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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
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplane(s) shown below.
Refer to Service Bulletin Index D6-1647 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP All 707-100 LONG BODY, -100B LONG BODY, -100B SHORT BODY, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B Airplanes -1 Airplane Models:
707-100 LONG BODY, 707-100B LONG BODY, 707-100B SHORT BODY, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B GroupVariable Number 1B0001 - B0029 1B0101 - B0125 1B0201 - B0203 1B0301 - B0306 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 13 of 106
GroupVariable Number 1B0401 - B0402 1B0501 - B0515 1B2001 - B2008 1B2091 - B2092 1B2101 - B2116 1B2191 - B2194 1B2199 1B2201 - B2227 1B2401 - B2403 1B2501 - B2502 1B2551 - B2553 1B2601 - B2608 100001 - 00002 100004 - 00006 100101 100103 - 00113 100115 - 00153 100201 - 00205 100301 - 00305 100401 - 00449 100471 - 00475 100501 - 00513 100601 100701 - 00703 102001 - 02020 102101 - 02121 102201 - 02207 102301 - 02303 102401 - 02418 104001 - 04005 104020 - 04022 104101 - 04106 104201 - 04218 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 14 of 106 BOEING SERVICE BULLETIN A3183
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GroupVariable Number 104271 - 04272 104301 - 04303 105001 - 05060 105101 - 05138 105201 - 05208 105301 - 05312 105401 105601 - 05605 105631 - 05635 105701 - 05703 105801 - 05802 105821 - 05827 105831 - 05833 105851 - 05854 105891 - 05892 105921 - 05923 105941 - 05942 105961 - 05970 106001 - 06002 106101 106401 - 06404 106451 106461 107001 - 07017 107041 - 07059 107071 - 07081 107101 - 07109 107181 107191 107201 - 07215 107251 - 07271 107401 - 07407 107451 - 07458 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 15 of 106 BOEING SERVICE BULLETIN A3183
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GroupVariable Number 107501 - 07504 107601 - 07626 107661 - 07662 107681 - 07684 107701 - 07702 107801 - 07821 107901 - 07907 108001 - 08008 108021 108051 - 08056 108071 - 08077 108101 - 08104 108121 - 08129 108141 - 08144 108151 - 08153 108171 - 08173 108191 - 08192 108201 - 08210 108221 - 08224 108241 - 08244 108251 108261 108271 108301 - 08320 108324 - 08330 108333 108401 - 08410 108451 - 08452 108471 - 08475 108501 - 08502 108551 - 08553 108581 - 08582 109001 - 09006 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 16 of 106 BOEING SERVICE BULLETIN A3183
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GroupVariable Number 109101 - 09107 109161 - 09167 109201 - 09204 109221 - 09223 109227 109231 - 09232 109251 109271 109281 109286 - 09290 109411 109421 109438 109441
2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use.
B. Concurrent Requirements None.
C. Reason 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 17 of 106 BOEING SERVICE BULLETIN A3183
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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.
Revision 1 was issued to provide improved access for inspection at the root of the upper tang of the fitting where primary cracking occurs.
Revision 2 was issued to modify inspection requirements so that repeat inspections on affected airplanes were accomplished at 1500 flight hours, 600 flight cycles, or 750 flight cycles, depending on model, whichever comes first. The 1.30 inch material removal dimension in Detail I and II of Figure 1 was changed to 1.50 inch to allow improved space for cleaning. Also, Notice of Status Change, dated November 30, 1979, was incorporated that added Boeing service Bulletin 3377, "Engine Nacelle Droop Strip Installation" to prior or concurrent incorporation recommendation.
Revision 3 was issued to tell operators of the 707/720 Structures Working Group recommendations.
Revision 4 was issued as a partial revision by telegraph to tell operators that the Accomplishment Instructions and Circle Notes 5, 8, and 9 in Figure 1, Inspection, were revised. It included the removal of the sailboat fairing, more cleaning, and new improved Borescope inspection instructions.
Revision 5 is issued as a follow-up of partial release telegraphic Revision 4.
New information about availability of replacement fittings is given. Figure 1 and 2 titles are changed to more accurately describe their contents. The illustrations in the Summary Page and in Figures 1 and 2 are revised to show locators. A new View A-A in Figure 1 is added to show a new lug area for inspection. Man hour requirements for Borescope inspection are included. Reference to new Airworthiness Directive (AD) 93-11-02, Amendment 39-8594, dated June 4, 1993, is included. Operators are referred to this AD for compliance thresholds for this bulletin. Therefore, the flight hour and flight cycle data for inspection thresholds in Notice of Status Change SB 3183 NSC 2 is not included in this revision.
Revision 6 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.
Boeing Service Related Problem (SRP) 707-SRP-54-0105 is related to this service bulletin.
D. Description 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 18 of 106 BOEING SERVICE BULLETIN A3183
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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 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.
NOTE: Prior or concurrent incorporation of Boeing service bulletin 3377 (707-3377), "Engine Nacelle Droop Strip Installation", is recommended.
Revision 6 - 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.
The work in this service bulletin is done in the maintenance zone(s) given below.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 19 of 106 BOEING SERVICE BULLETIN A3183
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Affected Maintenance Zones ZoneModel 4-55, 4-56, 4-57, 4-58707-100 LONG BODY, 707- 100B LONG BODY, 707-100B SHORT BODY, 707-200, 707- 300, 707-300B, 707-300C, 707- 400, 720, 720B E. 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.
NOTE: Table 1 is not intended to be mandated by the FAA. The actions in Table 1 do not satisfy the requirements of Table 2, 3, 4 and 5.
Table 1: Engine Number (#) 1, 2, 3 and 4 Nacelle Strut Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition Before every flight.Before every flight.Action 1.1: Do a side force inspection of the engine # 1, # 2, # 3 and # 4 to inspect for any unusual structural noises in accordance with Paragraph 3.B., Work Instructions Part 1.a.
All airplanes.
(a) Action 1.2: Do a general visual inspection of engine # 1, # 2, # 3 and # 4 nacelle strut for signs of droop or flexure damage in accordance with Paragraph 3.B., Work Instructions Part 1.b.
(a) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table 1: Engine Number (#) 1, 2, 3 and 4 Nacelle Strut Inspection Repeat Interval (Not to Exceed) Compliance TimeActionCondition Before further flight.
Before further flight.
Do the Life-Limit Program-Mid Interval Inspections in accordance with Paragraph 3.B., Work Instructions Part 4 or Part
5.
If any signs of droop or flexure damage or any unusual structural noises or broken midspar fitting are found during the inspections accomplished in accordance with Action 1.1 or Action 1.2.
(a) It is Boeing's intention, that this action does not have to be accomplished by a qualified mechanic.
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Table 2: Nacelle Strut # 2 and # 3 Midspar Fitting Life-Limit Program Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 3,000 flight cycles or 96 months, whichever occurs first. (a) Within 18 months after the Revision 6 date of this service bulletin.
Within 600 flight cycles after the Revision 6 date of this service bulletin.
Remove the inboard and outboard midspar fittings in accordance with Paragraph 3.B., Work Instructions, Part 2.d.
All airplanes.
Action 2.1: Do a detailed inspection and a surface High Frequency Eddy Current (HFEC) inspection of the inboard and outboard midspar fittings for any crack in accordance with Paragraph
3.B., Work Instructions, Part 2.e.
Action 2.2: Do an open hole HFEC inspections of the torque bulkhead, midspar chord, drag fitting and front spar support for any crack in accordance with Paragraph 3.B., Work Instructions, Part 2.f., Part 2.g. & Part
2.i.
Action 2.3: Do a surface HFEC inspection of the front spar support for any crack in accordance with Paragraph 3.B., Work Instructions, Part 2.j.
-Before further flight.Action 2.4: Do an open hole HFEC inspection for any crack in the two forward most fastener holes common to the inboard side of the nacelle strut overwing support fitting and the wing front spar upper chord in accordance with Paragraph 3.B., Work Instructions, Part 6.
Any crack equal to or larger than 0.3 inch found during the inspections accomplished in accordance with Action 2.1.
-Before further flight.Install oversize fasteners in accordance with Paragraph 3.B., Work Instructions, Part 6.a.(1).
No crack is found during the inspections accomplished in accordance with Action 2.4.
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Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 22 of 106 BOEING SERVICE BULLETIN A3183
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Table 2: Nacelle Strut # 2 and # 3 Midspar Fitting Life-Limit Program Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Before further flight.Action 2.5: Do an open hole HFEC inspection of the two forward most fastener holes common to the outboard side of the nacelle strut overwing support fitting and the wing front spar upper chord for any crack in accordance with Paragraph 3.B., Work Instructions, Part 6.a.(2).
Any crack found during the inspections accomplished in accordance with Action 2.4.
-Before further flight.Install oversize fasteners in accordance with Paragraph 3.B., Work Instructions, Part
6.a.(2)(a).
No crack is found during the inspections accomplished in accordance with Action 2.5.
-Before further flight.Contact Boeing for repair instructions and do the repair instructed by Boeing in accordance with Paragraph 3.B., Work Instructions, Part 6.a.(3).
Any crack found during the inspections accomplished in accordance with Action 2.4 or Action 2.5.
Or Install a new nacelle strut overwing support fitting in accordance with Paragraph 3.B., Work Instructions, Part 6.a.(3) and Boeing service bulletin 3173 (707-3173).
-Before further flight.Action 2.6: Oversize holes and do an open hole HFEC inspection in accordance with Paragraph 3.B., Work Instructions, Part 2.f.(1).
Any crack is found in a vacated torque bulkhead and midspar chord rivet hole during the inspections accomplished in accordance with Action 2.2.
-Before further flight.Oversize the crack free rivet holes and install new midspar fittings in accordance with Paragraph 3.B., Work Instructions, Part 2.f.(1)(a).
If the crack is removed by oversizing procedure accomplished in accordance with Action 2.6.
-Before further flight.Contact Boeing for repair instructions and new inboard and outboard midspar fitting installation instructions and do the work instructed by Boeing in accordance with Paragraph 3.B., Work Instructions, Part
2.f.(1)(b).
If the crack is not removed during the oversizing procedure accomplished in accordance with Action 2.6.
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Table 2: Nacelle Strut # 2 and # 3 Midspar Fitting Life-Limit Program Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Before further flight.Contact Boeing for repair instructions and new inboard and outboard midspar fitting installation instructions and do the work instructed by Boeing in accordance with Paragraph 3.B., Work Instructions, Part 2.f.(2).
Any crack is found in a vacated torque bulkhead and midspar chord bolt hole during the inspections accomplished in accordance with Action 2.2.
-Before further flight.Install new inboard and outboard midspar fittings and the existing torque bulkhead in accordance with Paragraph 3.B., Work Instructions, Part 2.f.(3).
No crack is found in the midspar chords or the torque bulkhead during the inspections accomplished in accordance with Action 2.2.
-Before further flight.Contact Boeing for repair instructions and do the repair instructed by Boeing in accordance with Paragraph 3.B., Work Instructions, Part 2.g.(1).
Any crack found in a drag fitting attachment hole during the inspections accomplished in accordance with Action 2.2.
-Before further flight.Install new bushings in accordance with Paragraph 3.B., Work Instructions, Part 2.g.(2).
No crack found in the drag fitting attachment holes during the inspections accomplished in accordance with Action 2.2.
-Before further flight.Install a new front spar support in accordance with Paragraph
3.B., Work Instructions, Part
2.i.(1); Part 2.j.(1) and Boeing service bulletin 3366 (707- 3366).
Any crack found in the front spar support during the inspections accomplished in accordance with Action 2.2 or Action
2.3.
(a) There is no terminating action for the repeat inspections.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 27, 1975 A3183Revision 6: February 07, 2014 24 of 106 BOEING SERVICE BULLETIN A3183