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Commercial Airplane Group 707 Service Bulletin ALERT Number: A3524 Date: July 18, 2007 Revision 1: September 18, 2008 ATA System: 5330 SUBJECT: FUSELAGE - Main Fuselage Section - Inspection for Stress Corrosion Cracks in Body Station 600K/620 and 820 Body Terminal Fittings.
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the 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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007 A3524Revision 1: September 18, 2008 1 of 68
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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 7 E. Compliance .............................................. 1 8 F . Approval ............................................... 2 2 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 4 I. Electrical Load Data ......................................... 2 4 J. References .............................................. 2 4
1. Existing Data: .......................................... 2 4
2. Data supplied with this Service Bulletin: ........................... 2 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 4 K. Publications Affected ......................................... 2 5 L. Interchangeability and Intermixability of Parts ........................... 2 5
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary For Each Airplane ................................. 2 7
1. Kits/Parts: ............................................ 2 7
2. Parts and Materials Supplied by the Operator: ........................ 2 7
3. Parts Modified and Reidentified: ................................ 2 7
4. Parts Removed and Not Replaced: .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 7 F . Special Tooling Necessary to do this Service Bulletin ....................... 2 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 2 9 FIGURE 1: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 620. [Group 1] .... 3 7 FIGURE 2: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 620. [Group 1] .... 4 0 FIGURE 3: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K. [Group 2-3] . . 43 FIGURE 4: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K. [Group 2-3] . . 46 FIGURE 5: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 820. .......... 4 9 FIGURE 6: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 820. ......... 5 3 FIGURE 7: LEFT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820. [Group 1 ] ................................................ 5 7 FIGURE 8: RIGHT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820. [Group 1 ] ................................................ 6 0 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 9: LEFT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820. [Group 2-4] ............................................... 6 3 FIGURE 10: RIGHT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820. [Group 2-4] ............................................... 6 6 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007 A3524Revision 1: September 18, 2008 4 of 68 BOEING SERVICE BULLETIN A3524
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Commercial Airplane Group 707 Service Bulletin ALERT Revision Transmittal SheetNumber: A3524Date: July 18, 2007 Revision 1: September 18, 2008 ATA System: 5330 SUBJECT: FUSELAGE - Main Fuselage Section - Inspection for Stress Corrosion Cracks in Body Station 600K/620 and 820 Body Terminal Fittings.
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed as shown in the original issue of this service bulletin. Ultrasonic inspection of the left and right STA 820 body terminal fittings for internal cracking is necessary.
Airplane variable numbers 08553 and 08206 are added to Group 4 of this service bulletin effectivity.
REASON FOR REVISION This revision is sent to correct the grouping of 707-300/-300B/-300C/-400 airplanes. This revision is also sent to give instruction for the ultrasonic inspection of the left and right Body Station (STA) 820 body terminal fittings for internal cracking.
These sections were changed:
1. Paragraph 1.A., Effectivity: 707-300/-300B/-300C/-400 airplanes in the original issue of this service bulletin are moved to groups 2 and 3. Group 2 airplanes are common to the effectivity of Boeing Service Bulletin 707-2912. Group 3 airplanes are not common to the effectivity of Boeing Service Bulletin 707-2912. Group 4 is added for airplane variable numbers 08553 and 08206 (line numbers 866 and 867) which require inspection of the STA 820 body terminal fittings only.
2. Paragraph 1.C., Reason: References to airplane groups are updated.
3. Paragraph 1.D., Description: Information is added for the ultrasonic inspections. Maintenance zone data is added.
4. Paragraph 1.E., Compliance: Existing compliance information is put in tables. Compliance information is added for the ultrasonic inspections.
5. Paragraph 1.G., Manpower: Estimates are added for the the ultrasonic inspections.
6. Paragraph 1.J., References: Reference to 707 Nondestructive Test (NDT) Manual Part 4, 53-10-07 is added to Existing Data.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007 A3524Revision 1: September 18, 2008 5 of 68
7. Paragraph 2.C.2., Parts Necessary For Each Airplane: The quantity of Corrosion Inhibiting Compound is increased.
8. Paragraph 3.B., Work Instructions: Instructions are added for the ultrasonic inspection and repair/replacement of the STA 820 body terminal fitting.
9. Figures 1 to 6: Instructions to use SOPM 20-41-05 are changed from mandatory to reference.
10. Figures 7 to 10: These figures are added for the ultrasonic inspections.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY July 18, 2007Original Issue:
September 18, 2008Revision 1:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007 A3524Revision 1: September 18, 2008 6 of 68 BOEING SERVICE BULLETIN A3524
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Commercial Airplane Group 707 Service Bulletin ALERT SummaryNumber: A3524Date: July 18, 2007 Revision 1: September 18, 2008 ATA System: 5330 SUBJECT: FUSELAGE - Main Fuselage Section - Inspection for Stress Corrosion Cracks in Body Station 600K/620 and 820 Body Terminal Fittings.
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 Accomplishment of this service bulletin will detect any cracks and corrosion in the body terminal fittings at Body Station (STA) 620 for group 1 airplanes, STA 600K for group 2 and 3 airplanes and at STA 820 for all airplanes.
This will help to maintain the structural integrity of the body terminal fittings at these body stations. Undetected cracks in the body terminal fittings can result in loss of support for the wing since the body terminal fittings provide the necessary support for the wings.
Boeing has received reports of cracks, found in the body terminal fittings during routine inspection. The cracks found at several locations in the body terminal fittings above and below the floor are attributed to stress corrosion.
The fittings are forgings made from 7079-T6 material.
This service bulletin gives instructions to inspect the body terminal fittings at STA 620 for group 1 airplanes, at STA 600K for group 2 and 3 airplanes and at STA 820 for all airplanes for any crack or corrosion and to repair or replace the fittings as necessary.
The STA 620 or STA 600K body terminal fittings on airplanes after Line Number 865 and STA 820 body terminal fittings on airplanes after Line Number 867 are made from 7075-T73 material and do not need to be inspected as given in this service bulletin.
Boeing Service Related Problem 707-SRP-53-0217 and 707-SRP-53-0307 are related to this service bulletin.
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July 18, 2007 A3524Revision 1: September 18, 2008 7 of 68
ACTION Group 1: Open the air conditioning equipment access doors to get access to the body terminal fittings at Body Station (STA) 620 below cabin floor level. Remove side wall panels, internal lining and insulation blankets at STA 620 to access the body terminal fittings above the cabin floor. Do a detailed inspection for any crack or corrosion on the flange and webs of the left and right body terminal fittings at STA 620 below and above the cabin floor level. If a body terminal fitting has a previous repair installed, do a detailed inspection of the repair for any crack or corrosion. If any crack or corrosion is found, contact Boeing for repair instructions or for instructions to replace the 7079-T6 body terminal fitting with a 7075-T73 body terminal fitting.
Group 2-3: Open the air conditioning equipment access doors to get access to the body terminal fittings at Body Station (STA) 600K below cabin floor level. Remove side wall panels, internal lining and insulation blankets at STA 600K to access the body terminal fittings above the cabin floor. Do a detailed inspection for any crack or corrosion on the flange and webs of the left and right body terminal fittings at STA 600K below and above the cabin floor level. If a body terminal fitting has a previous repair installed, do a detailed inspection of the repair for any crack or corrosion. If any crack or corrosion is found, contact Boeing for repair instructions or for instructions to replace the 7079-T6 body terminal fitting with a 7075-T73 body terminal fitting.
All Groups: Get access to the body terminal fittings at STA 820 below cabin floor level through the main gear wheel well. Remove side wall panels, internal lining and insulation blankets at STA 820 to access the body terminal fittings above the cabin floor. Do a detailed inspection for any crack or corrosion on the flange and webs of the 7079-T6 left and right body terminal fittings at STA 820 below and above the cabin floor level. If a body terminal fitting has a previous repair installed, do a detailed inspection of the repair for any crack or corrosion.
If any crack or corrosion is found, contact Boeing for repair instructions or for instructions to replace the 7079-T6 body terminal fitting with a 7075-T73 body terminal fitting.
All Groups: Get access to the body terminal fittings at STA 820 below cabin floor level through the main gear wheel well. Do an ultrasonic inspection for any internal crack within the outboard flange of the left and right body terminal fittings at STA 820 above and below Stringer 18A. If any crack is found, repair the fitting as given in this service bulletin, contact Boeing for instructions to repair the fitting or contact Boeing for instructions to replace the 7079-T6 body terminal fitting with a 7075-T73 body terminal fitting.
Do the inspections again at the specified interval.
NOTE: Prior or concurrent incorporation of 707 service bulletins 1966, "FUSELAGE - Station 820 Bulkhead Fitting Modification" and 2912, "FUSELAGE - Station 820 Body Terminal Fitting Inspection, Modification and Repair" is suggested on commonly affected airplanes due to common access.
EFFECTIVITY 707-100/100B/200/300/300B/300C/400, 720, 720B Series Airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections given in this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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MANPOWER Elapsed HoursTotal Task HoursAirplanes
22.553Group 1 airplanes 2354Group 2 and 3 airplanes 1844Group 4 airplanes
MATERIAL INFORMATION None.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN A3524
ALERT ALERT STA 600K (GROUPS 2 AND 3) STA 620 (GROUP 1) STA 820 GROUPS 1-3:
DO A DETAILED INSPECTION FOR
ANY CRACK OR CORROSION ON
THE FLANGES AND WEBS OF THE
LEFT AND RIGHT BODY TERMINAL FITTINGS.
IF ANY CRACK OR CORROSION IS
FOUND, REPAIR OR REPLACE THE FITTING.
ALL GROUPS:
DO A DETAILED INSPECTION FOR
ANY CRACK OR CORROSION ON
THE FLANGES AND WEBS OF THE
LEFT AND RIGHT BODY TERMINAL FITTINGS.
DO AN ULTRASONIC INSPECTION
FOR ANY CRACK WITHIN THE
OUTBOARD FLANGE OF THE LEFT
AND RIGHT BODY TERNINAL FITTINGS.
IF ANY CRACK OR CORROSION IS
FOUND, REPAIR OR REPLACE THE FITTING.
July 18, 2007 Revision 1: September 18, 2008 A3524 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 68
Commercial Airplane Group 707 Service Bulletin ALERT Number: A3524 Date: July 18, 2007 Revision 1: September 18, 2008 ATA System: 5330 SUBJECT: FUSELAGE - Main Fuselage Section - Inspection for Stress Corrosion Cracks in Body Station 600K/620 and 820 Body Terminal Fittings.
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 Refer to Service Bulletin Index Document D6-1647 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP 707-100/100B/200, 720, 720B series airplanes, line numbers 1 through 801. These airplanes have 7079-T6 Body Terminal Fittings at Body Station (STA) 620 and STA 820 and are common to the effectivity of Boeing Service Bulletin 707-2912 Revision 1.
-1 707-300/-300B/-300C/-400 series airplanes, line numbers 13 through
827. These airplanes have 7079-T6 Body Terminal Fittings at STA 600K and STA 820 and are common to the effectivity of Boeing Service Bulletin707-2912 Revision 1.
-2 707-300/-300B/-300C/-400 series airplanes, line numbers 828 through
865. These airplanes have 7079-T6 Body Terminal Fittings at STA 600K and STA 820 and are not common to the effectivity of Boeing Service Bulletin 707-2912 Revision 1.
-3 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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DESCRIPTIONCONFIGURATIONGROUP 707-300C series airplanes, line numbers 866 and 867. These airplanes have 7079-T6 Body Terminal Fittings at STA 820 and are not common to the effectivity of Boeing Service Bulletin 707-2912 Revision 1.
-4 Airplane Models:
707-100, 707-100B, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B GroupVariable Number 100001 - 00006 100101 - 00156 100201 - 00205 100301 - 00305 100401 - 00451 100471 - 00475 100501 - 00513 100601 - 00602 100701 - 00703 202001 - 02020 202101 - 02121 202201 - 02207 202301 - 02303 202401 - 02418 204001 - 04005 204020 - 04022 204101 - 04106 204201 - 04218 204271 - 04272 204301 - 04303 205001 - 05060 205101 - 05138 205201 - 05208 205301 - 05312 205401 205601 - 05605 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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