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Commercial Airplanes 707 Service Bulletin ALERT Number: A3365 Original Issue: August 17, 1979 Revision 3: March 09, 2017 ATA System: 5700 5401 SUBJECT: WINGS - INBOARD AND OUTBOARD NACELLE STRUT OVERWING SUPPORT
FITTING INSPECTION AND REPAIR AT WING FRONT SPAR
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 all 707 and 720 Airplanes, in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given 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, 707-100B Long Body, 707-100B Short Body, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720 and 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- B0029 1B0101 - B0125 1B0201 - B0203 1B0301 - B0306 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: August 17, 1979 A3365Revision 3: March 09, 2017 13 of 37
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- 04005 104020 - 04022 104101 - 04106 104201 - 04218 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: August 17, 1979 A3365Revision 3: March 09, 2017 14 of 37 BOEING SERVICE BULLETIN A3365
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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: August 17, 1979 A3365Revision 3: March 09, 2017 15 of 37 BOEING SERVICE BULLETIN A3365
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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: August 17, 1979 A3365Revision 3: March 09, 2017 16 of 37 BOEING SERVICE BULLETIN A3365
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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 None.
B. Concurrent Requirements None.
C. Reason Periodic inspection at the five holes in the inboard and outboard nacelle strut overwing support fitting at the wing front spar may detect any crack. Any crack found requires contacting The Boeing Company for repair instructions and doing the repair, or fitting replacement.
Seven operators have reported fitting cracks on eight airplanes that had accumulated 26,500 to 55,300 flight-hours (9,600 to 27,200 flight cycles). Seven of the fittings were at the inboard strut and one at the outboard strut. Four of the cracks initiated in the holes for the fasteners through the fitting and the wing front spar upper chord horizontal flange. Four initiated in the hole for bolt through the fitting and a bracket on the forward face of the chord vertical flange. One of the four fittings was completely severed, two cracked halfway through and the crack in the fourth fitting was removed by oversizing the hole.
Continued operation with a cracked overwing support fitting could eventually affect the structural integrity of the remaining nacelle strut attachments to the wing.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 17 of 37 BOEING SERVICE BULLETIN A3365
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The inboard and outboard nacelle struts are also supported by the more critical midspar fittings which are inspected and replaced if required in service bulletin 707A3183 Revision 6. Service bulletin 707A3183 Revision 6 has been created to address the fracture of the midspar fitting that resulted in the separation of the inboard strut and engine from the airplane. Service bulletin 707A3183 Revision 6 has new detailed inspections and High Frequency Eddy Current (HFEC) inspections with a mid-interval compliance time of 1500 flight cycles or 48 months, whichever comes first. Existing service and regulatory actions for other nacelle strut fittings, including the overwing support fitting, are not sufficient to make sure of in-time detection of any crack which could lead to separation of an engine. As a result, service bulletin 707A3365 Revision 3 has been created to increase the frequency of the detailed, HFEC and ultrasonic inspections of the overwing support fitting, in alignment with inspections for the midspar fittings.
Boeing Service Related Problem (SRP) 707-54-0155 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 707 FTD 54-05001 is related to this service bulletin.
Revision 1 of this bulletin was issued to advise repeat inspections of the overwing fittings in addition to the one-time inspection advised in the original issue of the bulletin.
Revision 2 of this bulletin was sent to add optional low interference cold working of the overwing support fitting holes. Master service bulletins 707-3478, 707-3479 and 707-3480 define these revisions to service bulletin 707-3365 Revision 1.
Revision 3 of this bulletin is sent to change the inspection interval for detailed inspections, High Frequency Eddy Current (HFEC) inspections and ultrasonic inspection and to add alternative HFEC inspections around the aft bolts. The option to repair parts by oversizing the holes has been removed.
The data given in Notice of Status Change (NSC) 707-3365 NSC 1 is included in this revision.
D. Description On nacelle strut overwing support fittings, do repeat inspections for any crack at the five affected fastener holes at the wing front spar upper chord.
Detailed Inspection must be made at all five holes. The hole immediately forward of the spar chord must be inspected with a surface High Frequency Eddy Current (HFEC) inspection with the bolt in place, or with an open hole HFEC inspection with the bolt removed. If the hole is bushed as a result of crack removal oversizing, remove bushing, do a detailed inspection, and either inspect hole with an open hole HFEC inspection or accomplish the surface HFEC inspection. If any crack is found, do an open hole HFEC inspection at the other four hole locations for any crack in the overwing support fitting, wing skin, chord and support bracket fastener holes.
At the holes for the four fasteners attaching the overwing support fitting to the spar upper chord, the fitting must be inspected either ultrasonically or with a surface HFEC inspection in addition to the detailed inspection. If any crack is found ultrasonically or with a surface HFEC inspection, remove the fastener and do an open hole HFEC inspection.
If any crack is found in any part, repair the cracked part by contacting The Boeing Company for repair instructions, and do the repair, or replace the cracked part.
Effects of this Revision on airplanes on which Original Issue, Revision 1 or Revision 2 was previously done:
None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 18 of 37 BOEING SERVICE BULLETIN A3365
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NOTE:
An inboard or outboard nacelle strut overwing support fitting may have been replaced per Service Bulletin 707-1798 or 707-2090. An inboard fitting may have been replaced per service bulletin 707-3173.
1.
2. Service Bulletin 707A3183 advises inspection at the inboard overwing fitting-to-wing front spar upper chord horizontal flange fasteners if any crack is found in the nacelle strut mid spar fittings. The inspections in this Service Bulletin 707A3365 Revision 3 do not supersede the inspections in service bulletin 707A3183.
3. Concurrent incorporation of Service Bulletins 707-3173, 707A3183, 707A3514 and 707A3364 is suggested on commonly affected airplanes, if not already incorporated, in the interest of man-hour and airplane down-time savings.
4. Please notify Boeing of inspection results and your planned action.
The work in this service bulletin is done in the maintenance zone(s) given below.
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 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.
Accomplish the required actions, based on the applicable conditions in Table 1, in accordance with Paragraph 3. Accomplishment Instructions.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 19 of 37 BOEING SERVICE BULLETIN A3365
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Table 1: Inspections of the Overwing Support Fitting for Any Crack at Nacelle Struts, Numbers 1, 2, 3 and 4 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Within 48 months after the Revision 3 date of this service bulletin.
Within 1500 flight cycles after the Revision 3 date of this service bulletin.
Action 1: Do a detailed inspection for any crack at all five holes in the overwing support fitting, and at the flange radii.
All Airplanes -Within 48 months after the Revision 3 date of this service bulletin.
Within 1500 flight cycles after the Revision 3 date of this service bulletin.
Action 2, (Option 1): Do a High Frequency Eddy Current (HFEC) surface inspection for any crack in the overwing support fitting around the hole immediately forward of the spar chord, with the bolt in place, and at the flange radii.
Action 2, (Option 2): Do an HFEC open hole inspection for any crack in the overwing support fitting at the hole immediately forward of the spar chord.
-Within 48 months after the Revision 3 date of this service bulletin.
Within 1500 flight cycles after the Revision 3 date of this service bulletin.
Action 3, (Option 1): Do an ultrasonic inspection for any crack in the overwing support fitting around the four holes common to the fitting and the spar chord, with the bolts in place.
Action 3, (Option 2): Do an HFEC surface inspection for any crack in the overwing support fitting around the four holes common to the fitting and the spar chord, with the bolts in place.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 20 of 37 BOEING SERVICE BULLETIN A3365
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Table 1: Inspections of the Overwing Support Fitting for Any Crack at Nacelle Struts, Numbers 1, 2, 3 and 4 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 250 flight cycles.
--Condition 1, Action 1: Repeat detailed inspection for any crack at all five holes in the overwing support fitting, and at the flange radii.
Condition 1: No crack is found in the overwing support fitting.
1500 flight cycles or 48 months, whichever occurs first.
--Condition 1, Action 2, (Option 1):
Repeat HFEC surface inspection for any crack in the overwing support fitting around the hole immediately forward of the spar chord, with the bolt in place, and at the flange radii.
Condition 1, Action 2, (Option 2):
Repeat HFEC open hole inspection for any crack in the overwing support fitting at the hole immediately forward of the spar chord.
1500 flight cycles or 48 months, whichever occurs first.
--Condition 1, Action 3, (Option 1):
Repeat ultrasonic inspection for any crack in the overwing support fitting around the four holes common to the fitting and the spar chord, with the bolts in place.
Condition 1, Action 3, (Option 2):
Repeat HFEC surface inspection for any crack in the overwing support fitting around the four holes common to the fitting and the spar chord, with the bolts in place.
--Before further flight.
Remove the fastener at the hole nearest to the crack, and do an open hole HFEC inspection.
Condition 2: Any crack is found in the overwing support fitting during the detailed, ultrasonic or surface HFEC inspection.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 21 of 37 BOEING SERVICE BULLETIN A3365
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Table 1: Inspections of the Overwing Support Fitting for Any Crack at Nacelle Struts, Numbers 1, 2, 3 and 4 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition --Before further flight.
Go to Condition 4 and do the actions.
Condition 2.1: No other crack is found after doing the open hole HFEC inspection at the hole nearest to the crack.
--Before further flight.
Remove the remaining overwing support fitting fasteners, and the support bracket fasteners and do an open hole HFEC inspection for any crack in the overwing support fitting, wing skin, chord and support bracket.
Condition 3: Any crack is found during open hole HFEC inspection in any of the five holes in the overwing support fitting.
--Before further flight.
Go to Condition 4 and do the actions.
Condition 3.1: No other crack is found after doing the open hole HFEC inspection at the remaining holes in the overwing support fitting, wing skin, chord and support bracket.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 22 of 37 BOEING SERVICE BULLETIN A3365
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Table 1: Inspections of the Overwing Support Fitting for Any Crack at Nacelle Struts, Numbers 1, 2, 3 and 4 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition --Before further flight.
Condition 4, Action 1, (Option 1):
Contact The Boeing Company for repair instructions and do the repair.
Condition 4: Any crack is found in the overwing support fitting, wing skin, chord or support bracket. Condition 4, Action 1, (Option 2):
Replace the cracked part.
250 flight cycles.
--Condition 4, Action 2: Repeat detailed inspection for any crack at all five holes in the overwing support fitting, and at the flange radii.
1500 flight cycles or 48 months, whichever occurs first.
--Condition 4, Action 3, (Option 1):
Repeat HFEC surface inspection for any crack in the overwing support fitting around the hole immediately forward of the spar chord, with the bolt in place, and at the flange radii.
Condition 4, Action 3, (Option 2):
Repeat HFEC open hole inspection for any crack in the overwing support fitting at the hole immediately forward of the spar chord.
1500 flight cycles or 48 months, whichever occurs first.
--Condition 4, Action 4, (Option 1):
Repeat ultrasonic inspection for any crack in the overwing support fitting around the four holes common to the fitting and the spar chord, with the bolts in place.
Condition 4, Action 4, (Option 2):
Repeat HFEC surface inspection for any crack in the overwing support fitting around the four holes common to the fitting and the spar chord, with the bolts in place.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 23 of 37 BOEING SERVICE BULLETIN A3365
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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 tables below shows an estimate of the task hours necessary to do this inspection and repair for each airplane. 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 - Inspection Elapsed HoursTask HoursNumber of PersonsTask 284Open Access
(a)(a)(a)FIGURE 1 3124Close Access
(a)(a)TOTAL FOR EACH AIRPLANE
(a) Total time required may vary depending upon conditions found during inspections.
Table 2 - Fitting Repair (At One Location) Elapsed HoursTask HoursNumber of PersonsTask 6366Open Access
(a)(a)(a)FIGURE 2 6366Close Access 881Fuel Leak Check
(a)(a)TOTAL FOR EACH LOCATION Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 17, 1979 A3365Revision 3: March 09, 2017 24 of 37 BOEING SERVICE BULLETIN A3365