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Page 1Open in PDF

April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 22

ALERT ALERT Commercial Airplane Group 707

ALERTALERT Service Bulletin Number: A3516 Date: April 04, 2008 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer and Horizontal Stabilizer Center Section - Inspections

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery 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.

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BLANK PAGE April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 22 BOEING SERVICE BULLETIN A3516

ALERT ALERT

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Page 3Open in PDF

Table of Contents April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 22 BOEING SERVICE BULLETIN A3516

ALERT ALERT

Table of Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 17 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 19

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 19

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Table of Contents April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 22 BOEING SERVICE BULLETIN A3516

ALERT ALERT

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Page 5Open in PDF

April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 22

ALERT ALERT Commercial Airplane Group 707

ALERTALERT Service Bulletin Number: A3516 Summary Date: April 04, 2008 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer and Horizontal Stabilizer Center Section - Inspections

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.

Service bulletin 707A3516 is issued to call for inspections of 707 horizontal stabilizer details listed in the Supplemental Structural Inspection Document that are exposed to an accelerated fatigue environment. This accelerated fatigue environment is generated by frequent use of the affected airplanes for training flights that include multiple touch-and-go cycles. This frequent use of the airplane for this type of training has been most prevalent by the military operators of commercial model 707 and 720 airplanes.

Boeing has received three reports of fatigue cracking in the rear spar upper chord, at a location near side of body. In all cases the fatigue prevention and fail-safe improvement modifications of service bulletin 707A3313 had been incorporated. The fatigue cracking is considered to be early in the life of the modified structure, and is generated by frequent use of the effective airplanes for training flights that include multiple touch-and-go cycles.

Simultaneous to the release of service bulletin 707A3516, service bulletin 707A3515 is released to specifically address fatigue cracking in the stabilizer rear spar upper chord.

The reported cracking is an indication that other details in the horizontal stabilizer installation directly affected by this type of airplane usage are more likely to develop early fatigue damage as well.

The actions of service bulletin 707A3516 are necessary to adequately detect early fatigue cracking.

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April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 22 BOEING SERVICE BULLETIN A3516

ALERT ALERT

The ability to interchange the horizontal stabilizer from airplane to airplane is of significance, since these stabilizer changes are known to occur. This makes it necessary to implement the inspections for early fatigue cracking on all affected airplanes at the time stated in the 1.E Compliance, regardless of the airplane current usage.

ACTION (PRR 18101-2RS ) Cycle Definition:

To adequately account for in-flight training maneuvers, incorporate the cycle counting procedure defined in this service bulletin.

Inspections:

Complete the inspections in accordance with the methods and times stated in this service bulletin.

EFFECTIVITY All 707 and 720 Airplanes. See Paragraph 1.A.1 for effectivity.

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.

See Service Bulletin Paragraph 1.E. for compliance information.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection procedures given in this service bulletin.

MANPOWER See Supplemental Structural Inspection Document, D6-44860 for manpower requirements.

MATERIAL INFORMATION None.

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April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 22

ALERT ALERT Commercial Airplane Group 707

ALERTALERT Service Bulletin Number: A3516 Date: April 04, 2008 ATA System: 5510 SUBJECT: STABILIZERS - Horizontal Stabilizer and Horizontal Stabilizer Center Section - Inspections

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. 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.

Airplane models:

707-100 707-100B 707-200 707-300 707-300B 707-300C 707-400 720 720B

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND NUMBER

ADC AIRLINES (ADN) 1 07816

AERO SANTAMARIA (SMK) 1 08475

AEROSPACE CONSORTIUM (CTU) 1 08223

GROUP CONFIGURATION DESCRIPTION 1 - All 707 and 720 Model Airplanes.

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AFRICAN AIRLINES (AFX) 1 05632

AGRO AIR INTERNATIONAL (AGR) 1 B0019

AIR ATLANTIC NIGERIA (NGE) 1 07042 08472

AIR GULF FALCON (GFG) 1 05961 08077

AIR MEMPHIS (MEP) 1 08405

AIR NACOIA (NAO) 1 07071 ALG TRANSPORTATION, INC. (ALW) 1 07052 07458

ARGENTINE AIR FORCE (AGF) 1 05854 06461 08310 08452

ASNET (SRC) 1 08127

AVIATION CONSULTANTS (ACT) 1 05965 07602–07603

AVIATION RESEARCH CENTRE (AVR) 1 07701–07702

BETA (BRQ) 1 07261 07270 07625 08072

BIN MAHFOOZ AVIATION (BMV) 1 08404

CARGO PLUS AVIATION (CPB) 1 08191

CHILEAN AIR FORCE (CHF) 1 05305 07619 07661

COLOMBIAN AIR FORCE (CLB) 1 07109 08582

CRYSTAL TRADING (CTR) 1 07907

DAIRO AIR SERVICES (DAR) 1 07616 07802

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DOLPHIN AIR (FDN) 1 09001

DRC PRESIDENTIAL AVIATION (ZAR) 1 00507 05824 08129

EURO OCEANIC AIR TRANSPORT (EOA) 1 08309

EXPORT RESTRICTED AIRPLANES (YWV) 1 05019 07016 08054 08101 08551–08553 09101–09107 09161–09167 09231–09232 09438

FEDERATIVE REPUBLIC OF BRAZIL (BRZ) 1 07080 08304 08308 08314

FIRST INTERNATIONAL AIRWAYS (FIW) 1 07207 09201 09203 G.M.A.S. (GMA) 1 07049

GE (GEC) 1 02017

GOVERNMENT OF ANGOLA (AGL) 1 05035 05051 06402

HEWA BORA AIRWAYS (EXD) 1 08206

HONEYWELL AEROSPACE (SGC) 1 B2109

INTERAIR (ITI) 1 07253

INTERNATIONAL AIR LEASES (IAL) 1 05125 07043 07606 07618

IRAQI AIRWAYS (IRQ) 1 09221–09223

ISRAELI AIR FORCE (ISR) 1 00304 02105 02114–02115 02203 06403 07406–07407 08243 09004 09251 09421 09441

ITALIAN AIR FORCE (ITC) 1 05823 05827 08329–08330

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JETT CLIPPER JOHNNY LLC (JCJ) 1 00513

JR EXECUTIVE (JRE) 1 B2205 B2207

KODA AIR (KGO) 1 07105 L-3 COMMUNICATIONS (LCS) 1 08172

LIBYAN AIRWAYS (LAA) 1 05037 07046 07502–07503 07819 09411 LOWA, LTD. (LOW) 1 05307

MIAMI AVIATION SERVICE (MIA) 1 06451

MIT LINCOLN LABORATORIES (MIT) 1 05009

NATO (NAT) 1 07905–07906 08221 08224

NORTHROP GRUMMAN CORPORATION (GRU) 1 07812 07817 09002

OMEGA AIR (OMG) 1 05966 07623 OMEGA AIR, INC. (OMH) 1 05055 05603 05968 08055 08209 09227 09290

PAKISTAN INT'L AIRLINES (PIA) 1 05633 07267 08144 08325

PARAGUAYAN AIR FORCE (FAP) 1 05018

PERUVIAN AIR FORCE (PRF) 1 07266

PRATT & WHITNEY CANADA (PWC) 1 B0112

PRATT & WHITNEY ENGINE SERVICE (PWE) 1 B0109

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QANTAS FOUNDATION MEMORIAL (QFM) 1 00501

ROMAVIA (ROA) 1 09202

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

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 09289

TAMRO (TMR) 1 09288

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

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IDENTIFICATION BY NUMBER Variable Group 00001–00006 1 00101–00156 1 00201–00205 1 00301–00305 1 00401–00451 1 00471–00475 1 00501–00513 1 00601–00602 1 00701–00703 1 02001–02020 1 02101–02121 1 02201–02207 1 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

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