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GroupVariable Number 107001 - 07017 107041 - 07059 107071 - 07081 107101 - 07109 107181 107191 107201 - 07208 107210 107212 - 07215 107251 - 07271 107401 - 07407 107451 - 07458 107501 - 07504 107601 - 07626 107661 - 07662 107681 - 07684 107701 - 07702 107801 - 07821 107901 - 07907 108001 - 08008 108021 108051 - 08056 108071 - 08077 108101 - 08104 108121 - 08129 108141 - 08144 108151 - 08153 108171 - 08173 108191 - 08192 108201 - 08208 308209 - 08210 108221 - 08224 108241 - 08244 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 13 of 38 BOEING SERVICE BULLETIN A3515
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GroupVariable Number 108251 108261 108271 108301 - 08320 108324 - 08330 108333 108401 - 08410 108451 - 08452 108471 - 08475 108501 - 08502 108551 - 08553 108581 - 08582 109001 - 09006 109101 - 09102 309103 - 09105 409106 - 09107 409161 - 09167 109201 - 09202 209203 409204 309221 - 09223 409227 209231 309232 409251 409271 409281 409286 - 09290 409411 409421 409438 409441 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 14 of 38 BOEING SERVICE BULLETIN A3515
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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 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.
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.
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Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 15 of 38 BOEING SERVICE BULLETIN A3515
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Revision 1 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.
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.
Revision 1 - No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 3-93, 3-94707-300, 707-300B, 707-300C, 707-400 Group 2-3:
Affected Maintenance Zones ZoneModel 3-93, 3-94707-300C Group 4:
Affected Maintenance Zones ZoneModel 3-93, 3-94707-300B, 707-300C E. Compliance Federal Aviation Administration (FAA) Airworthiness Directives AD 2012-17-13 and AD 85-12-01 R1 are related to this service bulletin.
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Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 16 of 38 BOEING SERVICE BULLETIN A3515
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Boeing recommends the following:
Applicable to all rear spar chord segments (upper inboard, upper outboard, lower inboard, lower outboard and center) made from 7079, do the Part 6 - Chord Replacement within 48 months after the Revision 1 date of this service bulletin.
Table 1: Determine Flight Cycles and Material of Horizontal Stabilizer Rear Spar Chord Segments Repeat Interval (Not to Exceed) Compliance TimeActionCondition -At time of original service bulletin release.
Determine flight cycles as given in Accomplishment Instructions paragraph 3.B.1. Part 1.
All airplanes 180 calendar days or 250 flight cycles, whichever occurs first. (a) Within 180 calendar days after the original release date of this service bulletin.
Determine material of the left and right side horizontal stabilizer rear spar chord segments as given in Accomplishment Instructions Paragraph 3.B.2. Part 2. (c) All airplanes N/ABefore further flight following the horizontal stabilizer replacement.
Airplanes on which the horizontal stabilizer is being replaced with a different horizontal stabilizer.
--Inspect and repair the horizontal stabilizer rear spar chord segments made from 7075 as given in Table 2. (b) (c) Airplanes with horizontal stabilizer rear spar chord segments made from 7075 as found in the Accomplishment Instructions Paragraph
3.B.2 Part 2. (c) --Inspect and repair the horizontal stabilizer rear spar chord segments made from 7079 as given in Table 3. (b) (c) Airplanes with horizontal stabilizer rear spar chord segments made from 7079 as found in the Accomplishment Instructions Paragraph
3.B.2 Part 2. (c)
(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."
(b) If you have a mixture of 7075 chord segments and 7079 chord segments, use Tables 2 and 3.
(c) Spar chord segments are as defined in APPENDIX A.
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Table 2: Inspect and Repair Horizontal Stabilizer Rear Spar Upper Inboard Chord Segments Made From 7075 Material Repeat Interval (Not to Exceed) Compliance TimeActionCondition 500 flight cycles.
(a) Within 180 calendar days or 500 flight cycles after the original release date of this service bulletin, whichever occurs first. (a) (c) Inspect and repair the upper inboard chord segment from stabilizer station -13.179 to 92.55 as given in Accomplishment Instructions Paragraph 3.B.3. Part 3. (d) Airplanes with horizontal stabilizer rear spar upper inboard chord segment made from 7075. (d) N/ABefore further flight following the horizontal stabilizer replacement.
(c) Airplanes on which the horizontal stabilizer is being replaced with a different horizontal stabilizer having the upper inboard chord segment made from 7075. (d) 500 flight cycles.
(a) Within 4000 flight cycles after the date of upper chord inboard segment replacement. (a) (d) Inspect and repair the upper inboard chord segment from stabilizer station -13.179 to 92.55 as given in Accomplishment Instructions Paragraph 3.B.3. Part 3. (b)
(d) Airplanes on which the horizontal stabilizer rear spar upper inboard chord segment is replaced as given in Accomplishment Instructions Paragraph 3.B.6 Part 6.
(d)
(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."
(b) Continued inspections are only necessary for rear spar upper inboard chord segments made from 7075.
Continued inspections are not necessary for other spar chord segments replaced with 7075 parts.
(c) When you replace the rear spar upper inboard chord segment as given in Accomplishment Instructions Paragraph 3.B.6 Part 6, you can defer that chord segment inspection given in Accomplishment Instructions Paragraph 3.B.3. Part 3 for a maximum of 4,000 flight cycles.
(d) Spar chord segments are as defined in APPENDIX A.
Table 3: Inspect and Repair Horizontal Stabilizer Rear Spar Upper and Lower Chord Segments Made From 7079 Material Repeat Interval (Not to Exceed) Compliance TimeActionCondition 180 calendar days or 250 flight cycles, whichever occurs first. (a) Within 180 calendar days or 250 flight cycles after the original release date of this service bulletin, whichever occurs first. (a) Inspect and repair the upper inboard chord segment from stabilizer station -13.179 to 92.55 as given in Accomplishment Instructions Paragraph 3.B.3. Part 3. (c) Airplanes with horizontal stabilizer rear spar upper inboard chord segment made from 7079. (c) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table 3: Inspect and Repair Horizontal Stabilizer Rear Spar Upper and Lower Chord Segments Made From 7079 Material Repeat Interval (Not to Exceed) Compliance TimeActionCondition 180 calendar days or 1000 flight cycles, whichever occurs first. (a) Within 180 calendar days or 1000 flight cycles after the original release date of this service bulletin, whichever occurs first. (a) Inspect and repair the web flanges of the rear spar upper and lower chord segments made from 7079, from stabilizer station 92.55 to 272.55 as given in Accomplishment Instructions Paragraph
3.B.4. Part 4. (b) (c) Airplanes with any of the following horizontal stabilizer rear spar chord segments made from 7079:
upper inboard, upper outboard, lower inboard, lower outboard. (c) Inspect and repair the forwardskin flanges of the rear spar upper and lower chord segments made from 7079, from stabilizer station -13.179 to 272.55 as given in Accomplishment Instructions Paragraph 3.B.5. Part 5. (b) (c) N/ABefore further flight following the horizontal stabilizer replacement.
(c) Do the Part 6 - Chord Replacement, for all rear spar chord segments made from 7079. (c) Airplanes on which the horizontal stabilizer is being replaced with a different horizontal stabilizer having rear spar chord segments made from 7079. (c) -Before further flight.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.
Airplanes with horizontal stabilizers that have rear spar chord segments made from 7079 for which the Service Bulletin 707- 3381 Part II - Preventative Modification is not completed. (c)
(a) See Part 1 - Cycle Counting Procedure for definition of "cycles."
(b) Only those chord segments 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. Chord segments 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.
(c) Spar chord segments are as defined in APPENDIX A.
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Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 19 of 38 BOEING SERVICE BULLETIN A3515
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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 R1. The inspections contained in this service bulletin have been reviewed and approved by the Manager of the FAA Seattle Aircraft Certification Office as an alternative method of compliance to the requirements of Paragraph A of AD 85-12-01 R1 for SSID items 55-A25-03, 55-A35-03 and 55-A45-03 covered by this service bulletin. All other provisions of AD 85-12-01 R1 that are not specifically referenced above remain fully applicable and must be complied with.
In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the flight cycle counting procedures, inspections or modifications defined in this service bulletin as an alternative method of compliance to the requirements of paragraphs (g), (h), (i), (j), (k), (l), and (m) of AD 2012-17-13 pertaining to Boeing Alert Service Bulletin 707 A3515, dated December 19, 2007. When the service bulletin specifies contacting Boeing for repair instructions, the repair must be approved by the FAA in accordance with paragraph (n) of the AD. All provisions of AD 2012-17-13 that are not specifically referenced in this paragraph remain fully applicable and must be complied with accordingly.
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.
Elapsed HoursTask HoursNumber of Persons Task
0.51.02Open Access
(a)(a)-Part 1
0.5(b)1.0(b)2Part 2
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Elapsed HoursTask HoursNumber of Persons Task
8.032.04Part 4
6.024.04Part 5
(c)(c)(c)Part 6
0.51.02Close Access
(d)(d)TOTAL FOR EACH AIRPLANE
(a) Considered Lost Time. Not able to estimate.
(b) Covers conductivity test only, does not include maintenance record review.
(c) No estimate is available.
(d) No total is given because of the variability in time required for Part 1, Part 2 and Part 6 activities.
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. Boeing Service Bulletin 707-3356, 707-3381
c. Service Related Problem (SRP) 707-SRP-55-0033.
d. 707 Supplemental Structural Inspection Document (SSID) D6-44860, Revision P, Item 55-A25-03, 55-A35-03 and 55-A45-03.
e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2012-17-13, 85-12-01 R1
f. Standard Overhaul Practices Manual (SOPM) 20-41-05
g. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-12, 20-10-19
h. 707, 720 Non-Destructive Testing (NDT) Manual Part 1, 51-01-00, Part 6, 51-00-00, Part 6, 55-10-07
i. 707 Aircraft Maintenance Manual (AMM) 27-07-31 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 21 of 38 BOEING SERVICE BULLETIN A3515
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2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None.
K. Publications Affected None.
L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary Not affected.
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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:
NotesNameQTYPart Number / Specification
(a) (d)Upper Chord, Inboard, Left Side165-95600-887
(a) (e)Upper Chord, Inboard, Right Side165-95600-888
(a) (f)Lower Chord, Inboard, Left Side165-95600-701
(a) (g)Lower Chord, Inboard, Right Side165-95600-702
(a) (j)Center Rear Spar, Left Side165-95600-703
(a) (k)Center Rear Spar, Right Side165-95600-704
(a) (h)Upper Chord, Outboard, Left Side165C80665-165
(a) (h)Lower Chord, Outboard, Right Side165C80665-165
(a) (i)Lower Chord, Outboard, Left Side165C80665-166
(a) (i)Upper Chord, Outboard, Right Side165C80665-166
(b)Corrosion Inhibiting compound1 PintBMS 3-23 Type II
(a) Discard the existing part.
(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
(c) This note has been deleted.
(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.
(j) 65-95600-703 is the same as 65-3323-27 plus two 66-11433-2 bushings.
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NotesNameQTYPart Number / Specification
(k) 65-95600-704 is the same as 65-3323-28 plus two 66-11433-2 bushings.
3. Parts Modified and Reidentified:
None.
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, 720 NDT Manual Part 1, 51-01-00.
– 8MIT65-6088 – 9MIT65-6088 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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