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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
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 2 Groups. 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 707-100 Long Body, -100B Long Body, -100B Short Body, -200, -300, -300B, -300C, -400, 720, and 720B airplanes, line numbers 1 through
917.
-1 707-300C airplanes, line numbers 918 through 1012.-2 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Number 1B0001 - B0029 1B0101 - B0125 1B0201 - B0203 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 13 of 48
GroupVariable Number 1B0301 - B0306 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- 02418 104001 - 04005 104020 - 04022 104101 - 04106 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 14 of 48 BOEING SERVICE BULLETIN A3514
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GroupVariable Number 104201 - 04218 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 15 of 48 BOEING SERVICE BULLETIN A3514
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GroupVariable Number 107451 - 07458 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 16 of 48 BOEING SERVICE BULLETIN A3514
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GroupVariable Number 109001 - 09006 109101 - 09107 109161 - 09165 209166 - 09167 109201 - 09203 209204 109221 - 09223 109227 109231 - 09232 109251 209271 109281 109286 - 09287 209288 - 09290 109411 209421 209438 209441
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 17 of 48 BOEING SERVICE BULLETIN A3514
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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.
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.
Revision 1 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.
D. Description 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 18 of 48 BOEING SERVICE BULLETIN A3514
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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.
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 The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
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 Group 2:
Affected Maintenance Zones ZoneModel 4-55, 4-56, 4-57, 4-58707-300C Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 19 of 48 BOEING SERVICE BULLETIN A3514
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E. 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.
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.
Accomplish the required actions, based on the applicable conditions in Table 1 and Table 2, 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.
Table 1: Detailed Inspection of the Front Spar Fittings for cracks at Nacelle Struts, Numbers 1, 2, 3 and 4 Repeat Interval Not to Exceed (Flight Hours) Initial Threshold (Whichever occurs later) Action Time Elapsed Since the Original Issue Date of this Service Bulletin Total Airplane Flight Hours Since the Original Airworthiness Certificate was Granted 700 (b)18 Months3500Detailed Inspection. Refer to Paragraph 3.B.
(a)
(a) Replace any cracked fitting prior to further flight.
(b) There is no terminating action at this time.
Table 2: Surface High Frequency Eddy Current (HFEC) Inspection of the Aft Lug(s) on the Front Spar Fittings for any crack at Nacelle Struts, Numbers 1, 2, 3 and 4 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Within 1,500 flight cycles or 48 months after the most recent Detailed Inspection specified in Table 1, whichever occurs first.
Do PART 2: SURFACE
HFEC INSPECTION OF
THE AFT LUG(S) ON THE
FRONT SPAR FITTINGS
AT NACELLE STRUTS NUMBERS 1, 2, 3 AND 4 for any crack.
All Airplanes Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 20 of 48 BOEING SERVICE BULLETIN A3514
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Table 2: Surface High Frequency Eddy Current (HFEC) Inspection of the Aft Lug(s) on the Front Spar Fittings for any crack at Nacelle Struts, Numbers 1, 2, 3 and 4 Repeat Interval (Not to Exceed) Compliance TimeActionCondition -Before further flight.CONDITION 1 (ACTION
1): Do PART 3: FRONT
SPAR FITTING REPLACE- MENT.
CONDITION 1: ANY
CRACK FOUND 1,500 flight cycles or 48 months, whichever occurs first.
-CONDITION 1 (ACTION
2): Repeat PART 2: SUR-
FACE HFEC INSPECTION
OF THE AFT LUG(S) ON
THE FRONT SPAR FIT-
TINGS AT NACELLE STRUTS NUMBERS 1, 2, 3 AND 4 for any crack.
1,500 flight cycles or 48 months, whichever occurs first.
-Repeat PART 2: SUR-
FACE HFEC INSPECTION
OF THE AFT LUG(S) ON
THE FRONT SPAR FIT-
TINGS AT NACELLE STRUTS NUMBERS 1, 2, 3 AND 4 for any crack.
CONDITION 2: NO
CRACK FOUND F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and are FAA approved. This service bulletin and the FAA approval were based on the airplane in its original Boeing delivery configuration or as modified by other FAA 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.
In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.
inspection or replacement) defined in this service bulletin as an alternative method of compliance to the requirements of paragraphs (f) and (g) ofAD 2005-08-15. All provisions of AD 2005-08-15 that are not specifically referenced in the above statement remain fully applicable and must be complied with.
G. Manpower The tables below show an estimate of the task-hours necessary to do this service bulletin 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 21 of 48 BOEING SERVICE BULLETIN A3514
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— Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools.
Detailed Inspection of the Front Spar Fittings at Nacelle Struts, Numbers 1, 2, 3 and 4 Elapsed HoursTask-HoursNumber of Persons Task
1.02.02Open Access
1.02.02FIGURE 2
1.02.02FIGURE 3
1.02.02FIGURE 4
1.02.02FIGURE 5
1.02.02Close Access
6.012.0TOTAL FOR EACH AIRPLANE 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 Elapsed HoursTask-HoursNumber of Persons Task
6.6013.202Open Access
1.201.201FIGURE 6
1.201.201FIGURE 7
1.201.201FIGURE 8
1.201.201FIGURE 9
6.6013.202Close Access
18.0031.20TOTAL FOR EACH AIRPLANE H. Weight and Balance Changes None.
I. Electrical Load Data Not changed.
J. References
1. Existing Data:
a. Boeing Service Bulletin 707-1541, 707-2958, 707A3183, 707A3364, 707A3365 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2004 A3514Revision 1: November 09, 2016 22 of 48 BOEING SERVICE BULLETIN A3514
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b. Boeing Service Related Problem (SRP) 707-SRP-54-0100, 707-SRP-54-0105, 707-SRP-54-0155
c. 707 Maintenance Manual (AMM) Subject 12-2-0, 27-16-202/201, 54-00 Revision Notice (RN) 54-18, 78-5-0/201
d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2005-08-15
e. Service Bulletin Index D6-1647
f. 707, 720 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00
g. 707 Fleet Team Digest (FTD) 54-05001
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number Life Extension Modification 707/720 Front Spar Chords and Fittings, Inboard and Outboard Struts.
65-80210 Fitting - Front Spar Outboard Nacelle strut, Assy Of.65-13347 Fitting - Front Spar Inboard Nacelle strut, Assy Of.65-42128 Inspection Hole Installation - Nacelle Strut65-58472 These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators.
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: July 29, 2004 A3514Revision 1: November 09, 2016 23 of 48 BOEING SERVICE BULLETIN A3514
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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 24 of 48 BOEING SERVICE BULLETIN A3514