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Commercial Airplanes 707 Service Bulletin ALERT Number: A3514 Original Issue: July 29, 2004 Revision 1: November 09, 2016 ATA System: 5410 SUBJECT: NACELLES - Nacelle Strut - Front Spar 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 © 2004 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Unpublished Work.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: July 29, 2004 A3514Revision 1: November 09, 2016 1 of 48
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 2 of 48 BOEING SERVICE BULLETIN A3514
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION13
A. Effectivity13
1. Airplanes13
2. Spares Affected17
B. Concurrent Requirements17
C. Reason17
D. Description18
E. Compliance20
F. Approval21
G. Manpower21
H. Weight and Balance Changes22
I. Electrical Load Data22
J. References22
1. Existing Data:22
2. Data Supplied with this Service Bulletin:23
3. Installation Drawings Used in the Preparation of this Service Bulletin:23
K. Publications Affected23
L. Interchangeability and Intermixability of Parts23
M. Software Accomplishment Summary23
2. MATERIAL INFORMATION25
A. Material - Price and Availability25
B. Industry Support Information25
C. Parts Necessary for Each Airplane25
1. Kits/Parts:25
2. Parts and Materials Supplied by the Operator:25
3. Parts Modified and Reidentified:25
4. Parts Removed and Not Replaced:26
D. Parts Necessary to Change Spares26
E. Special Tooling - Price and Availability26
F. Special Tooling Necessary to do this Service Bulletin26
3. ACCOMPLISHMENT INSTRUCTIONS27
A. GENERAL INFORMATION27
B. WORK INSTRUCTIONS28
FIGURE 1: NACELLE ACCESS - FRONT SPAR FITTING - ALL NACELLES [Group 1]32
FIGURE 2: NACELLE NUMBER 1 - FRONT SPAR FITTING - INSPECTION33
FIGURE 3: NACELLE NUMBER 2 - FRONT SPAR FITTING - INSPECTION34
FIGURE 4: NACELLE NUMBER 3 - FRONT SPAR FITTING - INSPECTION35
FIGURE 5: NACELLE NUMBER 4 - FRONT SPAR FITTING - INSPECTION36
FIGURE 6: NACELLE NUMBER 1 - FRONT SPAR FITTING AFT LUGS - SURFACE HIGH FREQUENCY
EDDY CURRENT INSPECTION37
FIGURE 7: NACELLE NUMBER 2 - FRONT SPAR FITTING AFT LUG - SURFACE HIGH FREQUENCY
EDDY CURRENT INSPECTION40
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 3 of 48 BOEING SERVICE BULLETIN A3514
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FIGURE 8: NACELLE NUMBER 3 - FRONT SPAR FITTING AFT LUG - SURFACE HIGH FREQUENCY
EDDY CURRENT INSPECTION43
FIGURE 9: NACELLE NUMBER 4 - FRONT SPAR FITTING AFT LUGS - SURFACE HIGH FREQUENCY
EDDY CURRENT INSPECTION46
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 4 of 48 BOEING SERVICE BULLETIN A3514
ALERTALERT
Commercial Airplanes 707 Service Bulletin ALERT Revision Transmittal SheetNumber: A3514Original Issue: July 29, 2004 Revision 1: November 09, 2016 ATA System: 5410 SUBJECT: NACELLES - Nacelle Strut - Front Spar Fitting - Inspection and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-08-15 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Effects of this Revision on airplanes on which Original Issue was previously done:
ActionConditionGroup Do a surface High Frequency Eddy Current (HFEC) inspection of the aft lug(s) on the front spar fittings at nacelle struts, numbers 1, 2, 3 and 4, for any crack. Continue to repeat the detailed inspection of the front spar fittings for cracks.
All AirplanesAll
REASON FOR REVISION This revision is sent to give instructions to do a surface High Frequency Eddy Current (HFEC) inspection of the aft lug(s) on the front spar fittings.
Terminology defined in Paragraph 3.A., General Information - Notes, only applies to the Accomplishment Instructions related to surface HFEC inspection of the aft lug(s) on the front spar fittings. Terminology in the Accomplishment Instructions related to detailed inspection of the front spar fittings has not been changed.
These sections were changed:
1. In Summary, Background, revised the paragraph, updated and added references to Service Related Problem (SRP) and Fleet Team Digest (FTD).
2. In Summary, Action, revised the paragraph, added instructions for surface HFEC inspection of the aft lug(s) on the front spar fittings.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 5 of 48
3. In Summary, Compliance, added FAA AD reference and effective date, added paragraph.
4. In Summary, Manpower, deleted the table, added reference to Paragraph 1.G., Manpower.
5. In Summary, Material Information, revised the paragraph.
6. In Summary, revised the summary illustration.
7. In Paragraph 1.A.1., Airplanes, updated the format of the effectivity, removed airplane variable numbers 00003, 00102, 00114, 00154-00156, 00450, 00451, 00602, 05828 and 05829, from this service bulletin effectivity.
8. In Paragraph 1.C., Reason, revised the paragraph, added references to SRP and FTD, added reason for revision.
9. In Paragraph 1.D., Description, revised the paragraph, added instructions for surface HFEC inspection of the aft lug(s) on the front spar fittings, added paragraph to give the effects of this revision on airplanes on which Original Issue was previously done, added tables for affected maintenance zones.
10. In Paragraph 1.E., Compliance, added FAA AD reference and effective date, added paragraphs, added Table 2.
11. In Paragraph 1.F., Approval, added Alternative Method of Compliance (AMOC) statement.
12. In Paragraph 1.G., Manpower, added table for surface HFEC inspection of the aft lug(s) on the front spar fittings.
13. In Paragraph 1.J.1., Existing Data, updated the list of references.
14. Added Paragraph 1.K.2., Damage Tolerance Based Structural Inspections.
15. Added Paragraph 1.M., Software Accomplishment Summary.
16. In Paragraph 2.A., Material - Price and Availability, revised the paragraph.
17. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added paragraph.
18. In Paragraph 3.A., General Information, revised the list of notes.
19. In Paragraph 3.B., Work Instructions, added instructions for surface HFEC inspection of the aft lug(s) on the front spar fittings.
20. In Figure 2 through Figure 5, revised the illustration to show lug hole.
21. Added Figure 6 through Figure 9 for surface HFEC inspection of the aft lug(s) on the front spar fittings.
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.
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Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 6 of 48 BOEING SERVICE BULLETIN A3514
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REVISION HISTORY July 29, 2004Original Issue:
November 09, 2016Revision 1:
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 8 of 48 BOEING SERVICE BULLETIN A3514
ALERTALERT
BLANK PAGE
Commercial Airplanes 707 Service Bulletin ALERT SummaryNumber: A3514Original Issue: July 29, 2004 Revision 1: November 09, 2016 ATA System: 5410 SUBJECT: NACELLES - Nacelle Strut - Front Spar Fitting - Inspection and Replacement
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 The inspections shown in this service bulletin will detect cracks in the upper surface and the aft lug(s) of the front spar fittings on the nacelle struts, numbers 1, 2, 3 and 4. Cracks in the front spar fitting are caused by fatigue failure originating from fastener holes.
One operator reported cracks in the front spar fitting on nacelle number 4. This airplane had accomplished Boeing Service Bulletins (SBs) 707-1541 and 707-2958 which provides an inspection and modification to the front spar fittings. Since the release of SBs 707-1541 and 707-2958 it is believed that the modification and equivalent production change may not be effective. Operators who have accomplished SBs 707-1541 and 707-2958 are required to do the inspections shown in this service bulletin.
Accomplishment of this service bulletin will detect cracks in the front spar fittings before they become critical.
Any cracked front spar fittings found during the inspections shown in this service bulletin will need to be replaced.
If the work given in this service bulletin is not done, cracks in the front spar fittings of the nacelle struts could remain undetected. If cracks grow beyond a critical length, the front spar fitting could fail, thus reducing the structural integrity of the nacelle. This in combination with damage to adjacent attachment structure, could result in a loss of an engine from the airplane.
This service bulletin is related to SBs 707A3183, 707A3364 and 707A3365, each with similar inspection intervals.
The inboard and outboard nacelle struts are also supported by the more critical midspar fittings which are inspected and replaced in accordance with SB 707A3183 Revision 6. SB 707A3183 Revision 6 addresses the fracture of the midspar fitting that resulted in the separation of the inboard strut and engine from the airplane.
SB 707A3183 Revision 6 gives instructions to do detailed inspections and High Frequency Eddy Current (HFEC) inspections of the midspar fittings. In addition to the midspar fittings, other nacelle fittings require more frequent inspections to ensure timely detection of cracking which could lead to separation of an engine. Revision 1 of this service bulletin aligns the HFEC inspection intervals of the front spar fittings with the midspar fittings. SB 707A3364 addresses the diagonal brace tube, end fittings, and mating fittings, and SB 707A3365 addresses the overwing fitting.
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Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 9 of 48
Boeing Service Related Problem (SRP) 707-SRP-54-0100, 707-SRP-54-0105 and 707-SRP-54-0155 are related to this service bulletin.
Boeing Fleet Team Digest (FTD) 707 FTD 54-05001 is related to this service bulletin.
ACTION Detailed Inspection of the Front Spar Fittings at Nacelle Struts, Numbers 1, 2, 3 and 4:
1. Deactivate the leading edge flaps and thrust reversers.
2. Remove and keep access panels or inspection hole caps on each nacelle strut.
3. Do a detailed inspection of the front spar fitting for cracks. If cracks are found, replace the front spar fitting.
4. Replace the removed access panels or inspection hole caps as applicable.
5. Reactivate the thrust reversers and leading edge flaps.
6. Repeat the detailed inspection at the intervals specified in Paragraph 1.E., Compliance.
Surface High Frequency Eddy Current (HFEC) Inspection of the Aft Lug(s) on the Front Spar Fittings at Nacelle Struts, Numbers 1, 2, 3 and 4:
1. Deactivate the leading edge flaps and thrust reversers.
2. Remove and keep access panels on each nacelle strut.
3. Remove and keep the bolt from the aft lug(s) on each front spar fitting. Disengage wing-to-spar fitting from front spar fitting.
4. Do a surface HFEC inspection of the front spar fitting aft lug(s) for any crack. If any crack is found, replace the front spar fitting.
5. Engage wing-to-spar fitting to front spar fitting. Install the kept bolt in the aft lug(s) on each front spar fitting.
6. Replace the removed access panels.
7. Reactivate the thrust reversers and leading edge flaps.
8. Repeat the surface HFEC inspection at the intervals specified in Paragraph 1.E., Compliance.
EFFECTIVITY All 707 and 720 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-08-15 is related to this service bulletin.
The effective date of AD 2005-08-15 is May 31, 2005.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 10 of 48 BOEING SERVICE BULLETIN A3514
ALERTALERT
The Federal Aviation Administration (FAA) will possibly release an additional 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 configuration changes, inspection and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION 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: July 29, 2004 A3514Revision 1: November 09, 2016 11 of 48 BOEING SERVICE BULLETIN A3514
ALERTALERT
BOEING SERVICE BULLETIN A3514
ALERT ALERT NACELLE STRUT NUMBER 2 SHOWN, NACELLE STRUTS NUMBER 1, 3 AND 4 SIMILAR.
DO A SURFACE HFEC
INSPECTION OF THE AFT LUG(S) FOR ANY CRACK.
TYPICAL CRACK
STRUT CAP SKIN
STRUT CAP SKIN NOT DO A DETAILED INSPECTION
SHOWN FOR CLARITY OF THE FRONT SPAR UP FITTING FOR CRACKS.
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