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Commercial Airplanes 707 Service Bulletin ALERT Number: A3183 Original Issue: June 27, 1975 Revision 6: February 07, 2014 ATA System: 5410 SUBJECT: NACELLE - Inboard and Outboard Nacelle Strut - Midspar Fitting - Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 1989 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Unpublished Work.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: June 27, 1975 A3183Revision 6: February 07, 2014 1 of 106
8.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 2 0 F. Approval ............................................... 3 3 G. Manpower .............................................. 3 4 H. Weight and Balance Changes .................................... 3 6 I. Electrical Load Data ......................................... 3 6 J. References .............................................. 3 6
1. Existing Data: ......................................... 3 6
2. Data Supplied with this Service Bulletin: ........................... 3 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 7 K. Publications Affected ........................................ 3 7 L. Interchangeability and Intermixability of Parts ........................... 3 8 M. Software Accomplishment Summary ................................ 3 8
2. MATERIAL INFORMATION ........................................ 3 9 A. Material - Price and Availability ................................... 3 9 B. Industry Support Information .................................... 3 9 C. Parts Necessary for Each Airplane ................................. 3 9
1. Kits/Parts ............................................ 3 9
2. Parts and Materials Supplied by the Operator ........................ 4 5
3. Parts Modified and Reidentified ................................ 4 6
4. Parts Removed and Not Replaced .............................. 4 6 D. Parts Necessary to Change Spares ................................. 4 6 E. Special Tooling - Price and Availability ............................... 4 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 0 FIGURE 1: THIS FIGURE IS DELETED .................................. 6 2 FIGURE 2: THIS FIGURE IS DELETED .................................. 6 3 FIGURE 3: NACELLE STRUT # 2 AND # 3 MIDSPAR FITTING INSPECTION - LIFE LIMIT PROGRAM .................................................. 6 4 FIGURE 4: NACELLE STRUT # 2 AND # 3 TORQUE BULKHEAD AND MIDSPAR CHORD INSPECTIONS .................................................. 6 7 FIGURE 5: NACELLE STRUT # 2 AND # 3 DRAG FITTING AND FRONT SPAR SUPPORT INSPECTIONS .................................................. 7 0 FIGURE 6: NACELLE STRUT # 1 AND # 4 MIDSPAR FITTING INSPECTION - LIFE LIMIT PROGRAM .................................................. 7 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 7: NACELLE STRUT # 1 AND # 4 TORQUE BULKHEAD AND MIDSPAR CHORD INSPECTIONS .................................................. 7 8 FIGURE 8: NACELLE STRUT # 1 AND # 4 DRAG FITTING AND FRONT SPAR SUPPORT INSPECTIONS .................................................. 8 1 FIGURE 9: NACELLE STRUT # 2 AND # 3 MIDSPAR FITTING INSPECTION - LIFE-LIMIT PROGRAM - MID INTERVAL INSPECTION ................................ 8 6 FIGURE 10: NACELLE STRUT # 1 AND # 4 MIDSPAR FITTING INSPECTION - LIFE-LIMIT PROGRAM - MID INTERVAL INSPECTION ................................ 8 9 FIGURE 11: NACELLE STRUT # 1, # 2, # 3 AND # 4 INBOARD SIDE OVERWING SUPPORT FITTING INSPECTION ......................................... 9 2 FIGURE 12: NACELLE STRUT # 1, # 2, # 3 AND # 4 OUTBOARD SIDE OVERWING SUPPORT FITTING INSPECTION ......................................... 9 4 FIGURE 13: NACELLE STRUT # 1, # 2, # 3 AND # 4 OUTBOARD SIDE OVERWING FASTENER INSTALLATION ........................................ 9 6 APPENDIX A: EXISTING PARTS ACCOUNTABILITY ............................ 9 8 APPENDIX B: NACELLE STRUT # 1 AND # 4 - DRAG FITTING - CHAMFER / RADIUS INSPECTION . 101 APPENDIX C: BUSHING DIMENSIONS FOR DRAG FITTING ATTACHMENT HOLES ......... 1 0 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 707 Service Bulletin ALERT Revision Transmittal SheetNumber: A3183Original Issue: June 27, 1975 Revision 6: February 07, 2014 ATA System: 5410 SUBJECT: NACELLE - Inboard and Outboard Nacelle Strut - Midspar Fitting - Inspection and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplane(s) changed in accordance with Revision 5 of this service bulletin. Install new inboard and outboard midspar fittings to each nacelle strut in accordance with the midspar fitting life-limit program. Also, do detailed inspection and High Frequency Eddy Current (HFEC) inspection of the nacelle strut midspar fittings in accordance with midspar fitting life-limit program mid interval inspection.
Federal Aviation Administration (FAA) Airworthiness Directive AD 93-11-02 is related to this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-16-12 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Airplane line numbers 0910-0912, 0914-0915, 0917-0919, 0922-0923, 0925-0925, 0928-0929, 0936-0936, 0938-0938, 0941-0941 were added to Group 1 of this service bulletin effectivity.
REASON FOR REVISION This revision is sent to give instructions to install new inboard and outboard midspar fittings to each nacelle strut and to add detailed inspections and High Frequency Eddy Current (HFEC) inspections of each nacelle strut midspar fitting. Instructions for detailed inspections and HFEC inspections of each nacelle strut torque bulkhead, midspar chord, drag fitting and front spar support are added.
These sections were changed:
1. Background: Is updated and a new planning table added.
2. Action and Description: Is updated to install new inboard and outboard midspar fittings to each nacelle strut and to add new detailed inspections and High Frequency Eddy Current (HFEC) inspections of the midspar fittings, torque bulkhead, midspar chords, drag fitting and front spar support with the engine and nacelle removed from the airplane.
3. Summary, Effectivity, statement is updated.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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4. Summary, Compliance: Added/Changed Federal Aviation Administration (FAA) Airworthiness Directive statements.
5. Summary, Industry Support Information: Section is added.
6. Summary, Manpower: Is updated to show a new reference.
7. Paragraph 1.E., Compliance: Added/Changed Federal Aviation Administration (FAA) Airworthiness Directive statements. Added compliance times and tables.
8. Paragraph 1.F., Approval: Is updated and new approval statements are added.
9. Paragraph 1.G., Manpower: New manpower times and tables are added.
10. Paragraph 1.J.1., Existing Data: Reference to Standard Overhaul Practices Manual (SOPM), Boeing Service Related Problem (SRP) and Non-Destructive Testing (NDT) and an Airworthiness Directive are added.
11. Paragraph 1.J.2., Data Supplied With This Service Bulletin: New drawings are added.
12. Paragraph 1.J.3., Installation Drawings Used in the Preparation of this Service Bulletin: New drawings are added.
13. Paragraph 1.K., Publications Affected: A new publication is added.
14. Paragraph 1.M., Software Accomplishment Summary: Section is added.
15. Paragraph 2.A., Material - Price and Availability: Is updated to show price and availability of new top kits.
16. Paragraph 2.C.1., Kits/Parts: Are updated to show two new top kits.
17. Paragraph 3.A., General Information: The notes section is updated.
18. Paragraph 3.B., Work Instructions: Are updated to include installation of new inboard and outboard midspar fittings to each nacelle strut and new detailed inspections and High Frequency Eddy Current (HFEC) inspections of the midspar fittings, torque bulkhead, midspar chords, drag fitting and front spar support with the engine and nacelle removed from the airplane.
19. FIGURE 1 and FIGURE 2: Are deleted.
20. FIGURE 3 and FIGURE 6: Are added to inspect the midspar fittings.
21. FIGURE 4 and FIGURE 7: Are added to inspect the torque bulkhead and midspar chords.
22. FIGURE 5 and FIGURE 8: Are added to inspect the drag fittings and front spar supports.
23. FIGURE 9 and FIGURE 10: Are added to inspect the midspar fittings.
24. FIGURE 11, FIGURE 12 and FIGURE 13: Are added to inspect the inboard and outboard overwing support fitting.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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25. Appendix A: The existing parts accountability data has been moved from the material information section to Appendix A.
26. Appendix B: Is added to show drag fitting chamfer/radius data for nacelle struts # 1 and # 4.
27. Appendix C: Is added to show bushing dimensions for drag fittings attachment holes.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY June 27, 1975Original Issue:
May 13, 1977Revision 1:
January 28, 1988Revision 2:
January 31, 1991Revision 3:
July 09, 1992Revision 4:
September 16, 1993Revision 5:
February 07, 2014Revision 6:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BLANK PAGE
Commercial Airplanes 707 Service Bulletin ALERT SummaryNumber: A3183Original Issue: June 27, 1975 Revision 6: February 07, 2014 ATA System: 5410 SUBJECT: NACELLE - Inboard and Outboard Nacelle Strut - Midspar Fitting - Inspection and Replacement
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions to inspect for any crack and to install a new number (#) 1, # 2, # 3 and # 4 engine nacelle strut inboard and outboard midspar fitting. If the work given in this service bulletin is not accomplished, a crack in the inboard and outboard midspar fitting may go undetected. An undetected crack could result in the loss of structural integrity of the midspar fitting which could cause an unsafe separation of the engine which may result in a wing fire and/or the loss of the airplane.
Operators have reported more than 45 cracked midspar fittings on more than 40 turbofan airplanes with approximately 9,900 to 63,000 flight hours. On five airplanes, fracture of the midspar fittings resulted in separation of the inboard strut and engine from the airplane in flight. In two of those instances, the inboard nacelle strut contacted the outboard engine, causing it to separate from the airplane. Operators have also reported cracking in the transition radius of the # 1 and # 4 engine nacelle strut inboard and outboard midspar fittings. There have been several documented cases of the outboard engine departing the airplane in flight. However, the midspar fittings cannot be clearly shown to be the major cause of the outboard engines departing the airplane.
The reported cracks on the # 1, # 2, # 3 and # 4 engine nacelle strut inboard and outboard midspar fittings were found to be vertical at the lug hole or across the double horizontal tangs at the radius where tangs merge with lug. Analysis indicates the 4330 steel midspar fittings cracked as a result of stress corrosion and/or fatigue at lug and fatigue at tangs.
A new life limiting program for the # 1, # 2, # 3 and # 4 engine nacelle strut inboard and outboard midspar fittings and a redesign of the # 1 and # 4 engine nacelle strut inboard and outboard midspar fittings will prevent an unsafe separation of an engine due to an undetected cracked condition in a midspar fitting.
Boeing Service Related Problem (SRP) 707-SRP-54-0105 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedYesSpares Affected Paragraph 1.E., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedYesAirplane 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 Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 18114-RS, PRR 17941) Midspar Fitting Life-Limit Program:
Remove each engine and nacelle strut from the airplane. Remove the inboard and outboard midspar fittings from each nacelle strut. Do a detailed inspection and a High Frequency Eddy Current (HFEC) inspection of each nacelle strut inboard and outboard midspar fitting for any crack. If any crack equal to or larger than 0.3 inch is found in the inboard or outboard midspar fitting, do detailed inspection and HFEC inspection of the overwing support fitting for any crack. If any crack is found in overwing support fitting contact Boeing for repair instructions and do the repair instructed by Boeing or install a new overwing support fitting in accordance with Boeing service bulletin 3173 (707-3173). Do an open hole HFEC inspection of the vacated holes on each torque bulkhead and each midspar chord for any crack. If any crack is found in a torque bulkhead or midspar chord rivet hole, oversize the hole or contact Boeing for repair instructions and do the repair instructed by Boeing. If any crack is found in a torque bulkhead or midspar chord bolt hole, contact Boeing for repair instructions and do the repair instructed by Boeing. Do an open hole HFEC inspection of each drag fitting attachment hole for any crack. If any crack is found in a drag fitting attachment hole, contact Boeing for repair instructions and do the repair instructed by Boeing. If no crack is found in a drag fitting attachment hole, install new operator supplied bushings. Do an open hole and a surface HFEC inspection of each front spar support for any crack. If any crack is found in the front spar support, install a new front spar support in accordance with Boeing service bulletin 3366 (707-3366). Install new inboard and outboard midspar fittings.
Midspar Fitting Life-Limit Program Mid Interval Inspection:
Remove each engine and nacelle strut from the airplane. Do a detailed inspection and a HFEC inspection of each nacelle strut inboard and outboard midspar fitting for any crack. If any crack is found in the inboard or outboard midspar fitting, remove the torque bulkhead and each inboard and outboard midspar fittings. Do an open hole HFEC inspection of the vacated holes on the torque bulkhead and midspar chord for any crack. If any crack is found in the torque bulkhead or midspar chord rivet hole, oversize the hole or contact Boeing for repair instructions and do the repair instructed by Boeing. If any crack is found in the torque bulkhead or midspar Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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chord bolt hole, contact Boeing for repair instructions and do the repair instructed by Boeing. If any crack equal to or larger than 0.3 inch is found in the inboard or outboard midspar fitting, do a detailed inspection and an open hole HFEC inspection of the overwing support fitting for any crack. If any crack is found in overwing support fitting contact Boeing for repair instructions and do the repair instructed by Boeing or install a new overwing support fitting in accordance with Boeing service bulletin 3173 (707-3173). Do an open hole HFEC inspection of each drag fitting attachment hole for any crack. If any crack is found in a drag fitting attachment hole, contact Boeing for repair instructions and do the repair instructed by Boeing. If no crack is found in a drag fitting attachment hole, install new operator supplied bushings. Do an open hole and a surface HFEC inspection of each front spar support for any crack. If any crack is found in the front spar support, install a new front spar support in accordance with Boeing service bulletin 3366 (707-3366). If any crack is found in the inboard or outboard midspar fitting, replace the midspar fitting.
EFFECTIVITY All 707-100 LONG BODY, -100B LONG BODY, -100B SHORT BODY, -200, -300, -300B, -300C, -400, and 720, 720B Airplane(s). Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 93-11-02 is related to this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-16-12 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
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: June 27, 1975 A3183Revision 6: February 07, 2014 11 of 106 BOEING SERVICE BULLETIN A3183
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BOEING SERVICE BULLETIN A3183
ALERT ALERT
NACELLE STRUT #4
NACELLE STRUT #3
NACELLE STRUT #2 NACELLE STRUT #1 MIDSPAR FITTING CRACKS UPPER
HORIZONTAL TANG
VERTICAL TANG
NACELLE STRUT FWD ' LOWER HORIZONTAL TANG (TYPICAL)
INSTALL NEW MIDSPAR FITTING IN ACCORDANCE WITH MIDSPAR FITTING LIFE-LIMIT PROGRAM.
DO INSPECTIONS OF THE MIDSPAR FITTINGS FOR
ANY CRACK IN ACCORDANCE WITH MIDSPAR FITTING LIFE-LIMIT PROGRAM MID INTERVAL INSPECTION.
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