information, update manpower information and insert fastener code information. This revision is also sent to give operators supporting information that will help in the accomplishment of the fastener removal, drill ream, and spot facing steps of the service bulletin. This revision is also sent to provide additional access instructions. The supporting information is the result of a successful service bulletin validation.
The data given in Information Notices 747-54A2245 IN 01, IN 02, and IN 03 is included in this revision.
As a part of a service bulletin validation program, this inspection, repair, and fastener installation modification was completed on airplane RU031 by Service Bulletin 747-54A2245 Original Issue before the release of Revision 01 of this service bulletin. The inspection, repair, and fastener installation change completed on airplane RU031 by Service Bulletin 747-54A2245 Original Issue is equivalent to the Revision 1 of this service bulletin. Airplane RU031 has the configuration of a Group 1 airplane.
These sections were changed:
1. In Summary, Background, added validation information.
2. In Summary, Compliance, added NPRM information.
3. In Summary, Manpower, updated Manpower Tables.
4. In Paragraph 1.C., Reason, added validation information and reason for this revision.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 5 of 132
5. In Paragraph 1.D., Description, added effects of this revision.
6. In Paragraph 1.E., Compliance, added NPRM information.
7. In Paragraph 1.G., Manpower, updated Manpower Tables.
8. Updated Paragraph 1.J., References, Existing Data.
9. In Paragraph 1.J.2., Data Supplied with this Service Bulletin, updated the revision of the drawing.
10. In Paragraph 1.J.3., Installation Drawings Used in the Preparation of this Service Bulletin, added drawings.
11. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added leveling compound, bolt, collar and footnotes.
12. In Paragraph 3.A., General Information, added a note.
13. In Paragraph 3.B., Work Instructions, updated terminology to say "go to" and added access information.
14. In FIGURE 3 and FIGURE 4, added caution note, a footnote and a paragraph.
15. In FIGURE 5 and FIGURE 6, added footnotes.
16. In FIGURE 7 and FIGURE 8, updated illustrations. Added flag notes and spot face requirement for a fastener location.
17. Added FIGURE 9, FIGURE 10, FIGURE 11, and FIGURE 12 to give removal and installation of panel for access.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY December 18, 2015Original Issue:
September 20, 2016Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 6 of 132 BOEING SERVICE BULLETIN 747-54A2245
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Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-54A2245Original Issue: December 18, 2015 Revision 1: September 20, 2016 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 DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT 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.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 7 of 132
As a part of a service bulletin validation program, this inspection, repair, and fastener installation modification was completed on airplane RU031 by Service Bulletin 747-54A2245 Original Issue before the release of Revision 01 of this service bulletin. The inspection, repair, and fastener installation change completed on airplane RU031 by Service Bulletin 747-54A2245 Original Issue is equivalent to the Revision 1 of this service bulletin. Airplane RU031 has the configuration of a Group 1 airplane.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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.
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 Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2016-NM-004-AD, is related to this service bulletin.
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
4.04.0All Airplanes Table 2: Fastener Hole Inspection, Repair, and Fastener Installation Modification Elapsed HoursTotal Task HoursAirplanes
90.5494.0All Airplanes Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 9 of 132 BOEING SERVICE BULLETIN 747-54A2245
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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.
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 10 of 132 BOEING SERVICE BULLETIN 747-54A2245
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BOEING SERVICE BULLETIN 747-54A2245
ALERT ALERT
DO A SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC)
INSPECTION OF THE STRUT SIDE SKIN FOR CRACKS ENGINES SIMILAR) GE CF6-80 SERIES ENGINES SHOWN (PW4000 SERIES REPAIR, AND FASTENER INSTALLATION MODIFICATION. IF NO CRACKING IS FOUND, REPEAT THE INSPECTIONS UNTIL THE FASTENER HOLE INSPECTION, REPAIR AND FASTENER INSTALLATION MODIFICATION IS ACCOMPLISHED. IF ANY CRACK IS FOUND, DO THE FASTENER HOLE INSPECTION, Л NO.1 AND NO.4 NACELLE STRUTS 2433039 (TYPICAL) Original Issue: December 18, 2015 Revision 1: September 20, 2016 Export Controlled ECCN: 9E991 - BOEING 747-54A2245 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 132
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 12 of 132 BOEING SERVICE BULLETIN 747-54A2245