2000-05-30 BOEING: Amendment 39-11640. Docket 99-NM-22-AD.\n\n\tApplicability: Model 747-100, -100B, -100B SUD, -200B, -200C, -200F, -300, SR, and SP series airplanes; certificated in any category; equipped with Pratt & Whitney Model JT9D-3 or -7 series engines, General Electric Model CF6-45 or -50 series engines, or Rolls-Royce Model RB211-524B, C, or D series engines. \n \n\tNOTE 1: This AD applies to each airplane identified in the preceding applicability provision, regardless of whether it has been modified, altered, or repaired in the area subject to the requirements of this AD. For airplanes that have been modified, altered, or repaired so that the performance of the requirements of this AD is affected, the owner/operator must request approval for an alternative method of compliance in accordance with paragraph (h) of this AD. The request should include an assessment of the effect of the modification, alteration, or repair on the unsafe condition addressed by this AD; and,if the unsafe condition has not been eliminated, the request should include specific proposed actions to address it. \n\n\tCompliance: Required as indicated, unless accomplished previously. \n\n\tTo prevent engine thrust control cable failures, which could result in a severe asymmetric thrust condition during landing, and consequent reduced controllability of the airplane, accomplish the following: \n\n\tNOTE 2: For the purposes of this AD, a detailed visual inspection is defined as: "An intensive visual examination of a specific structural area, system, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at intensity deemed appropriate by the inspector. Inspection aids such as mirror, magnifying lenses, etc., may be used. Surface cleaning and elaborate access procedures may be required."\n\nRepetitive Inspections\n\n\t(a)\tFor all airplanes: Within 18 months after the effective dateof this AD, accomplish the "Thrust Control Cable Inspection Procedure" specified in Appendix 1. (including Figure 1) of this AD to verify the integrity of the engine thrust control cables. Prior to further flight, replace any discrepant component found, in accordance with the procedures described in the Boeing 747 Maintenance Manual. Repeat the detailed visual inspection thereafter at intervals not to exceed 18 months.\n\nModification\n\n\t(b)\tFor airplanes identified in Boeing Service Bulletin 747-76-2019, dated June 9, 1971: Within 18 months after the effective date of this AD, modify the strut bulkhead assembly to enlarge the holes (2 places in each strut) through which the engine thrust control cables pass, in accordance with the service bulletin.\n\nInspection/Replacement\n\n\t(c)\tFor airplanes equipped with General Electric Model CF6 series engines and identified in Boeing Service Bulletin 747-76-2067, Revision 1, dated November 19, 1987: Within 18 months after the effective date of this AD, perform a one-time inspection of each nacelle strut idler pulley to determine the type of pulley installed, in accordance with the service bulletin.\n\n\tNOTE 3: This paragraph does not apply to airplanes equipped with Pratt & Whitney Model JT9D-70 engines.\n\n\t\t(1)\tIf no aluminum-type pulley is installed, no further action is required by this \t\t\tparagraph.\n\n\t\t(2)\tIf any aluminum-type pulley is installed, prior to further flight, accomplish \t\t\t\tparagraphs (c)(2)(i) and (c)(2)(ii) of this AD in accordance with the service \tbulletin.\n\n\t\t\t(i)\tReplace any aluminum-type pulley with a phenolic-type pulley having Boeing part number BACP30F4.\n\n\t\t\t(ii)\tExcept as provided by paragraph (d) of this AD: Perform a detailed visual inspection of the engine thrust control cables in any area where an aluminum-type pulley was installed, to detect wear. If any wear outside the criteria contained in Chapter 20-21-03 of the Boeing 747 Maintenance Manual is found, prior to further flight, replace the cable with a new cable, in accordance with the service bulletin. If any wear within the criteria contained in the maintenance manual is found, no further action is required by this paragraph.\n\n\tNOTE 4: Accomplishment of the actions specified in Boeing Service Bulletin 747-76-2067, dated September 26, 1986, is acceptable for compliance with the actions required by paragraph (c) of this AD.\n\n\t(d)\tWhere Boeing Service Bulletin 747-76-2067, Revision 1, dated November 19, 1987, specifies that the actions required by paragraph (c)(2)(ii) of this AD may be accomplished in accordance with an "operator's comparable procedure," the actions must be accomplished in accordance with the applicable chapters of the Boeing 747 Maintenance Manual, as specified in the service bulletin.\n\nReplacement\n\n\t(e)\tFor airplanes identified in Boeing Service Bulletin 747-76A2068, Revision 3, dated August 22, 1991; including Notice of Status Change 747-76A2068 NSC 2, dated December 12, 1991: \t\n\tWithin 18 months after the effective date of this AD, replace aluminum idler pulley brackets with steel brackets, in accordance with paragraphs E., F., G., and H. of the Accomplishment Instructions of the service bulletin.\n\nInspection/Modification\n\n\t(f)\tFor airplanes identified in Boeing Alert Service Bulletin 747-76A2073, Revision 1, dated July 28, 1988: Within 18 months after the effective date of this AD, accomplish paragraphs (f)(1) and (f)(2) of this AD, in accordance with the alert service bulletin.\n\n\t\t(1)\tPerform a detailed visual inspection of the engine thrust control cables and pulley mounting bracket screws in the area aft and above main entry door number 2 on the left and right sides of the airplane to detect damage. If any damage is found, prior to further flight, replace the cable with a new cable.\n\n\t\t(2)\tModify the pulley mounting bracket.\n\n\tNOTE 5: Accomplishment of the actions specified in Boeing Alert Service Bulletin 747-76A2073, dated February 4,1988, is acceptable for compliance with the actions required by paragraph (f) of this AD.\n\nInspection/Modification/Replacement\n\n\t(g)\tFor Model 747-100B SUD series airplanes identified in Boeing Service Bulletin 747-53-2327, Revision 2, dated September 24, 1998, with angle assemblies having Boeing part numbers 015U0454-63 and 015U0454-64 installed at body station 970: Within 18 months after the effective date of this AD, perform a detailed visual inspection to measure the clearance between the engine thrust control cables and the cable penetration holes, in accordance with the Cable Chafing Inspection of the Accomplishment Instructions of the service bulletin. If insufficient clearance exists, as specified in the service bulletin, prior to further flight, accomplish paragraphs (g)(1) and (g)(2) of this AD.\n\n\t\t(1)\tModify the cable penetration holes or replace the plate, as applicable, in accordance with Figure 7 of the service bulletin.\n\n\t\t(2)\tPerform a detailed visual inspection of the engine thrust control cables in any area of the plate to detect wear, in accordance with Chapter 20-21-03 of the Boeing 747 Maintenance Manual. If any wear outside the criteria contained in the maintenance manual is found, prior to further flight, replace the cable with a new cable, in accordance with the procedures described in the Boeing 747 Maintenance Manual. If any wear within the criteria contained in the maintenance manual is found, no further action is required by this paragraph.\n\nAlternative Methods of Compliance\n\n\t(h)\tAn alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA, Transport Airplane Directorate. Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Seattle ACO.\n\n\tNOTE 6: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Seattle ACO.\n\nSpecial Flight Permits\n\n\t(i)\tSpecial flight permits may be issued in accordance with sections 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the airplane to a location where the requirements of this AD can be accomplished. \n\nIncorporation by Reference\n\n\t(j)\tExcept as provided by paragraphs (a), (d), and (g)(2) of this AD, the actions shall be done in accordance with the following Boeing Service Bulletins, which contain the specified list of effective pages, as applicable:\n\n\n\nService Bulletin Referenced & Date\nPage Number Shown on Page\nRevision Level Shown on Page\nDate Shown on Page\n76-2019, June 9, 1971\n1-6\nOriginal\nJune 9, 1971\n747-76-2067, Revision 1,\nNovember 19, 1987\n1-4\n5-12\n1\nOriginal\nNovember 19, 1987\nSeptember 26, 1986\n747-76A2068, Revision 3\nAugust 22, 1991\n1, 3-30\n2\n3\n2\nAugust 22, 1991July 20, 1989\nNotice of Status Change \n747-76A2068, NSC 2\nDecember 12, 1991\n1\nOriginal\nDecember 12, 1991\n747-76A2073, Revision 1\nJuly 28, 1988\n1-4, 12\n5-11, 13\n1\nOriginal\nJuly 28, 1988\nFebruary 4, 1988\n747-53-2327, Revision 2\nSeptember 24, 1998\n1-80\n2\nSeptember 24, 1998\n\n\n\n\tThis incorporation by reference was approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington 98124-2207. Copies may be inspected at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC.\n\n\t(k)\tThis amendment becomes effective on April 24, 2000.\n\n\n\n\n\nAPPENDIX 1\nTHRUST CONTROL CABLE INSPECTION PROCEDURE\n\n1.\tGeneral\n\tA.\tClean the cables, if necessary, for the inspection, in accordance with Boeing 747 Maintenance Manual 12-21-05.\n\tB.\tUse these procedures to verify the integrity of the thrust control cable system. The procedures must be performed along the entire cable run for each engine. To ensure verification of the portions of the cables which are in contact with pulleys and quadrants, the thrust control must be moved by operation of the thrust and/or the reverse thrust levers to expose those portions of the cables.\n\tC.\tThe first task is an inspection of the control cable wire rope. The second task is an inspection of the control cable fittings. The third task is an inspection of the pulleys.\n\t\tNOTE:\tThese three tasks may be performed concurrently at one location of the cable system on the airplane, if desired, for convenience.\n\n2.\tInspection of the Control Cable Wire Rope\n\tA.\tPerform a detailed visual inspection to ensure that the cable does not contact parts other than pulleys, quadrants, cable seals, or grommets installed to control the cable routing. Look for evidence of contactwith other parts. Correct the condition if evidence of contact is found.\n\tB.\tPerform a detailed visual inspection of the cable runs to detect incorrect routing, kinks in the wire rope, or other damage. Replace the cable assembly if:\n\t\t(1)\tOne cable strand had worn wires where one wire cross section is decreased by more than 40 percent (see Figure 1),\n\t\t(2)\tA kink is found, or\n\t\t(3)\tCorrosion is found.\n\tC.\tPerform a detailed visual inspection of the cable: To check for broken wires, rub a cloth along the length of the cable. The cloth catches on broken wires.\n\t\t(1)\tReplace the 7x7 cable assembly if there are two or more broken wires in 12 continuous inches of cable or there are three or more broken wires anywhere in the total cable assembly.\n\t\t(2)\tReplace the 7x19 cable assembly if there are four or more broken wires in 12 continuous inches of cable or there are six or more broken wires anywhere in the total cable assembly.\n3.\tInspection of the Control Cable Fittings\n\tA.\tPerform a detailed visual inspection to ensure that the means of locking the joints are intact (wire locking, cotter pins, turnbuckle clips, etc.). Install any missing parts.\n\tB.\tPerform a detailed visual inspection of the swaged portions of swaged end fitting to detect surface cracks or corrosion. Replace the cable assembly if cracks or corrosion are found.\n\tC.\tPerform a detailed visual inspection of the unswaged portion of the end fitting. Replace the cable assembly if a crack is visible, if corrosion is present, or if the end fitting is bent more than 2 degrees.\n\tD.\tPerform a detailed visual inspection of the turnbuckle. Replace the turnbuckle if a crack is visible or if corrosion is present.\n4.\tInspection of Pulleys\n\tA.\tPerform a detailed visual inspection to ensure that pulleys are free to rotate. Replace pulleys which are not free to rotate.