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December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 41
ALERT ALERT Commercial Airplane Group 707
ALERTALERT Service Bulletin Number: A3515 Date: December 19, 2007 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection and Repair
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery 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.
BLANK PAGE December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 41 BOEING SERVICE BULLETIN A3515
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Table of Contents December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 41 BOEING SERVICE BULLETIN A3515
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Table of Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 22
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 22 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 23
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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 Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 26
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUTBOARD - CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 - INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 FIGURE 3: HORIZONTAL STABILIZER - REAR SPAR - UPPER INBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION 37 FIGURE 4: HORIZONTAL STABILIZER - REAR SPAR - LOWER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FIGURE 5: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN
Table of Contents December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 41 BOEING SERVICE BULLETIN A3515
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FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION 39 FIGURE 6: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION -13.179 TO STABILIZER STATION 92.55 - INSPECTION 40 APPENDIX A: CONFIGURATION VERIFICATION - INSPECTION RESULTS FORM - MATERIAL DATA 41
December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 41
ALERT ALERT Commercial Airplane Group 707
ALERTALERT Service Bulletin Number: A3515 Summary Date: December 19, 2007 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection and Repair
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.
CONCURRENT REQUIREMENTS None.
BACKGROUND Boeing Service Related Problem (SRP) 707-SRP-55-0033 is related to this service bulletin.
1. ISSUE 1 - Stress Corrosion Cracking in Chords Made from 7079 Aluminum in the Horizontal Stabilizer Rear Spar Boeing has received numerous reports of stress corrosion cracking in the chord segments made from 7079 aluminum in the 707 horizontal stabilizer rear spar This is a material that is known to be susceptible to stress corrosion cracking. Early reports led to service bulletins 707-3356 and 707-3381. Incorporation of the modifications in those service bulletins has helped to slow the development of stress corrosion cracks.
Service Bulletin 707A3515 continues the inspections of 707-3356 and 707-3381, but at shorter intervals, and in concurrence with the necessary actions that are the subject of Issue 2 below.
The actions of this service bulletin addressing Issue 1 are necessary to adequately detect development of stress corrosion cracking.
2. ISSUE 2 - Early Fatigue Cracking in the Inboard Segment of the Upper Chord in the Horizontal Stabilizer Rear Spar Boeing has received three reports of fatigue cracking in the upper chord of the horizontal stabilizer rear spar at a location near the side of the body. In all cases the fatigue prevention and fail safety improvement modifications of bulletin 707A3313 had been incorporated. The fatigue cracking is considered to be early in the life of the modified structure. The fatigue cracks are generated by frequent use of the airplanes for training flights that include multiple Touch and Goes. This frequent use of the airplane for this type of training has been most prevalent with military operators of commercial model 707 and 720 airplanes.
The actions of this service bulletin are necessary to adequately detect early fatigue cracking.
December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 41
3. CONFIGURATION The ability to move the horizontal stabilizer to a different airplane is of significance to Issue 1 and Issue 2.
Parts made from 7079 have been discovered on airplanes not originally delivered with those parts.
Therefore, to adequately address Issue 1, it is necessary to determine the horizontal stabilizer rear spar chord configuration on the airplane. It is also necessary to carefully maintain a record of that configuration until all 7079 horizontal stabilizer rear spar chord segments have been removed from the fleet.
Regarding Issue 2, since horizontal stabilizers can be moved to different airplanes, it is necessary to implement the inspections for early fatigue cracking on all effective airplanes at the time stated in the 1.E Compliance section, regardless of the current usage of the airplane.
ACTION (PRR 18101-2RS) Cycle Definition:
To adequately account for in-flight training maneuvers, incorporate the cycle counting procedure defined in this service bulletin.
Configuration Check:
To Maintain configuration identity, determine the material for each horizontal stabilizer rear spar chord segment addressed by this service bulletin. Maintain the configuration identity indefinitely.
Inspections:
Complete the inspections for stress corrosion cracking and fatigue cracking in accordance with the methods and times stated in this service bulletin.
Repair:
Contact Boeing for repair instructions or replace the cracked part with a spare part made from 7075 aluminum.
EFFECTIVITY All 707-300, 707-300B, 707-300C and 707-400 Airplanes. See Paragraph 1.A.1 for effectivity.
COMPLIANCE See Service Bulletin Paragraph 1.E. for compliance information.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.
MANPOWER See Service Bulletin Paragraph 1.G. for manpower information.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 41 BOEING SERVICE BULLETIN A3515
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REPAIR AS NECESSARY
INSPECT CHORDS
DEFINE CHORD MATERIAL CHORD A A 182.55
STAB STA
STAB STA
92.55
272.55
STAB STA
FRONT SPAR
LEFT HORIZONTAL STABILIZER SHOWN,
RIGHT OPPOSITE A-A
ELEVATOR
REAR SPAR HINGE 496408
December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 41 BOEING SERVICE BULLETIN A3515
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December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 41
ALERT ALERT Commercial Airplane Group 707
ALERTALERT Service Bulletin Number: A3515 Date: December 19, 2007 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection and Repair
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 airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 18101-2RS for data about this change.
Refer to Service Bulletin Index Document D6-1647 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
Airplane models:
707-300 707-300B 707-300C 707-400
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND NUMBER
ADC AIRLINES (ADN) 1 07816
GROUP CONFIGURATION DESCRIPTION 1 - All horizontal stabilizer rear spar chords made from 7079-T6.
2 - Horizontal stabilizer rear spar upper inboard and upper outboard chords made of 7079-T6.
3 - Left side horizontal stabilizer rear spar upper inboard chords made from 7079-T6.
4 - All horizontal stabilizer rear spar chords made from 7075-T73511.
December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 41 BOEING SERVICE BULLETIN A3515
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AERO SANTAMARIA (SMK) 1 08475
AEROSPACE CONSORTIUM (CTU) 1 08223
AFRICAN AIRLINES (AFX) 1 05632
AIR ATLANTIC NIGERIA (NGE) 1 07042 08472
AIR GULF FALCON (GFG) 1 05961 08077
AIR MEMPHIS (MEP) 1 08405
AIR NACOIA (NAO) 1 07071 ALG TRANSPORTATION, INC. (ALW) 1 07052 07458
ARGENTINE AIR FORCE (AGF) 1 05854 08310 08452 4 06461
ASNET (SRC) 1 08127
AVIATION CONSULTANTS (ACT) 1 05965 07602–07603
AVIATION RESEARCH CENTRE (AVR) 1 07701–07702
BETA (BRQ) 1 07261 07270 07625 08072
BIN MAHFOOZ AVIATION (BMV) 1 08404
CARGO PLUS AVIATION (CPB) 1 08191
CHILEAN AIR FORCE (CHF) 1 05305 07619 07661
COLOMBIAN AIR FORCE (CLB) 1 07109 08582
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CRYSTAL TRADING (CTR) 1 07907
DAIRO AIR SERVICES (DAR) 1 07616 07802
DOLPHIN AIR (FDN) 1 09001
EURO OCEANIC AIR TRANSPORT (EOA) 1 08309
EXPORT RESTRICTED AIRPLANES (YWV) 1 05019 07016 08054 08101 08551–08553 09101–09102 2 09231 3 09103–09105 09232 4 09106–09107 09161–09167 09438
FEDERATIVE REPUBLIC OF BRAZIL (BRZ) 1 07080 08304 08308 08314
FIRST INTERNATIONAL AIRWAYS (FIW) 1 07207 09201 2 09203 G.M.A.S. (GMA) 1 07049
GE (GEC) 1 02017
GOVERNMENT OF ANGOLA (AGL) 1 05035 05051 06402
HEWA BORA AIRWAYS (EXD) 1 08206
INTER AIR (ITI) 1 07253
INTERNATIONAL AIR LEASES (IAL) 1 05125 07043 07606 07618
IRAQI AIRWAYS (IRQ) 3 09221–09223
ISRAELI AIR FORCE (ISR) 1 02105 02114–02115 02203 02206–02207 05208 06403 07406–07407 08021 08243 08251 09004 4 09251 09421 09441
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ITALIAN AIR FORCE (ITC) 1 05823 05827 08329–08330
KODA AIR (KGO) 1 07105 L-3 COMMUNICATIONS (LCS) 1 08172
LIBYAN AIRWAYS (LAA) 1 05037 07046 07502–07503 07819 4 09411 LOWA, LTD. (LOW) 1 05307
MIAMI AVIATION SERVICE (MIA) 4 06451
MIT LINCOLN LABORATORIES (MIT) 1 05009
NATO (NAT) 1 07905–07906 08221 08224
NORTHROP GRUMMAN CORPORATION (GRU) 1 07812 07817 09002
OMEGA AIR (OMG) 1 05966 07623 OMEGA AIR, INC. (OMH) 1 05055 05603 05968 08055 3 08209 4 09227 09290