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December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 41 BOEING SERVICE BULLETIN A3515
ALERT ALERT
2. MATERIAL INFORMATION A. Material - Price and Availability None.
B. Industry Support Information Boeing warranty remedies are not available for the inspection procedures given in this service bulletin.
C. Parts Necessary For Each Airplane
1. Kits/Parts:
None.
2. Parts and Materials Supplied by the Operator:
3. Parts Modified and Reidentified:
None.
Part Number / Specification QTY Name Notes 65-95600-887 1 Upper Chord, Inboard, Left Side (a) (c) (d) 65-95600-888 1 Upper Chord, Inboard, Right Side (a) (c) (e) 65-95600-701 1 Lower Chord, Inboard, Left Side (a) (c) (f) 65-95600-702 1 Lower Chord, Inboard, Right Side (a) (c) (g) 65C80665-165 1 Upper Chord, Outboard, Left Side (a) (c) (h) 65C380665-165 1 Lower Chord, Outboard, Right Side (a) (c) (h) 65C380665-166 1 Lower Chord, Outboard, Left Side (a) (c) (I) 65C80665-166 1 Upper Chord, Outboard, Right Side (a) (c) (i) BMS 3-23 Type II 1 Pint Corrosion Inhibiting compound (b)
(a) Discard the existing part.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(c) You can use the existing part to replace the new or changed part. If you use the existing part, you cancel the effect of the change given in this service bulletin. The existing part is interchangeable and intermixable with the new part.
(d) 65-95600-887 is the same as 65-3321-27 plus two 66-11433-4 bushings.
(e) 65-95600-888 is the same as 65-3321-28 plus two 66-11433-4 bushings.
(f) 65-95600-701 is the same as 65-3322-15 plus two 69-38158-1 bushings plus two 69-38158-2 bushings.
(g) 65-95600-702 is the same as 65-3322-16 plus two 69-38158-1 bushings plus two 69-38158-2 bushings.
(h) 65C80665-165 is the same as 65-05201-3.
(i) 65C80665-166 is the same as 65-05201-4.
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ALERT ALERT
4. Parts Removed and Not Replaced:
None.
D. Parts Necessary to Change Spares None.
E. Special Tooling - Price and Availability The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Tool price and supply data are not given.
F. Special Tooling Necessary to do this Service Bulletin See 707 NDT Manual D6-48023 Part 1, Section 51-01-00.
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ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES
CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES
OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE.
NOTE:
1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. A Special Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. The examination is likely to make extensive use of specialized Inspection techniques and/or equipment. Intricate cleaning and substantial access or disassembly procedure may be required.
4. These work instructions refer to procedures included on other Boeing documents. When the words “refer to” are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words “as given in” are included in the instruction, the procedure in the Boeing document must be used.
5. Refer to Appendix A for configuration verification, inspection, material data results form.
B. WORK INSTRUCTIONS
1. Part 1 - Cycle Counting Procedure
a. Determine flight cycles.
NOTE: The term “flight cycle” wherever stated in this bulletin is defined as any one of the following:
1. A complete flight cycle (takeoff and full stop landing).
2. Any touch-and-go cycle within a flight cycle for which the airplane makes a runway approach, with or without runway contact.
2. Part 2 - Configuration Records Inspection
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ALERT ALERT
a. Determine what material the left and right side horizontal stabilizer, rear spar, upper chords and lower chords on the inboard and outboard ends of the rear spar are made of using one of the following methods:
(1) Review the airplane's maintenance records or the previously completed Appendix A data sheet to identify the location of the upper and lower chords on the horizontal stabilizer rear spar that are made from 7079. If the material cannot be conclusively determined, do step (2).
(2) Do a conductivity test to determine whether each upper chord and lower chord on the horizontal stabilizer rear spar listed in Appendix A is made from 7079-T6 or 7075-T73511 material. Refer to 707, 720 NDT, Part 6, 51-00-00, Figure 20 dated April 5, 2004 as an accepted procedure.
b. Optional.
(1) Record the material of each upper chord and lower chord segment on the Appendix A data sheet. Describe any existing repairs in the “Comments” field.
(2) Retain the Appendix A data sheet with the airplane records.
3. Part 3 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Inboard - Upper Chord - Stabilizer Station -13.179 to 92.55e Upper Chords, Horizontal Stabilizer Rear Spar, Inboard Side, Made From 7075 and 7079
a. Do a special detailed inspection of the upper chord on the inboard side of the rear spar of the left and right side horizontal stabilizer as follows:
(1) Inspect for cracks in the forward flange of the upper chord of the rear spar along the fasteners common to the skin and the upper chord. Inspect from the inboard edge of the inspar skin to 25.5 inches outboard of the inspar skin on the horizontal stabilizer.
Refer to 707, 720 NDT, Part 6, 55-10-07, Figure 1, as an accepted procedure.
(2) Inspect for cracks in the space between the inspar skin and the forward edge of the exposed upper surface of the upper chord of the rear spar. Inspect from the side of the body outboard towards Stabilizer Station 92.55. Refer to 707, 720 NDT, Part 6, 55-10-07, Figure 2, as an accepted procedure.
(3) Inspect for cracks in the space between the trailing edge skin and the aft edge of the exposed upper surface of the upper chord of the rear spar. Inspect from the side of the body outboard to Stabilizer Station 92.55. Refer to 707, 720 NDT, Part 6, 55-10-07, Figure 2 as an accepted procedure.
(4) Inspect for cracks in the aft flange of the upper chord of the rear
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ALERT ALERT
spar along the fasteners common to the skin and the upper chord.
Inspect from the inboard edge of the inspar skin to 25.5 inches outboard of the inspar skin on the horizontal stabilizer. Refer to 707, 720 NDT, Part 6, 55-10-07 Figure 3, as an accepted procedure.
(5) Inspect for cracks along the forward and aft edges of the exposed upper surface of the upper chord of the rear spar. Inspect from the side of the body outboard to Stabilizer Station 92.55. Refer to 707, 720 NDT, Part 6, 55-10-07 Figure 7, as an accepted procedure.
b. If a crack is found:
(1) Contact Boeing for repair instructions or
(2) Replace the spar chord as given in Accomplishment Instructions Paragraph 3.B.6.
Part 6.
c. Apply corrosion inhibiting compound BMS 3-23 or equivalent to the exposed area of the upper chord. Refer to SOPM 20-41-05 as an accepted procedure.
d. Put the airplane back to a serviceable condition.
4. Part 4 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Upper and Lower Chord - Web Flange - Stabilizer Station 92.55 to 272.55 Upper and Lower Chords, Horizontal Stabilizer Rear Spar, Made From 7079
a. Remove and keep the elevator balance bay number 2 through number 5 panels. Refer to 707 AMM 27-07-31 as an accepted procedure.
b. Remove and keep the cove shells and supporting structures as required to get access to the aft surface of the vertical flanges of the upper and lower chords of the horizontal stabilizer rear spar.
c. Do a High Frequency Eddy Current (HFEC) inspection of the web flanges of the upper and lower chords on the inboard and outboard ends of the rear spar of the left and right side horizontal stabilizer between stabilizer station 92.55 and 272.55 for cracks as given in Figure 1.
d. If a crack is found:
(1) Replace the spar chord as given in Accomplishment Instructions Paragraph 3.B.6.
Part 6 or
(2) Complete steps (a) and (b) that follow:
(a) Determine if the crack meets the limits defined in service bulletin 707-3356 and has been repaired according to service bulletin 707-3356.
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ALERT ALERT
1) For each crack that meets the limits of service bulletin 707-3356, Part III - Repair, Notes (a) and (b), contact Boeing for new repair instructions.
2) For each crack that has been repaired according to service bulletin 707-3356, Part III - Repair Paragraph C, determine if the crack still meets the limits of service bulletin 707-3356, Part III - Repair Paragraph C, and determine if the crack meets the following supplemental limits:
{a} The crack path must be within the limits as given in Figure 1, View B-B.
{b} The crack must terminate in an existing fastener hole.
{c} There must be two or more fastener locations in the repair area as given in Figure 1, View B-B that have no cracks indicated in the adjacent spaces.
{d} A stiffener bay with a crack in the upper chord must not also have a crack in the upper or lower chord of either of the adjacent stiffener bays.
{e} A stiffener bay with a crack in the lower chord must not also have a crack in the upper or lower chord of either of the adjacent stiffener bays.
3) For a crack that meets the limits of service bulletin 707- 3356, Part III - Repair Paragraph C, but is not repaired as given in service bulletin 707-3356, Part III - Repair Paragraph C, accomplish the repair as given in service bulletin 707-3356, Part III - Repair Paragraph C. Obey the supplemental limits that follow:
{a} The crack path must be within the limits as given in Figure 1, View B-B.
{b} They crack must terminate in an existing fastener hole.
{c} There must be two or more fastener locations in the repair area as given in Figure 1, View B-B that have no crack indicated in the adjacent spaces.
{d} A stiffener bay with a crack in the upper chord must have no crack in the upper or lower chord of either of the adjacent stiffener bays.
{e} A stiffener bay with a crack in the lower chord must have no crack in the upper or lower chord of either of the adjacent stiffener bays.
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4) For a crack that meets the limits of service bulletin 707- 3356, Part III - Repair Paragraph D, accomplish the repair according to service bulletin 707-3356, Part III - Repair Paragraph D, unless already accomplished.
5) For a crack that does not meet the limits defined in paragraph (1)(b) through (1)(d), contact Boeing for new repair instructions.
(b) Determine if all 7079 upper and lower chord segments installed on the horizontal stabilizer have had Service Bulletin 707-3356 Part II, Group 1 Preventative Modification done. If not yet accomplished, do the Service Bulletin 707-3356 Part II, Group 1 Preventative Modification on all 7079 chord segments still installed on the horizontal stabilizer.
NOTE: Service Bulletin 707-3356 Part II, Group 1 Preventative Modification is applicable to airplanes for which all chord segments (upper and lower inboard, upper and lower outboard) are made from 7079. It is therefore inclusive of all configurations where 7079 chord segments remain. Since 7079 chords may have been replaced with 7075 chords, it is only necessary to do the modification where the 7079 chord segments are identified.
e. Apply corrosion inhibiting compound BMS 3-23 or equivalent to the exposed area of the horizontal stabilizer rear spar chords. Refer to SOPM 20-41-05 as an accepted procedure.
f. Restore the airplane to a serviceable condition.
5. Part 5 - Chord Inspection - Horizontal Stabilizer - Rear Spar - Upper and Lower Chord - Forward Skin Flange - Stabilizer Station -13.179 to 272.55 Upper and Lower Chords of the Horizontal Stabilizer Rear Spar Made From 7079
a. Remove and keep the elevator balance bay number 0 through number 5 panels. Refer to 707 AMM 27-07-31 as an accepted procedure.
b. Do a Low Frequency Eddy Current (LFEC) inspection of the forward skin flange of the upper chord on the outboard end of the rear spar of the left and right side horizontal stabilizer between stabilizer station
182.55 and 272.55 for cracks as given in Figure 2.
c. Do a LFEC inspection of the forward skin flange of the upper chord on the inboard end of the rear spar of the left and right side horizontal stabilizer between stabilizer station 92.55 and 182.55 for cracks as given in Figure 3.
d. Do a LFEC inspection of the forward skin flange of the lower chord on the outboard end of the rear spar of the left and right side horizontal
December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 41 BOEING SERVICE BULLETIN A3515
ALERT ALERT
stabilizer between stabilizer station 182.55 and 272.55 for cracks as given in Figure 4.
e. Do a LFEC inspection of the forward skin flange of the lower chord on the inboard end of the rear spar of the left and right side horizontal stabilizer between stabilizer station 92.55 and 182.55 for cracks as given in Figure 5.
f. Do a LFEC inspection of the forward skin flange of the lower chord on the inboard end of the rear spar of the left and right side horizontal stabilizer between stabilizer station -13.179 and 92.55 for cracks as given in Figure 6.
g. If a crack is found:
(1) Replace the lower chord as given in Accomplishment Instructions Paragraph 3.B.6.
Part 6 or
(2) Complete steps (a) and (b) that follow:
(a) Contact Boeing for repair instructions.
(b) Determine if all 7079 upper and lower chord segments installed on the horizontal stabilizer have had Service Bulletin 707-3381 Part II - Preventative Modification accomplished. If not yet accomplished, do the Service Bulletin 707-3381 Part II
- Preventative Modification on all 7079 chord segments still installed on the horizontal stabilizer.
NOTE: Service Bulletin 707-3381 Part II - Preventative Modification is applicable to airplanes for which all chord segments (upper and lower inboard, upper and lower outboard) are made from 7079. It is therefore inclusive of all configurations where 7079 chord segments remain. Since 7079 chords may have been replaced with 7075 chords, it is only necessary to do the modification where the 7079 chord segments are identified.
h. Apply corrosion inhibiting compound BMS 3-23 or equivalent to exposed area of the upper and lower chords of the horizontal stabilizer rear spar.
Refer to SOPM 20-41-05 as an accepted procedure.
i. Restore the airplane to a serviceable condition.
6. Part 6 - Chord Replacement
a. Replace the chord with the part number given in the Material Information section, Paragraph 2.C.2, Parts and Materials Supplied by the Operator.
b. Contact Boeing if chord replacement instructions are needed.
December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 41 BOEING SERVICE BULLETIN A3515
ALERT ALERT
c. Optional.
(1) Upon completion of chord replacement, revise the data on the Appendix A data sheet to match the chord configuration currently on the airplane.
(2) Retain the updated Appendix A data sheet with the airplane records.
FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUT- BOARD - CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 -
INSPECTION December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 41 BOEING SERVICE BULLETIN A3515
ALERT ALERT
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 BAY NO.3
BALANCE BAY NO.2
BALANCE BAY NO.1 BALANCE BAY NO.0
BALANCE BAY NO.5
BALANCE BAY NO.4
BALANCE A A
182.55
STAB STA
137.55
STAB STA
STAB STA
92.55
47.55
STAB STA
272.55
STAB STA
STAB STA
227.55 CHORD B B
LEFT HORIZONTAL STABILIZER SHOWN,
RIGHT OPPOSITE A-A
ELEVATOR
REAR SPAR
FRONT SPAR HINGE 1 1 2 2 496234 (SHEET 1 OF 2)
FIGURE 1: HORIZONTAL STABILIZER - REAR SPAR - UPPER AND LOWER - INBOARD AND OUT- BOARD - CHORD WEB FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 272.55 -
INSPECTION December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 41 BOEING SERVICE BULLETIN A3515
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The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Access Balance Bay Number 2, 3, 4 and 5 - - 2 Inspect Chord Web Flange - 2 See Table 1.(a)
(a) Do a High Frequency Eddy Current (HFEC) inspection of the left and right side horizontal stabilizer rear spar upper and lower inboard and outboard chord web flange between stabilizer station 92.55 and 272.55 for any cracking. Use a pencil probe to scan the aft surface of the chord vertical flange between fasteners and along the tangent line of the flange fillet. Refer to 707, 720 NDT, Part 6, 51-00-00, Figure 4 as an accepted procedure.
Table 1 7079 Chord Segment Balance Bay to Inspect Upper Inboard 2,3 Lower Inboard 2,3 Upper Outboard 4,5 Lower Outboard 4,5 B-B 2 2
FASTENER TO FARTHEST POINT OF CRACK
0.125 MAXIMUM FROM CENTERLINE OF
FASTENER TO NEAREST POINT OF CRACK
0.22 MINIMUM FROM CENTERLINE OF
FASTENER
REPAIRFASTENEREXISTING UPPER CHORD STIFFENERSTIFFENER CRACK
REAR SPAR UPPER CHORD
REAR VIEW
STIFFENER BAY
REPAIR AREA WEB D64427 (SHEET 2 OF 2)
FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION December 19, 2007 A3515 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 41 BOEING SERVICE BULLETIN A3515
ALERT ALERT
FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
STEP TASK NAME IDENTIFICATION QTY MORE DATA 1 Inspect Forward Skin Flange - 2 (a)
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear spar upper outboard chord forward skin flange between stabilizer station 182.55 and 272.55 for any cracking.
Refer to 707, 720 NDT, Part 6, 55-10-07, Figure 8 as an accepted procedure.
A A FWD INBD PANEL NO.4
BALANCE BAY PANEL NO.5
BALANCE BAY
UPPER CHORD
REAR SPAR
RIGHT OPPOSITE
LEFT HORIZONTAL STABILIZER UPPER SURFACE SHOWN, A-A
272.55 1
182.55263.55