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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. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque limits to tighten nuts and bolts are in SRM Chapter 51
4. Use the approved fastener and process material substitutions in accordance with SRM Chapter 51. Alternate fasteners are listed in SRM Chapter 51.
5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.
6. The necessary conditions for selection of clamp type and size are included in SWPM 20-10-12. If any wire bundle support clamp specified in this service bulletin does not make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted procedure to select a clamp that fits correctly.
7. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51.
8. These work instructions refer to procedures included in 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 "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.
9. Boeing Service Letter 707-SL-51-029 Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided.
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10. Refer to APPENDIX A, for configuration verification, inspection, material data results form..
11. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools.
12. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed.
13. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part.
The removed part can be discarded if a new or serviceable part is installed.
14. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems.
15. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data.
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
a. Refer to APPENDIX A for definition of the inboard and outboard segments of the left and right horizontal stabilizer rear spar upper and lower chords. Determine the material of all of the spar chord segments listed in APPENDIX A using one of the following methods.
(1) Review the airplanes 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).
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(2) Do a conductivity test to determine whether each upper chord and lower chord segment on the horizontal stabilizer rear spar listed in APPENDIX A is made from 7079-T6 or 7075-T73511 material in accordance with 707, 720 NDT, Part 6, 51-00-00, Figure 20, dated April 5, 2004.
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 92.55.
Upper Chords, Horizontal Stabilizer Rear Spar, Inboard Segment, Made From 7075 and 7079
a. Do a special detailed inspection of the upper chord.
(1) Inspect for cracks in the forward flange of the chord along the fasteners common to the skin. Inspect from the inboard edge of the inspar skin to 25.5 inches outboard in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 1.
(2) Inspect for cracks in the space between the inspar skin and the forward edge of the exposed upper surface of the chord. Inspect from the side of the body outboard to Stabilizer Station 92.55 in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 2.
(3) Inspect for cracks in the space between the trailing edge skin and the aft edge of the exposed upper surface of the chord. Inspect from the side of the body outboard to Stabilizer Station 92.55 in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 2.
(4) Inspect for cracks in the aft flange of the chord along the fasteners common to the skin.
Inspect from the inboard edge of the trailing edge skin to 25.5 inches outboard in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 3.
(5) Inspect for cracks along the forward and aft edges of the exposed upper surface of the chord. Inspect from the side of the body outboard to Stabilizer Station 92.55 in accordance with 707, 720 NDT Manual Part 6, 55-10-07, Figure 7.
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 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 27 of 38 BOEING SERVICE BULLETIN A3515
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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.
c. Do a High Frequency Eddy Current (HFEC) inspection of the web flanges of the upper and lower chords 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 Boeing Service Bulletin 707-3356 and has been repaired according to Boeing Service Bulletin 707-3356.
1) For each crack that meets the limits of Boeing 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 Boeing Service Bulletin 707-3356, Part III - Repair Paragraph C, determine if the crack still meets the limits of Boeing 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 Boeing Service Bulletin 707-3356, Part III - Repair Paragraph C, but is not repaired as given in Boeing Service Bulletin 707-3356, Part III - Repair Paragraph C, accomplish the repair as given in Boeing 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) The crack must terminate in an existing fastener hole.
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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.
4) For a crack that meets the limits of Boeing Service Bulletin 707-3356, Part III - Repair Paragraph D, accomplish the repair according to Boeing Service Bulletin 707-3356, Part III - Repair Paragraph D, unless already accomplished.
5) For a crack that does not meet the limits defined in the preceding paragraphs
1., 2., 3., & 4. above, contact Boeing for new repair instructions.
(b) Determine if all 7079 upper and lower chord segments installed on the horizontal stabilizer have had Boeing Service Bulletin 707-3356 Part II, Group 1 Preventative Modification done. If not yet accomplished, do the Boeing Service Bulletin 707-3356 Part II, Group 1 Preventative Modification on all 7079 chord segments still installed on the horizontal stabilizer.
NOTE: Boeing 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 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 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 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 between stabilizer station
92.55 and 182.55 for cracks as given in FIGURE 5.
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f. Do a LFEC inspection of the forward skin flange of the lower chord 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. 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 applicable rear spar chord segment or segments according to standard procedures and instructions supplied with the applicable parts kits and tooling. Reference assembly drawing 65-3321, 65-3322 and 65-3323 for the rear spar upper, lower and center inboard chords respectively.
b. Upon completion of chord replacement, revise the data on the APPENDIX A data sheet to match the chord configuration currently on the airplane.
c. Retain the updated APPENDIX A data sheet with the airplane records Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1: October 10, 2014 30 of 38 BOEING SERVICE BULLETIN A3515
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BOEING SERVICE BULLETIN А3515
ALERT ALERT ¡EFRONT SPAR
STAB STA
47.55
STAB STA
92.55
CREAR SPAR
STAB STA
137.55
STAB STA
182.55 •@ELEVATOR
STAB STA HINGE
227.55
STAB STA
272.55
BALANCE CHORD BALANCE BAY NO.O BAY NO.1 1101 102. 101 101 101 BALANCE BALANCE BAY NO.2 BAY NO.4 BALANCE BALANCE BAY NO.3 BAY NO.5 A-A
LEFT HORIZONTAL STABILIZER SHOWN,
RIGHT OPPOSITE 496234 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 (SHEET 1 OF 2) Original Issue: December 19, 2007 Revision 1 October 10, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING A3515 Work - See page 1 for details. 31 of 38
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP --Number 2, 3, 4 and 5Balance BayAccess1 See Table 1.(a)2-Chord Web FlangeInspect2
(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 in accordance with 707, 720 NDT, Part 6, 51-00-00, Figure 4.
Table 1 Balance Bay to Inspect7079 Chord Segment 2,3Upper Inboard 2,3Lower Inboard 4,5Upper Outboard 4,5Lower Outboard 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 (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 19, 2007 A3515Revision 1 October 10, 2014 32 of 38 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.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)2-Forward Skin FlangeInspect1
(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 in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
FIGURE 2: HORIZONTAL STABILIZER - REAR SPAR - UPPER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION (SHEET 1 OF 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 33 of 38 BOEING SERVICE BULLETIN A3515
ALERTALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear spar upper inboard chord forward skin flange between stabilizer station 92.55 and 182.55 for any cracking in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
FIGURE 3: HORIZONTAL STABILIZER - REAR SPAR - UPPER INBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION (SHEET 1 OF 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 34 of 38 BOEING SERVICE BULLETIN A3515
ALERTALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear spar lower outboard chord forward skin flange between stabilizer station 182.55 and 272.55 for any cracking in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
FIGURE 4: HORIZONTAL STABILIZER - REAR SPAR - LOWER OUTBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 182.55 TO STABILIZER STATION 272.55 - INSPECTION (SHEET 1 OF 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 35 of 38 BOEING SERVICE BULLETIN A3515
ALERTALERT
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a) (b)2-Forward Skin FlangeInspect1
(a) Do a Low Frequency Eddy Current (LFEC) inspection of the left and right side horizontal stabilizer rear spar lower inboard chord forward skin flange between stabilizer station 92.55 and 182.55 for any cracking in accordance with 707, 720 NDT, Part 6, 55-10-07, Figure 8.
(b) Exclude inspection of areas not accessible due to interference with any vortex generators mounted on the lower surface. However, if any cracks are found at any of the first six (6) inspectable fasteners on either side of the vortex generator, remove the vortex generator and inspect all fastener locations.
FIGURE 5: HORIZONTAL STABILIZER - REAR SPAR - LOWER INBOARD CHORD - FORWARD SKIN FLANGE - STABILIZER STATION 92.55 TO STABILIZER STATION 182.55 - INSPECTION (SHEET 1 OF 1) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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