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Commercial Airplanes 707 Service Bulletin ALERT Number: A3515 Original Issue: December 19, 2007 Revision 1: October 10, 2014 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2007 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 1 of 38
10.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 2 of 38 BOEING SERVICE BULLETIN A3515
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 6 E. Compliance .............................................. 1 6 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1
1. Existing Data: ......................................... 2 1
2. Data Supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 2 M. Software Accomplishment Summary ................................ 2 2
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary for Each Airplane ................................. 2 3
1. Kits/Parts: ........................................... 2 3
2. Parts and Materials Supplied by the Operator: ........................ 2 3
3. Parts Modified and Reidentified: ............................... 2 4
4. Parts Removed and Not Replaced: .............................. 2 4 D. Parts Necessary to Change Spares ................................. 2 4 E. Special Tooling - Price and Availability ............................... 2 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 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 .......................................... 3 1 FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION .................................................. 3 3 FIGURE 3: HORIZONTAL STABILIZER - REAR SPAR - UPPER INBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION .................................................. 3 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 3 of 38 BOEING SERVICE BULLETIN A3515
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FIGURE 4: HORIZONTAL STABILIZER - REAR SPAR - LOWER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION .................................................. 3 5 FIGURE 5: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION .................................................. 3 6 FIGURE 6: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION -13.179 TO STABILIZER STATION 92.55 - INSPECTION .................................................. 3 7 Appendix A: CONFIGURATION VERIFICATION - INSPECTION RESULTS FORM - MATERIAL DATA . 38 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 4 of 38 BOEING SERVICE BULLETIN A3515
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Commercial Airplanes 707 Service Bulletin ALERT Revision Transmittal SheetNumber: A3515Original Issue: December 19, 2007 Revision 1: October 10, 2014 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1 are related to this service bulletin.
No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION This revision is sent to updated compliance table and wording to clarify requirements, provide clarifying information for the Compliance requirements for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords, to clarify Parts 3, 4 & 5 by removing unnecessary redundant wording, and to add reference to Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-17-13.
These sections were changed:
1. Summary, Background, added clarifying information for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords.
2. Summary, Compliance, added FAA Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1.
3. Paragraph 1.C., Reason, added clarifying information for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords.
4. Paragraph 1.E., Compliance, updated compliance table to clarify requirements, added clarifying information for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords and added FAA Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1.
5. Paragraph 1.F., Approval, added FAA Airworthiness Directive AD 2012-17-13.
6. Paragraph 1.J., References, added FAA Airworthiness Directives AD 85-12-01 R1 and AD 2012-17-13.
7. Paragraph 2.C.2., Parts and Materials Supplied by the Operator, removed footnote (c) and added parts 65-95600-703 and 65-95600-704 and footnotes (j) and (k).
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 5 of 38
8. Paragraph 3.B.3., Work Instructions, removed unnecessary redundant wording.
9. Paragraph 3.B.4., Work Instructions, removed unnecessary redundant wording.
10. Paragraph 3.B.5., Work Instructions, removed unnecessary redundant wording.
11. Paragraph 3.B.6., Work Instructions, added clarifying information for the Part 6 7079 aluminum chord replacement with 7075 aluminum chords.
12. Paragraph 3.B., Work Instructions, Figures 1 through 6 and Appendix A, changed all NDT callouts to "in accordance with".
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY December 19, 2007Original Issue:
October 10, 2014Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 6 of 38 BOEING SERVICE BULLETIN A3515
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Commercial Airplanes 707 Service Bulletin ALERT SummaryNumber: A3515Original Issue: December 19, 2007 Revision 1: October 10, 2014 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 Boeing 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. Boeing Service Bulletin 707-A3515 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, until the 7079 aluminum chord segments are replaced by ones made from 7075. The actions of this service bulletin addressing Issue 1 are necessary to adequately detect development of stress corrosion cracking in 7079 aluminum chords.
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 Boeing Service Bulletin 707-A3313 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 7 of 38
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 Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1 are related to this service bulletin.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 8 of 38 BOEING SERVICE BULLETIN A3515
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BOEING SERVICE BULLETIN A3515
ALERT ALERT
LEFRONT SPAR
STAB STA
92.55
CREAR SPAR
STAB STA
182.55 - ELEVATOR HINGE
STAB STA
272.55 CHORD A-A
LEFT HORIZONTAL STABILIZER SHOWN,
RIGHT OPPOSITE
DEFINE CHORD MATERIAL INSPECT CHORDS 496408
REPAIR AS NECESSARY Original Issue: December 19, 2007 Revision 1: October 10, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3515 Work - See page 1 for details. 9 of 38
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 10 of 38 BOEING SERVICE BULLETIN A3515
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BLANK PAGE
Commercial Airplanes 707 Service Bulletin ALERT Number: A3515 Original Issue: December 19, 2007 Revision 1: October 10, 2014 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.
DESCRIPTIONCONFIGURATIONGROUP All horizontal stabilizer rear spar chords made from 7079-T6.-1 Horizontal stabilizer rear spar upper inboard and upper outboard chords made of 7079-T6.
-2 Left side horizontal stabilizer rear spar upper inboard chords made from 7079-T6.
-3 All horizontal stabilizer rear spar chords made from 7075-T73511.-4 Airplane Models:
707-300, 707-300B, 707-300C, 707-400 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 11 of 38
GroupVariable Number 102001 - 02020 102101 - 02121 102201 - 02207 102301 - 02303 102401 - 02418 104001 - 04005 104020 - 04022 104101 - 04106 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 406451 406461 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 12 of 38 BOEING SERVICE BULLETIN A3515