Boeing SB A3515: U.S. DOT/FAA - Boeing Service Bulletin A3515, text

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Page 13Open in PDF

ALERT ALERT

ROYAL AUSTRALIAN AIR FORCE (RAA) 1 07814–07815 07818 07820 4 09288

ROYAL JORDANIAN (RJA) 1 07078 08173 09003 09006

SKY AIR CARGO (SAC) 1 07201

SKY AVIATION (SYV) 1 05048

SKYMASTER AIRLINES (SKA) 1 07058 07077 07622 07801 08471

SOUTH AFRICAN AIRFORCE (SFF) 1 08004–08005 08008 08242 08244

SPANISH AIR FORCE (SAF) 1 05131 07405 07611 4 09289

TRANS MEDITERRANEAN AIRWAYS (TMA) 1 07041 07206 07453 08121–08122

TRISTAR (TYS) 1 08203

US AIR FORCE (USF) 1 05826 07057 07107 07212–07213 07254 07256 07258 07807–07810 07813 08222 08271 08313 08327 08407–08410

VENEZUELAN AIR FORCE (VEN) 1 08103–08104

WIMBI DIRA (WIM) 1 07262

WORLD AIRWAYS (GMR) 1 07075

IDENTIFICATION BY NUMBER Variable Group 02001–02020 1 02101–02121 1 02201–02207 1

Page 14Open in PDF

ALERT ALERT

02301–02303 1 02401–02418 1 04001–04005 1 04020–04022 1 04101–04106 1 04201–04218 1 04271–04272 1 04301–04303 1 05001–05060 1 05101–05138 1 05201–05208 1 05301–05312 1 05401 1 05601–05605 1 05631–05635 1 05701–05703 1 05801–05802 1 05821–05827 1 05831–05833 1 05851–05854 1 05891–05892 1 05921–05923 1 05941–05942 1 05961–05970 1 06001–06002 1 06101 1 06401–06404 1 06451 4 06461 4 07001–07017 1 07041–07059 1 07071–07081 1 07101–07109 1 07181 1 07191 1 07201–07208 1 07210 1 07212–07215 1 07251–07271 1 Variable Group

Page 15Open in PDF

ALERT ALERT

07401–07407 1 07451–07458 1 07501–07504 1 07601–07626 1 07661–07662 1 07681–07684 1 07701–07702 1 07801–07821 1 07901–07907 1 08001–08008 1 08021 1 08051–08056 1 08071–08077 1 08101–08104 1 08121–08129 1 08141–08144 1 08151–08153 1 08171–08173 1 08191–08192 1 08201–08208 1 08209–08210 3 08221–08224 1 08241–08244 1 08251 1 08261 1 08271 1 08301–08320 1 08324–08330 1 08333 1 08401–08410 1 08451–08452 1 08471–08475 1 08501–08502 1 08551–08553 1 08581–08582 1 09001–09006 1 09101–09102 1 09103–09105 3 09106–09107 4 Variable Group

Page 16Open in PDF

ALERT ALERT

2. Spares Affected None.

B. Concurrent Requirements None.

C. Reason 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 09161–09167 4 09201–09202 1 09203 2 09204 4 09221–09223 3 09227 4 09231 2 09232 3 09251 4 09271 4 09281 4 09286–09290 4 09411 4 09421 4 09438 4 09441 4 Variable Group

Page 17Open in PDF

ALERT ALERT

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.

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.

D. Description 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.

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.

Page 18Open in PDF

ALERT ALERT

Boeing recommends the following:

Table 1: Determine Flight Cycles and Material of Horizontal Stabilizer Structural Components Condition Action Compliance Time Repeat Interval (Not to Exceed) All airplanes Determine flight cycles as given in Accomplishment Instructions paragraph 3.B.1. Part 1.

At time of service bulletin release - All airplanes Determine material of the left and right side horizontal stabilizer structural components as given in Accomplishment Instructions Paragraph 3.B.2.

Part 2.

Within 180 calendar days after the date of this service bulletin or before further flight when the horizontal stabilizer is replaced 180 calender days or 250 total flight cycles, whichever occurs first (a) Airplanes with horizontal stabilizer components made from 7075 as found in the Accomplishment Instructions Paragraph 3.B.2 Part 2 Inspect and repair the horizontal stabilizer structural components as given in Table 2. (b) -- Airplanes with horizontal stabilizer components made from 7079 as found in the Accomplishment Instructions Paragraph 3.B.2 Part 2 Inspect and repair the horizontal stabilizer structural components as given in Table 3. (b) --

(a) See Part 1 - Cycle Counting Procedure for definition of “cycles.”

(b) If you have a mixture of 7075 components and 7079 components, use Tables 2 and 3.

Page 19Open in PDF

ALERT ALERT

Table 2: Inspect and Repair Horizontal Stabilizer Structural Components Made From 7075 Material Condition Action Compliance Time Repeat Interval (Not to Exceed) Airplanes with horizontal stabilizer components made from 7075 Inspect and repair the upper chord on the inboard end of the rear spar in the left and right side horizontal stabilizers from stabilizer station -13.179 to 92.55 as given in Accomplishment Instructions Paragraph 3.B.3. Part 3.

Within 180 calendar days or 500 flight cycles after the date of this service bulletin, whichever occurs first (a) (c) or before further flight when the horizontal stabilizer is being replaced (c) 500 total flight cycles (a) The chord is replaced as given in Accomplishment Instructions Paragraph 3.B.6 Part 6 Inspect and repair the upper chord on the inboard end of the rear spar that was replaced from stabilizer station -13.179 to 92.55 as given in Accomplishment Instructions Paragraph 3.B.3.

Part 3. (b) Within 4000 total flight cycles after the date of chord replacement (a) 500 total flight cycles (a)

(a) See Part 1 - Cycle Counting Procedure for definition of “cycles.”

(b) Continued inspections are only necessary for upper chords of the inboard end of the rear spar that are made from 7075. Continued inspections are not necessary for other spar chord components replaced with 7075 parts.

(c) When you replace the chord as given in Accomplishment Instructions Paragraph 3.B.6 Part 6, you can defer the chord inspection given in Accomplishment Instructions Paragraph 3.B.3. Part 3 for a maximum of 4,000 total flight cycles.

Page 20Open in PDF

ALERT ALERT

Table 3: Inspect and Repair Horizontal Stabilizer Structural Components Made From 7079 Material Condition Action Compliance Time Repeat Interval (Not to Exceed) Airplanes with horizontal stabilizers that have rear spar chord compenents made from 7079 Inspect and repair the upper chord of the inboard side of the rear spar in the left and right side horizontal stabilizers from stabilizer station -13.179 to

92.55 as given in Accomplishment Instructions Paragraph 3.B.3. Part 3.

Within 180 calendar days or 250 flight cycles after the date of this service bulletin, whichever occurs first (a) or before further flight when the horizontal stabilizer is being replaced 180 calender days or 250 total flight cycles, whichever occurs first (a) Inspect and repair the web flanges of the upper and lower chords of the rear spar in the left and right side horizontal stabilizers from stabilizer station 92.55 to 272.55 as given in Accomplishment Instructions Paragraph 3.B.4.

Part 4. (b) Within 180 calendar days or 1000 flight cycles after the date of this service bulletin, whichever occurs first (a) or before further flight when the horizontal stabilizer is being replaced 180 calender days or 1000 total flight cycles, whichever occurs first (a) Inspect and repair the forward skin flanges of the upper and lower chords of the rear spar in the left and right side horizontal stabilizers from stabilizer station -13.179 to

272.55 as given in Accomplishment Instructions Paragraph 3.B.5. Part 5. (b) Airplanes with horizontal stabilizers that have rear spar chord components made from 7079 for which the Service Bulletin 707-3381 Part II - Preventative Modificaiton is not completed Do Boeing service bulletin 707- 3381 Part II - Preventative Modification as given in Accomplishment Instructions Paragraphs 3.B.4 Part 4 and

3.B.5 Part 5 or replace the chord as given in Accomplishment Instructions Paragraph 3.B.6 Part 6.

Before further flight -

(a) See Part 1 - Cycle Counting Procedure for definition of “cycles.”

(b) Only those components made from 7079 material require the inspection and repair given in the Accomplishment Instructions Paragraphs 3.B.4. Part 4 and 3.B.5. Part 5. Components made from 7075 material do not require the inspection and repair given in the Accomplishment Instructions Paragraphs 3.B.4.

Part 4 and 3.B.5. Part 5.

Page 21Open in PDF

ALERT ALERT

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.

The Part 3 inspections of this service bulletin supersede and replace the 707 Supplemental Structural Inspection Document (SSID) inspections 55-A25-03, 55-A35-03 and 55-A45-03 mandated by Paragraph (A) of AD 85-12-01, Revision 1. The inspections contained in this service bulletin have been reviewed and approved as an alternate method of compliance to the requirements of Paragraph (A) of AD 85-12-01 for SSID item 55-A25-03, 55-A35-03 and 55-A45-03 covered by this service bulletin. All other provisions of AD 85-12-01 that are not specifically referenced above remain fully applicable and must be complied with.

G. Manpower The table below shows 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 — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools.

Task Number of Persons Task Hours Elapsed Hours Open Access 2 1.0 0.5 Part 1 - (a) (a) Part 2 2 1.0(b) 0.5(b) Part 3 4 26.0 6.5 Part 4 4 32.0 8.0 Part 5 4 24.0 6.0 Part 6 (c) (c) (c) Close Access 2 1.0 0.5 TOTAL FOR EACH AIRPLANE (d) (d)

(a) Considered Lost Time. Not able to estimate.

Page 22Open in PDF

ALERT ALERT

H. Weight and Balance Changes None.

I. Electrical Load Data Not applicable.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 18101-2RS.

b. 707 Aircraft Maintenance Manual (AMM) 27-07-31.

c. 707 Nondestructive Test (NDT) Manual D6-48023, Part 6, Subject 51-00-00, Figure 20.

d. 707 Nondestructive Test (NDT) Manual D6-48023, Part 6, Subject 55-10-07, Figure 1, Figure 3 and Figure 7.

e. 707 Supplemental Structural Inspection Document (SSID) D6-44860, Revision P, Item 55- A25-03, 55-A35-03 and 55-A45-03.

f. 707, 720 Nondestructive Testing (NDT) Manual, Part 6, 51-00-00, Figure 20, Part 6, 55-10-07 Figure 1, Figure 3 and Figure 7.

g. Boeing Service Bulletin 707-3356 - “STABILIZERS - HORIZONTAL STABILIZER REAR SPAR CHORD INSPECTION, MODIFICATION AND REPAIR”.

h. Boeing Service Bulletin 707-3381 -”EMPENNAGE - HORIZONTAL STABILIZER REAR SPAR CHORD FORWARD FLANGE INSPECTION”.

i. Service Related Problem (SRP) 707-SRP-55-0033.

j. Standard Overhaul Practices Manual (SOPM) 20-41-05.

2. Data supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

None.

(b) Covers conductivity test only, does not include maintenance record review.

(d) No total is given because of the variability in time required for Part 1, Part 2 and Part 6 activities.

Task Number of Persons Task Hours Elapsed Hours

Page 23Open in PDF

ALERT ALERT

K. Publications Affected None.

L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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ALERT ALERT

BLANK PAGE

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