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April 04, 2008 A3516 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 22 BOEING SERVICE BULLETIN A3516
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06101 1 06401–06404 1 06451 1 06461 1 07001–07017 1 07041–07059 1 07071–07081 1 07101–07109 1 07181 1 07191 1 07201–07208 1 07210 1 07212–07215 1 07251–07271 1 07401–07407 1 07451–07458 1 07501–07504 1 07601–07626 1 07661–07662 1 07681–07684 1 07701–07702 1 07801–07821 1 07901–07907 1 08001–08008 1 08021 1 08051–08056 1 08071–08077 1 08101–08104 1 08121–08129 1 08141–08144 1 08151–08153 1 08171–08173 1 08191–08192 1 08201–08210 1 08221–08224 1 08241–08244 1 08251 1 08261 1 08271 1 Variable Group
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08301–08320 1 08324–08330 1 08333 1 08401–08410 1 08451–08452 1 08471–08475 1 08501–08502 1 08551–08553 1 08581–08582 1 09001–09006 1 09101–09107 1 09161–09167 1 09201–09204 1 09221–09223 1 09227 1 09231–09232 1 09251 1 09271 1 09281 1 09286–09290 1 09411 1 09421 1 09438 1 09441 1 B0001–B0029 1 B0101–B0125 1 B0201–B0203 1 B0301–B0306 1 B0401–B0402 1 B0501–B0515 1 B2001–B2008 1 B2091–B2092 1 B2101–B2116 1 B2191–B2194 1 B2199 1 B2201–B2227 1 B2401–B2403 1 Variable Group
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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.
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.
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.
D. Description 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.
B2501–B2502 1 B2551–B2553 1 B2601–B2608 1 Variable Group
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E. 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.
Boeing recommends the following:
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.
G. Manpower See Supplemental Structural Inspection Document, D6-44860 for manpower requirements.
H. Weight and Balance Changes None.
I. Electrical Load Data Not applicable.
Table 1: Determine Flight Cycles And Horizontal Stabilizer Inspection Procedures Condition Action Compliance Time (Whichever Occurs First) Repeat Interval (Not to Exceed) All airplanes. Determine flight cycles as given in Accomplishment Instructions Paragraph
3.B.1. Part 1.
At time of service bulletin release.
- All airplanes effective for any of the Supplemental Structural Inspection Document (SSID) details listed in Accomplishment Instructions Paragraph
3.B.2 Part 2. Table 1.
Do the inspection procedures as given in Accomplishment Instructions Paragraph
3.B.2. Part 2.
Within 180 calendar days after the date on this service bulletin.
Within 1000 flight cycles after the date on this service bulletin. (a) At the time as given in the D6- 44860, 707 Supplemental Structural Inspection Document. (a)
(a) See Accomplishment Instructions Paragraph 3.B.1. Part 1 -Cycle Counting Procedure for definition of “cycles.”
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J. References
1. Existing Data:
a. Engineering Change Memo PRR 18101-2RS.
b. Service Related Problem (SRP) 707-SRP-55-0033.
c. 707 Supplemental Structural Inspection Document (SSID) D6-44860.
d. Boeing Service Bulletin 707A3515 “STABILIZERS - Horizontal Stabilizer - Rear Spar Upper and Lower Chords - Inspection and Repair”.
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.
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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:
None.
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 the applicable 707 SSID sections for special tooling requirements.
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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. 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.
B. WORK INSTRUCTIONS
1. Part 1 - Cycle Counting Procedure
a. Determine flight cycles.
NOTE: The term “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 - Inspection Procedure
a. At the times specified in paragraph 1.E - Compliance, do the inspection procedures for each applicable detail listed in Table 1 below.
TABLE 1: Inspection Procedures Structurally Significant Item (SSI) D6-44860 Rev. P Section D6-44860 Rev. P Page(s) 55-A00-01, 55-A10-01, 55-A20-01, 55-A30-01, 55-A40-01 7.5 3 55-A00-02, 55-A10-02, 55-A20-02, 55-A30-02, 55-A40-02 7.5 4-5 55-A10-03 7.5 6 55-A00-04, 55-A10-04 8.5 3-4 55-A00-05, 55-A10-05 8.5 5 55-A20-05, 55-A30-05, 55-A40-05 8.5 6
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b. Put the airplane back to a serviceable condition.
55-A05-01, 55-A15-01 8.5 7-8 55-A25-01, 55-A35-01, 55-A45-01 8.5 9-10 55-A05-02, 55-A15-02 8.5 11 55-A25-02, 55-A35-02, 55-A45-02 8.5 12 55-A05-03, 55-A15-03 8.5 13 TABLE 1: Inspection Procedures Structurally Significant Item (SSI) D6-44860 Rev. P Section D6-44860 Rev. P Page(s)