# Boeing Alert Service Bulletin 747-54A2245: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2016-7261; AD 2017-02-04 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 747-54A2245](https://openairdocs.org/service-documents/boeing/747-54a2245.md) - Title as filed: SB-747-54A2245-01--BOEING - Pages: 132 - PDF: https://openairdocs.org/files/sha256/f1/5c/f15ca03db0e5444ef96522ab0f22d3d56459763844016115ac572a1e2274064f - Page: https://openairdocs.org/service-documents/boeing/747-54a2245/file/f15ca03db0e5 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 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 Unpublished Work.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1: September 20, 2016 1 of 132 2.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 2 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 S u m m a r y ...................................................... 7 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 ALERTALERT ### Page 4 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 ALERTALERT ### Page 5 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 ### Page 6 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 ALERTALERT ### Page 7 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 ### Page 8 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 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. 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 8 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 9 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 ALERTALERT ### Page 10 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 ALERTALERT ### Page 11 (OCR) 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 ### Page 12 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 ALERTALERT BLANK PAGE ### Page 13 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 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. 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 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 13 of 132 ### Page 14 GroupVariable Number 1RL411 - RL436 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 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 14 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 15 GroupVariable Number 1RM241 - RM246 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 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 15 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 16 GroupVariable Number 1RT121 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. Original Issue: December 18, 2015 747-54A2245Revision 1: September 20, 2016 16 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 17 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. 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. Revision 1 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. 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 17 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 18 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. 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. Effects of this Revision on airplanes on which Original Issue was previously done: None. 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 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 18 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 19 E. Compliance Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2016-NM-004-AD, is related to this service bulletin. 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. 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) 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 19 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 20 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 -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. 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) 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 20 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 21 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 -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. 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 0.50.51OPEN ACCESS 1.51.51FIGURE 1 1.51.51FIGURE 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 21 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 22 Table 1: Initial and Repeat Inspection of the Strut Side Skin Surface Elapsed HoursTask HoursNumber of PersonsTask 0.50.51CLOSE ACCESS 4.04.0TOTAL FOR EACH AIRPLANE Table 2: Fastener Hole Inspection, Repair, and Fastener Installation Modification Elapsed HoursTask HoursNumber of PersonsTask 18.0144.08OPEN ACCESS 1.01.01FIGURE 9 1.01.01FIGURE 10 9.036.04FIGURE 3 9.036.04FIGURE 4 7.7531.04FIGURE 5 7.7531.04FIGURE 6 8.534.04FIGURE 7 8.534.04FIGURE 8 1.01.01FIGURE 11 1.01.01FIGURE 12 18.0144.08CLOSE ACCESS 90.5494.0TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes None. 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. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM) 2016-NM-004-AD d. Service Bulletin Index D6-30300 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 22 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 23 e. 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 f. 747 Fleet Team Digest (FTD) 54-15001 g. 747 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00 h. 747-100/200/300 Aircraft Maintenance Manual (AMM) 12-09-09, 27-81-00, 51-41-01, 54-10-01, 54-10-04, 71-00-02 i. 747-100/200/300 Structural Repair Manual (SRM) 51-10-08, 51-30-08 j. 747-400 Aircraft Maintenance Manual (AMM) 06-09-09, 27-81-00, 51-41-01, 54-51-01, 54-51-03, 71-00-02 k. 747-400 Structural Repair Manual (SRM) 51-20-07, 51-40-08 l. 747-400F Structural Repair Manual (SRM) 51-20-07, 51-40-08 m. 747-400LCF Structural Repair Manual (SRM) 51-20-07, 51-40-08 n. 747-400SF Structural Repair Manual (SRM) 51-20-07, 51-40-08 2. Data Supplied with this Service Bulletin: a. Drawings: ADCNDCN/REVSheetTitleDrawing No -D1SPOT 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 FRAME, INSTL-STA 298.93, OUTBD STRUT, PW4256321U4310 SPRING BEAM SUPPORT INSTL - OUTBOARD STRUT CF6-80C2321U2140 BULKHEAD INSTL - AFT ENG. MT. OUTBD NAC STRUT, CF6- 80 321U2240 VAPOR BARRIER INSTL-STRUT/WING-OUTBD NAC STRUT CF6-80C2 321U2080 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. 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 23 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 24 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. 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 24 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 25 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 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 25 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 26 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 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 26 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 27 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) 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 27 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 28 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. 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 28 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 29 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 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 29 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 30 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 (b) (f)LEVELING COMPOUND-BMS 5-125 (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 (g)BOLT-BACB30NX10K16 (g)BOLT-BACB30NX10K22 (g)COLLAR-BACC30X10 (a) Refer to SOPM 20-43-03 for material information. 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 30 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 31 NotesNameQTYPart Number / Specification (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. (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. (f) This leveling compound is used if the beam cover in FIGURES 9-10 is removed for addi- tional access. (g) This is only required if it is removed for additional access during spot face. 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 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 31 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 32 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 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 32 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 33 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. 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 33 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 34 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. 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 34 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 35 18. The Work Instructions include drill/ream tasks on the strut structure. All fasteners were installed in production with fastener holes perpendicular to the strut side skin. Maintain fastener holes perpendicular to the strut side skin for correct fastener installation. 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. Go 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. Go 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. Go 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. 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 35 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 36 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. 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. d. Remove the beam cover installed on strut 1 and strut 4 on the inboard strut side to gain additional access. Remove the beam cover in accordance with the figures below: No. 4 StrutNo. 1 Strut FIGURE 10FIGURE 9 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: 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 36 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 37 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 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 removed beam cover on strut 1 and strut 4 on the inboard strut side, if removed. Install the panel in accordance with the figures below: No. 4 StrutNo. 1 Strut FIGURE 12FIGURE 11 b. 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. c. 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. d. 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. 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 37 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 38 (OCR) BOEING SERVICE BULLETIN 747-54A2245 ALERT ALERT J GE CF6-80 SERIES PW4000 SERIES ENGINES ENGINES OUTER SPRING BEAM SUPPORT FITTINGS 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) Original Issue: December 18, 2015 Revision 1 September 20, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-54A2245 Work - See page 1 for details. 38 of 132 ### Page 39 (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) 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. 39 of 132 ### Page 40 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) 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 40 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 41 (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) 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. 41 of 132 ### Page 42 (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) Original Issue: December 18, 2015 Revision 1 September 20, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-54A2245 Work - See page 1 for details. 42 of 132 ### Page 43 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) 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 43 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 44 (OCR) BOEING SERVICE BULLETIN 747-54A2245 ALERT ALERT J GE CF6-80 SERIES ENGINES PW4000 SERIES ENGINES B - SUPPORT FITTING OUTER SPRING BEAM 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 8) 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. 44 of 132 ### Page 45 (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 8) Original Issue: December 18, 2015 Revision 1 September 20, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-54A2245 Work - See page 1 for details. 45 of 132 ### Page 46 (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 8) 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. 46 of 132 ### Page 47 (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 8) Original Issue: December 18, 2015 Revision 1 September 20, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-54A2245 Work - See page 1 for details. 47 of 132 ### Page 48 (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 8) 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. 48 of 132 ### Page 49 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 CAUTION: WHEN REMOVING FASTENERS USING OPTION 2, PAY PARTICULAR ATTENTION NOT TO DAMAGE THE BULKHEAD FLANGE DUE TO LIMITED CLEARANCE IN THE BULKHEAD STRUCTURE. (a) (f)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 8) 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 49 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 50 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. (f) There are two options to remove the fasteners: – OPTION 1: Fasteners can be removed by tapping them out from the inside of the strut after the collars are removed. This option was successfully done during the validation. – OPTION 2: Fasteners can be removed by drilling out the countersink heads and tapping them in from the outside. When using this option for the fasteners common to the bulkhead (fastener locations "B" and "C"), pay particular attention not to damage the bulkhead flange due to limited clearance in the bulkhead structure. When tapping the fasteners through the structure from outside, place a steel plate between the fastener and the bulkhead flange to protect the bulkhead structure and prevent damage. After the fastener has been tapped part-way into the strut from outside, and before it contacts the plate that protects the bulkhead flange, cut the bolt to create more space for the fastener to tap through the structure. Repeat this process until the fastener has been removed from the structure. FIGURE 3: NO. 1 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION (SHEET 7 OF 8) 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 50 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 51 The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. 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 8 OF 8) 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 51 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 52 (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 8) 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. 52 of 132 ### Page 53 (OCR) BOEING SERVICE BULLETIN 747-54A2245 ALERT ALERT 1 7 LOCATIONS NAC STA 308.9 OUTER SPRING BEAM SUPPORT FITTING SKIN 1 7 LOCATIONS A-A NAC STA 17 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 8) 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. 53 of 132 ### Page 54 (OCR) BOEING SERVICE BULLETIN 747-54A2245 ALERT ALERT OUTER SPRING BEAM FILLER A FILLER B 35 € 7 LOCATIONS SUPPORT FITTING CHORD BULKHEAD PILOT HOLE (7 LOCATIONS) FILLER C BULKHEAD FACE REMOVED FOR CLARITY C-C OUTER SPRING BEAM € € 7 LOCATIONS SUPPORT FITTING BULKHEAD FILLER A CHORD FILLER B FWD FILLER C (7 LOCATIONS) PILOT HOLE BULKHEAD FACE REMOVED FOR CLARITY 2435397 D-D FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION (SHEET 3 OF 8) 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. 54 of 132 ### Page 55 (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 2456827 FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION (SHEET 4 OF 8) Original Issue: December 18, 2015 Revision 1 September 20, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-54A2245 Work - See page 1 for details. 55 of 132 ### Page 56 (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 8) 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. 56 of 132 ### Page 57 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 CAUTION: WHEN REMOVING FASTENERS USING OPTION 2, PAY PARTICULAR ATTENTION NOT TO DAMAGE THE BULKHEAD FLANGE DUE TO LIMITED CLEARANCE IN THE BULKHEAD STRUCTURE. (a) (f)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 8) 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 57 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 58 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. (f) There are two options to remove the fasteners: – OPTION 1: Fasteners can be removed by tapping them out from the inside of the strut after the collars are removed. This option was successfully done during the validation. – OPTION 2: Fasteners can be removed by drilling out the countersink heads and tapping them in from the outside. When using this option for the fasteners common to the bulkhead (fastener locations "B" and "C"), pay particular attention not to damage the bulkhead flange due to limited clearance in the bulkhead structure. When tapping the fasteners through the structure from outside, place a steel plate between the fastener and the bulkhead flange to protect the bulkhead structure and prevent damage. After the fastener has been tapped part-way into the strut from outside, and before it contacts the plate that protects the bulkhead flange, cut the bolt to create more space for the fastener to tap through the structure. Repeat this process until the fastener has been removed from the structure. FIGURE 4: NO. 4 STRUT - OUTER SPRING BEAM SUPPORT FITTING - FILLER PREPARATION (SHEET 7 OF 8) 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 58 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 59 The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. 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 8 OF 8) 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 59 of 132 BOEING SERVICE BULLETIN 747-54A2245 ALERTALERT ### Page 60 (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 Revision 1 September 20, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-54A2245 Work - See page 1 for details. 60 of 132 The text continues at https://openairdocs.org/service-documents/boeing/747-54a2245/file/f15ca03db0e5.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. 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