# Boeing Service Bulletin A3524: Revision 1

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- Document: [Boeing Service Bulletin A3524](https://openairdocs.org/service-documents/boeing/a3524.md)
- Title as filed: Boeing - Alert Service Bulletin
- Pages: 68
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## Text

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### Page 1

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Unpublished Work - All Rights Reserved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.
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July 18, 2007
A3524Revision 1: September 18, 2008
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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ..................................................... 7
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
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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
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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.
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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:
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July 18, 2007
A3524Revision 1: September 18, 2008
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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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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.
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MANPOWER
Elapsed HoursTotal Task HoursAirplanes
22.553Group 1 airplanes
2354Group 2 and 3 airplanes
1844Group 4 airplanes
MATERIAL INFORMATION
None.
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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
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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.
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
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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
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GroupVariable Number
205631 - 05635
205701 - 05703
205801 - 05802
205821 - 05825
305826 - 05827
205831 - 05833
205851 - 05854
205891
305892
205921 - 05923
205941 - 05942
205961 - 05970
306001 - 06002
306101
207001 - 07017
207041 - 07059
207071 - 07081
207101 - 07109
207181
207191
207201 - 07208
207210
207212 - 07215
207251 - 07271
207401 - 07405
307406 - 07407
207451 - 07458
207501 - 07504
207601 - 07626
207661 - 07662
207681 - 07684
207701 - 07702
207801 - 07821
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number
207901 - 07906
307907
208001 - 08008
308021
208051 - 08055
308056
208071 - 08074
308075 - 08077
208101 - 08104
208121 - 08129
208141 - 08144
208151 - 08153
208171 - 08173
208191 - 08192
208201 - 08202
308203 - 08205
408206
208221 - 08224
208241 - 08243
308244
208251
208261
208271
208301 - 08318
308319 - 08320
308324 - 08330
308333
208401 - 08408
308409 - 08410
208451 - 08452
208471 - 08473
308474 - 08475
208501
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GroupVariable Number
308502
308551 - 08552
408553
208581
308582
1B0001 - B0029
1B0101 - B0125
1B0201 - B0203
1B0301 - B0306
1B0401 - B0402
1B0501 - B0515
1B2001 - B2008
1B2091 - B2092
1B2101 - B2116
1B2191 - B2194
1B2199
1B2201 - B2227
1B2401 - B2403
1B2501 - B2502
1B2551 - B2553
1B2601 - B2608
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1: September 18, 2008
15 of 68
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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.
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: All 707-300/-300B/-300C/-400 airplanes in the initial release of this
service bulletin are moved to groups 2 and 3. Group 2 airplanes are common to the effectivity of
Service Bulletin 707-2912. Group 3 airplanes are not common to the effectivity of Service Bulletin
707-2912. Group 4 is added for airplanes 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.
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.
Boeing Service Related Problem 707-SRP-53-0217 and 707-SRP-53-0307 are related to this service
bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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D. Description
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.
Group 1: 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 Body Station (STA) 820 from 7 inches above Stringer 18A down to
10 inches 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.
Group 2-4: 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 Body Station (STA) 820 from 7 inches above Stringer 18A down to
15 inches 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.
The work in this service bulletin is done in the maintenance zone(s) given below.
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Group 1:
Affected Maintenance Zones
ZoneModel
1-77707-100, 707-100B, 707-200,
720, 720B
Group 2:
Affected Maintenance Zones
ZoneModel
1-77707-300, 707-300B, 707-300C,
707-400
Group 3:
Affected Maintenance Zones
ZoneModel
1-77707-300B, 707-300C
Group 4:
Affected Maintenance Zones
ZoneModel
1-77707-300C
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.
Group 1:
Table 1: Inspections and repair/replacement of 7079-T6 body terminal fittings
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
24 months (a)within 24 months from the date on
the original issue of this service
bulletin
Do detailed inspections
of the left and right body
terminal fittings at STA
620 for any crack or
corrosion as given in
Work Instructions
paragraphs 3.B.1.c. and
3.B.1.d. (a)
All airplanes
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Group 1:
Table 1: Inspections and repair/replacement of 7079-T6 body terminal fittings
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
24 months (a)within 24 months from the date on
the original issue of this service
bulletin
Do detailed inspections
of the left and right body
terminal fittings at STA
820 for any crack or
corrosion as given in
Work Instructions
paragraphs 3.B.3.c. and
3.B.3.d. (a)
All airplanes
--No ultrasonic inspections
are required by this
service bulletin (a) (b) (c)
Airplanes that have not
been changed by Boeing
Service Bulletin 707-2912
R01 Paragraph II.,
Accomplishment
Instructions, PART II.
PREVENTIVE
MODIFICATION DATA or
PART III. REPAIR DATA
2000 flight cycles
or 24 months,
whichever occurs
first (a)
within 24 months
of the date of
Revision 1 to this
service bulletin or
within 24 months
of the date the
change was
made, whichever
occurs last
within 2000 flight
cycles of the date
of Revision 1 to
this service
bulletin or within
2000 flight cycles
of the date the
change was
made, whichever
occurs last
Do ultrasonic inspections
of the left and right body
terminal fittings at STA
820 for any internal crack
as given in Work
Instructions paragraphs
3.B.4.b.(2) and 3.B.4.b.(3)
(a) (c)
Airplanes that have been
changed by Boeing Service
Bulletin 707-2912 R01
Paragraph II.,
Accomplishment
Instructions, PART II.
PREVENTIVE
MODIFICATION DATA or
PART III. REPAIR DATA
(b)
-Before further flightRepair or replace the
fitting as given in
Paragraph 3.B., Work
Instructions
Any crack or corrosion
found
(a) For each body terminal fitting location, if the fitting has been replaced with a Boeing and FAA approved
fitting made from 7075-T73 material, the requirement for inspections is terminated for that fitting.
(b) After the airplane has been changed by Boeing Service Bulletin 707-2912 R01 Paragraph II.,
Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA or PART III. REPAIR DATA,
the ultrasonic inspections as given in this service bulletin are necessary. This includes airplanes changed
after the release date of Revision 1 to this service bulletin.
(c) All provisions and requirements of Boeing Service Bulletin 707-2912 R01, D6-54996 and AD 94-10-06
remain fully applicable and must be complied with.
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Group 2:
Table 2: Inspections and repair/replacement of 7079-T6 body terminal fittings
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
24 months (a)within 24 months from the date on
the original issue of this service
bulletin
Do detailed inspections
of the left and right body
terminal fittings at STA
600K for any crack or
corrosion as given in
Work Instructions
paragraphs 3.B.2.c. and
3.B.2.d. (a)
All airplanes
24 months (a)within 24 months from the date on
the original issue of this service
bulletin
Do detailed inspections
of the left and right body
terminal fittings at STA
820 for any crack or
corrosion as given in
Work Instructions
paragraphs 3.B.3.c. and
3.B.3.d. (a)
All airplanes
--No ultrasonic inspections
are required by this
service bulletin (a) (b) (c)
Airplanes that have not
been changed by Boeing
Service Bulletin 707-2912
R01 Paragraph II.,
Accomplishment
Instructions, PART II.
PREVENTIVE
MODIFICATION DATA or
PART III. REPAIR DATA
2000 flight cycles
or 24 months,
whichever occurs
first (a)
within 24 months
of the date of
Revision 1 to this
service bulletin
or within 24
months of the
date the change
was made,
whichever
occurs last
within 2000 flight
cycles of the
date of Revision
1 to this service
bulletin or within
2000 flight
cycles of the
date the change
was made,
whichever
occurs last
Do ultrasonic inspections
of the left and right body
terminal fittings at STA
820 for any internal crack
as given in Work
Instructions paragraphs
3.B.4.b.(4) and 3.B.4.b.(5)
(a) (c)
Airplanes that have been
changed by Boeing Service
Bulletin 707-2912 R01
Paragraph II.,
Accomplishment
Instructions, PART II.
PREVENTIVE
MODIFICATION DATA or
PART III. REPAIR DATA
(b)
-Before further flightRepair or replace the
fitting as given in
Paragraph 3.B., Work
Instructions
Any crack or corrosion
found
(a) For each body terminal fitting location, if the fitting has been replaced with a Boeing and FAA approved
fitting made from 7075-T73 material, the requirement for inspections is terminated for that fitting.
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Group 2:
Table 2: Inspections and repair/replacement of 7079-T6 body terminal fittings
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
(b) After the airplane has been changed by Boeing Service Bulletin 707-2912 R01 Paragraph II.,
Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA or PART III REPAIR DATA,
the ultrasonic inspections as given in this service bulletin are necessary.This includes airplanes changed
after the release date of Revision 1 to this service bulletin.
(c) All provisions and requirements of Boeing Service Bulletin 707-2912 R01, D6-54996 and AD 94-10-06
remain fully applicable and must be complied with.
Group 3:
Table 3: Inspections and repair/replacement of 7079-T6 body terminal fittings
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
24 months (a)within 24 months from the date on
the original issue of this service
bulletin
Do detailed inspections
of the left and right body
terminal fittings at STA
600K for any crack or
corrosion as given in
Work Instructions
paragraphs 3.B.2.c. and
3.B.2.d. (a)
All airplanes
24 months (a)within 24 months from the date on
the original issue of this service
bulletin
Do detailed inspections
of the left and right body
terminal fittings at STA
820 for any crack or
corrosion as given in
Work Instructions
paragraphs 3.B.3.c. and
3.B.3.d. (a)
All airplanes
24 months or
2000 flight cycles
whichever occurs
first (a)
within 24 months
from the date of
Revision 1 to this
service bulletin
within 2000 flight
cycles from the
date of Revision
1 to this service
bulletin
Do ultrasonic inspections
of the left and right body
terminal fittings at STA
820 for any internal crack
as given in Work
Instructions paragraphs
3.B.4.b.(6) and 3.B.4.b.(7)
(a)
All airplanes
-Before further flightRepair or replace the
fitting as given in
Paragraph 3.B., Work
Instructions
Any crack or corrosion
found
(a) For each body terminal fitting location, if the fitting has been replaced with a Boeing and FAA approved
fitting made from 7075-T73 material, the requirement for inspections is terminated for that fitting.
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Group 4:
Table 4: Inspections and repair/replacement of 7079-T6 body terminal fittings
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
24 months (a)within 24 months from the date on
the original issue of this service
bulletin
Do detailed inspections
of the left and right body
terminal fittings at STA
820 for any crack or
corrosion as given in
Work Instructions
paragraphs 3.B.3.c. and
3.B.3.d. (a)
All airplanes
24 months or
2000 flight cycles
whichever occurs
first (a)
within 24 months
from the date of
Revision 1 to this
service bulletin
within 2000 flight
cycles from the
date of Revision
1 to this service
bulletin
Do ultrasonic inspections
of the left and right body
terminal fittings at STA
820 for any internal crack
as given in Work
Instructions paragraphs
3.B.4.b.(6) and 3.B.4.b.(7)
(a)
All airplanes
-Before further flightRepair or replace the
fitting as given in
Paragraph 3.B., Work
Instructions
Any crack or corrosion
found
(a) For each body terminal fitting location, if the fitting has been replaced with a new fitting made from 7075-T73
material, the requirement for inspections is terminated at that location.
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
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:
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 Time to adjust to the workplace
 Time to schedule the work
 Time to inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
Group 1:
Manpower Table
Elapsed HoursTask-HoursNumber of
Persons
Task
4123Open Access
2.552Figure 1
2.552Figure 2
2.552Figure 5
2.552Figure 6
2.254.52Figure 7
2.254.52Figure 8
4123Close Access
22.553TOTAL FOR EACH AIRPLANE
Group 2-3:
Manpower Table
Elapsed HoursTask-HoursNumber of
Persons
Task
4123Open Access
2.552Figure 3
2.552Figure 4
2.552Figure 5
2.552Figure 6
2.552Figure 9
2.552Figure 10
4123Close Access
2354TOTAL FOR EACH AIRPLANE
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Group 4:
Manpower Table
Elapsed HoursTask-HoursNumber of
Persons
Task
4123Open Access
2.552Figure 5
2.552Figure 6
2.552Figure 9
2.552Figure 10
4123Close Access
1844TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not applicable.
J. References
1. Existing Data:
a. Boeing Service Related Problem (SRP) 707-SRP-53-0217 and 707-SRP-53-0307 .
b. Boeing Service Bulletin 707-1966, and 707-2912.
c. Standard Overhaul Practices Manual (SOPM) 20-41-05.
d. 707, 720 Nondestructive Test (NDT) Manual Part 4, 53-10-07.
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Bulkhead Installation - Wing Front Spar50-02529
Bulkhead Installation - Station 82065-01904
Bulkhead Installation - Station 82065-32004
Bulkhead Installation - Station 8205-84084
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These drawings were used to prepare this service bulletin. These drawings are not necessary to
make the specified changes, and are not supplied with this service bulletin. These drawings may
not be applicable to all airplane configurations or operators.
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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### Page 27

2.    MATERIAL INFORMATION
A. Material - Price and Availability
None.
B. Industry Support Information
Boeing warranty remedies are not available for the inspections 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)Corrosion Inhibiting Compound18 ozBMS 3-23, Type II
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for
supplier data.
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
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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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 Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate procedures may be required.
4. These work instructions refer to procedures included on 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 "as
given in" are included in the instruction, the procedure in the Boeing document must
be used.
5. At any point it is optional to replace the body terminal fittings with Boeing and FAA
approved fittings made from 7075-T73 material. This will terminate the requirement
for the inspections given in this service bulletin for each fitting that is replaced. Contact
Boeing for instructions.
B. WORK INSTRUCTIONS
1. Group 1:
DETAILED INSPECTION - BODY TERMINAL FITTINGS AT BODY STATION (STA) 620.
a. Get access to the body terminal fittings at STA 620 below the cabin floor level through the air
conditioning equipment access doors 1124L and 1124R.
b. Remove the side wall panels, internal lining and insulation blankets at STA 620 to access the
body terminal fittings above the cabin floor level.
c. Do a detailed inspection of the left body terminal fitting at STA 620 as given in Figure 1.
(1) If any crack or corrosion is found, contact Boeing for repair instructions or for instructions
to replace the body terminal fitting with a body terminal fitting made from 7075-T73
material. Provide a detailed description of any crack or corrosion to Boeing when
requesting repair instructions.
(2) If there is an existing repair, inspect the repair for any crack or corrosion.
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(a) If no crack or corrosion is found, it is not necessary to remove the repair.
(b) If any crack or corrosion is found, remove the repair and do a detailed inspection of
the fitting in the area covered by the repair. Send a detailed description of any crack
or corrosion to Boeing and request repair instructions.
d. Do a detailed inspection of the right body terminal fitting at STA 620 as given in Figure 2.
(1) If any crack or corrosion is found, contact Boeing for repair instructions or for instructions
to replace the body terminal fitting with a body terminal fitting made from 7075-T73
material. Provide a detailed description of any crack or corrosion to Boeing when
requesting repair instructions.
(2) If there is an existing repair, inspect the repair for any crack or corrosion.
(a) If no crack or corrosion is found, it is not necessary to remove the repair.
(b) If any crack or corrosion is found, remove the repair and do a detailed inspection of
the fitting in the area covered by the repair. Send a detailed description of any crack
or corrosion to Boeing and request repair instructions.
e. Close the air conditioning equipment access doors 1124L and 1124R.
f. Install the insulation blankets, internal lining and side wall panels at STA 620.
2. Group 2-3:
DETAILED INSPECTION - BODY TERMINAL FITTINGS AT BODY STATION (STA) 600K.
a. Get access to the body terminal fittings at STA 600K below the cabin floor level through the
air conditioning equipment access doors 1124L and 1124R.
b. Remove the side wall panels, internal lining and insulation blankets at STA 600K to access
the body terminal fittings above the cabin floor level.
c. Do a detailed inspection of the left body terminal fitting at STA 600K as given in Figure 3.
(1) If any crack or corrosion is found, contact Boeing for repair instructions or for instructions
to replace the body terminal fitting with a body terminal fitting made from 7075-T73
material. Provide a detailed description of any crack or corrosion to Boeing when
requesting repair instructions.
(2) If there is an existing repair, inspect the repair for any crack or corrosion.
(a) If no crack or corrosion is found, it is not necessary to remove the repair.
(b) If any crack or corrosion is found, remove the repair and do a detailed inspection of
the fitting in the area covered by the repair. Send a detailed description of any crack
or corrosion to Boeing and request repair instructions.
d. Do a detailed inspection of the right body terminal fitting at STA 600K as given in Figure 4.
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(1) If any crack or corrosion is found, contact Boeing for repair instructions or for instructions
to replace the body terminal fitting with a body terminal fitting made from 7075-T73
material. Provide a detailed description of any crack or corrosion to Boeing when
requesting repair instructions.
(2) If there is an existing repair, inspect the repair for any crack or corrosion.
(a) If no crack or corrosion is found, it is not necessary to remove the repair.
(b) If any crack or corrosion is found, remove the repair and do a detailed inspection of
the fitting in the area covered by the repair. Send a detailed description of any crack
or corrosion to Boeing and request repair instructions.
e. Close the air conditioning equipment access doors 1124L and 1124R.
f. Install the insulation blankets, internal lining and side wall panels at STA 600K.
3. DETAILED INSPECTION - BODY TERMINAL FITTINGS AT BODY STATION (STA) 820
BULKHEAD.
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 recommended on commonly affected
airplanes due to common access.
a. Get access to the body terminal fittings at STA 820 below the cabin floor level through the
main landing gear wheel well.
b. Remove the side wall panels, internal lining and insulation blankets at STA 820 to access the
body terminal fittings above the cabin floor level.
c. Do a detailed inspection of the left body terminal fitting on the STA 820 bulkhead as given in
Figure 5.
(1) If any crack or corrosion is found, contact Boeing for repair instructions or for instructions
to replace the body terminal fitting with a body terminal fitting made from 7075-T73
material. Provide a detailed description of any crack or corrosion to Boeing when
requesting repair instructions.
(2) If there is an existing repair, inspect the repair for any crack or corrosion.
(a) If no crack or corrosion is found, it is not necessary to remove the repair.
(b) If any crack or corrosion is found, remove the repair and do a detailed inspection of
the fitting in the area covered by the repair. Send a detailed description of any crack
or corrosion to Boeing and request repair instructions.
d. Do a detailed inspection of the right body terminal fitting on the STA 820 bulkhead as given
in Figure 6.
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(1) If any crack or corrosion is found, contact Boeing for repair instructions or for instructions
to replace the body terminal fitting with a body terminal fitting made from 7075-T73
material. Provide a detailed description of any crack or corrosion to Boeing when
requesting repair instructions.
(2) If there is an existing repair, inspect the repair for any crack or corrosion.
(a) If no crack or corrosion is found, it is not necessary to remove the repair.
(b) If any crack or corrosion is found, remove the repair and do a detailed inspection of
the fitting in the area covered by the repair. Send a detailed description of any crack
or corrosion to Boeing and request repair instructions.
e. Install the insulation blankets, internal lining and side wall panels at body station (STA) 820.
4. ULTRASONIC INSPECTION - BODY TERMINAL FITTINGS AT BODY STATION (STA) 820
BULKHEAD.
a. If the airplane has not been changed by Boeing Service Bulletin 707-2912 R01 Paragraph II.,
Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA or PART III.
REPAIR DATA, no inspections are required by this service bulletin. See Paragraph 1.E.,
Compliance for more information.
b. For airplanes that have been changed by Boeing Service Bulletin 707-2912 R01 Paragraph
II., Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA or PART III.
REPAIR DATA, do the following:
(1) Get access to the body terminal fittings at STA 820 below the cabin floor level through
the main landing gear wheel well.
(2) Group 1:
Do an ultrasonic inspection for any internal crack in the left body terminal fitting on the
STA 820 bulkhead as given in Figure 7.
(a) If no crack is found:
1) If the modification is not in accordance with Boeing Service Bulletin 707-2912
R01 Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION
DATA, remove the modification, contact Boeing for repair instructions and do
the work instructed by Boeing.
2) If the modification is in accordance with Boeing Service Bulletin 707-2912 R01
Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA,
no more work is necessary.
(b) If any crack is found:
1) If the modification or repair was installed as given in Boeing Service Bulletin
707-2912 R01, inspect the crack to verify that the modification or repair still
meets the requirements of Boeing Service Bulletin 707-2912 R01.
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a) If the crack is within the repair limits of the modification or repair as given
in Boeing Service Bulletin 707-2912 R01, no more work is necessary.
b) If the crack has grown beyond the repair limits of the modification or repair
as given in Boeing Service Bulletin 707-2912 R01, but is still within the
repair limits of Boeing Service Bulletin 707-2912 R01, Accomplishment
Instructions, PART III. REPAIR DATA, repair the crack as given in Boeing
Service Bulletin 707-2912 R01, Accomplishment Instructions, PART III.
REPAIR DATA.
c) If the crack has grown beyond the repair limits of Boeing Service Bulletin
707-2912 R01, contact Boeing for new repair instructions and do the work
instructed by Boeing.
2) If the modification or repair was not installed as given in Boeing Service Bulletin
707-2912 R01, remove the modification or repair and do the ultrasonic inspection.
Contact Boeing for new repair instructions and do the work instructed by Boeing.
(3) Group 1:
Do an ultrasonic inspection for any internal crack of the right body terminal fitting on the
STA 820 bulkhead as given in Figure 8.
(a) If no crack is found:
1) If the modification is not in accordance with Boeing Service Bulletin 707-2912
R01 Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION
DATA, remove the modification, contact Boeing for repair instructions and do
the work instructed by Boeing.
2) If the modification is in accordance with Boeing Service Bulletin 707-2912 R01
Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA,
no more work is necessary.
(b) If any crack is found:
1) If the modification or repair was installed as given in Boeing Service Bulletin
707-2912 R01, inspect the crack to verify that the modification or repair still
meets the requirements of Boeing Service Bulletin 707-2912 R01.
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ALERTALERT

### Page 34

a) If the crack is within the repair limits of the modification or repair as given
in Boeing Service Bulletin 707-2912 R01, no more work is necessary.
b) If the crack has grown beyond the repair limits of the modification or repair
as given in Boeing Service Bulletin 707-2912 R01, but is still within the
repair limits of Boeing Service Bulletin 707-2912 R01, Accomplishment
Instructions, PART III. REPAIR DATA, repair the crack as given in Boeing
Service Bulletin 707-2912 R01, Accomplishment Instructions, PART III.
REPAIR DATA.
c) If the crack has grown beyond the repair limits of Boeing Service Bulletin
707-2912 R01, contact Boeing for new repair instructions and do the work
instructed by Boeing.
2) If the modification or repair was not installed as given in Boeing Service Bulletin
707-2912 R01, remove the modification or repair and do the ultrasonic inspection.
Contact Boeing for new repair instructions and do the work instructed by Boeing.
(4) Group 2:
Do an ultrasonic inspection for any internal crack in the left body terminal fitting on the
STA 820 bulkhead as given in Figure 9.
(a) If no crack is found:
1) If the modification is not in accordance with Boeing Service Bulletin 707-2912
R01 Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION
DATA, remove the modification, contact Boeing for repair instructions and do
the work instructed by Boeing.
2) If the modification is in accordance with Boeing Service Bulletin 707-2912 R01
Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA,
no more work is necessary.
(b) If any crack is found:
1) If the modification or repair was installed as given in Boeing Service Bulletin
707-2912 R01, inspect the crack to verify that the modification or repair still
meets the requirements of Boeing Service Bulletin 707-2912 R01.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1: September 18, 2008
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ALERTALERT

### Page 35

a) If the crack is within the repair limits of the modification or repair as given
in Boeing Service Bulletin 707-2912 R01, no more work is necessary.
b) If the crack has grown beyond the repair limits of the modification or repair
as given in Boeing Service Bulletin 707-2912 R01, but is still within the
repair limits of Boeing Service Bulletin 707-2912 R01, Accomplishment
Instructions, PART III. REPAIR DATA, repair the crack as given in Boeing
Service Bulletin 707-2912 R01, Accomplishment Instructions, PART III.
REPAIR DATA.
c) If the crack has grown beyond the repair limits of Boeing Service Bulletin
707-2912 R01, contact Boeing for new repair instructions and do the work
instructed by Boeing.
2) If the modification or repair was not installed as given in Boeing Service Bulletin
707-2912 R01, remove the modification or repair and do the ultrasonic inspection.
Contact Boeing for new repair instructions and do the work instructed by Boeing.
(5) Group 2:
Do an ultrasonic inspection for any internal crack of the right body terminal fitting on the
STA 820 bulkhead as given in Figure 10.
(a) If no crack is found:
1) If the modification is not in accordance with Boeing Service Bulletin 707-2912
R01 Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION
DATA, remove the modification, contact Boeing for repair instructions and do
the work instructed by Boeing.
2) If the modification is in accordance with Boeing Service Bulletin 707-2912 R01
Accomplishment Instructions, PART II. PREVENTIVE MODIFICATION DATA,
no more work is necessary.
(b) If any crack is found:
1) If the modification or repair was installed as given in Boeing Service Bulletin
707-2912 R01, inspect the crack to verify that the modification or repair still
meets the requirements of Boeing Service Bulletin 707-2912 R01.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1: September 18, 2008
35 of 68
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ALERTALERT

### Page 36

a) If the crack is within the repair limits of the modification or repair as given
in Boeing Service Bulletin 707-2912 R01, no more work is necessary.
b) If the crack has grown beyond the repair limits of the modification or repair
as given in Boeing Service Bulletin 707-2912 R01, but is still within the
repair limits of Boeing Service Bulletin 707-2912 R01, Accomplishment
Instructions, PART III. REPAIR DATA, repair the crack as given in Boeing
Service Bulletin 707-2912 R01, Accomplishment Instructions, PART III.
REPAIR DATA.
c) If the crack has grown beyond the repair limits of Boeing Service Bulletin
707-2912 R01, contact Boeing for new repair instructions and do the work
instructed by Boeing.
2) If the modification or repair was not installed as given in Boeing Service Bulletin
707-2912 R01, remove the modification or repair and do the ultrasonic inspection.
Contact Boeing for new repair instructions and do the work instructed by Boeing.
(6) Group 3-4:
Do an ultrasonic inspection for any internal crack in the left body terminal fitting on the
STA 820 bulkhead as given in Figure 9.
(a) If no crack is found and no modification or repair is installed, no additional work is
required.
(b) If no crack is found and a modification/repair is installed, provide a description of the
modification or repair to Boeing, request modification instructions and do the work
instructed by Boeing.
(c) If any crack is found, provide a description of the crack and of any existing modification
or repair to Boeing, request additional work instructions and do the work instructed
by Boeing.
(7) Group 3-4:
Do an ultrasonic inspection for any internal crack in the right body terminal fitting on the
STA 820 bulkhead as given in Figure 10.
(a) If no crack is found and no modification or repair is installed, no additional work is
required.
(b) If no crack is found and a modification or repair is installed, provide a description of
the modification or repair to Boeing, request additional work instructions and do the
work instructed by Boeing.
(c) If any crack is found, provide a description of the crack and of any existing modification
or repair to Boeing, request additional work instructions and do the work instructed
by Boeing.
5. Put the airplane back to a serviceable condition.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1: September 18, 2008
36 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 37 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
This Figure applies only to: Group 1.
STA
620
— S-12
S-18
• S-22
UP
- S-23
INBD <
FIGURE 1: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 620.
(SHEET 1 OF 3)
July 18, 2007
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### Page 38 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
STA
620
S-12 -
023
FWD C
S-18
A—A  J23044
FIGURE 1: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 620.
(SHEET 2 OF 3)
July 18, 2007
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### Page 39

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
If present to enable detection of any crack
or corrosion on the surface. Refer to
SOPM 20-41-05 as an accepted
procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Remove1
Do a Detailed Inspection of the visible
surfaces of the entire fitting, including the
web, flanges, ribs and all repairs on it for
any crack or corrosion. (a)
150-5345-1, or
50-5345-5, or
50-5345-7, or
50-5345-11
Body Terminal FittingInspect2
To the entire fitting after inspection if no
crack or corrosion is found. Refer to
SOPM 20-41-05 as an accepted
procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Apply3
(a) Pay particular attention to fastener locations. Removal of fasteners or structure is not required.
FIGURE 1: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 620.
(SHEET 3 OF 3)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1 September 18, 2008
39 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 40 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
This Figure applies only to: Group 1.
STA
620
S-12 —
S-18
S-22
UP
S-23
> INBD
FIGURE 2: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 620.
(SHEET 1 OF 3)
July 18, 2007
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### Page 41 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
STA
620
- S-12
023
- S-18
A—A  J23045
FIGURE 2: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 620.
(SHEET 2 OF 3)
July 18, 2007
Revision 1 September 18, 2008  A3524
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  41 of 68

### Page 42

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Refer to SOPM 20-41-05 as an accepted
procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Remove1
Do a Detailed Inspection of the visible
surfaces of the entire fitting, including the
web, flanges, ribs and all repairs on it for
any crack or corrosion. (a)
150-5345-2, or
50-5345-6, or
50-5345-8, or
50-5345-12
Body Terminal FittingInspect2
To the entire fitting after inspection if no
crack or corrosion is found. Refer to SOPM
20-41-05 as an accepted procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Apply3
(a) Pay particular attention to fastener locations. Removal of fasteners or structure is not required.
FIGURE 2: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 620.
(SHEET 3 OF 3)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1 September 18, 2008
42 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 43 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
This Figure applies only to: Group 2-3.
STA
600K
→S-12L
- WL 208
- WL 202
UP
INBD
FIGURE 3: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K.
(SHEET 1 OF 3)
July 18, 2007
Revision 1 September 18, 2008
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### Page 44 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
STA
600K
S-12 -
023
‡  + + +
+ + +  #+ + ++++++++
++++
+
+ +
FWD C
S-18 -
A—A
FIGURE 3: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K.
(SHEET 2 OF 3)
July 18, 2007
Revision 1 September 18, 2008  A3524
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  44 of 68

### Page 45

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
If present to enable detection of any crack
or corrosion on the surface. Refer to
SOPM 20-41-05 as an accepted
procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Remove1
Do a Detailed Inspection of the visible
surfaces of the entire fitting, including the
web, flanges, ribs and all repairs on it for
any crack or corrosion. (a)
150-5345-3 or
50-5345-11
Body Terminal FittingInspect2
To the entire fitting after inspection if no
crack or corrosion is found. Refer to SOPM
20-41-05 as an accepted procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Apply3
(a) Pay particular attention to fastener locations. Removal of fasteners or structure is not required.
FIGURE 3: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K.
(SHEET 3 OF 3)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1 September 18, 2008
45 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 46 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
This Figure applies only to: Group 2-3.
STA
600K
S12L_
WL 208-
WL 202 —
123  UP
0 FRO
UP
— INBD
FIGURE 4: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K.
(SHEET 1 OF 3)
July 18, 2007
Revision 1 September 18, 2008  A3524
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### Page 47 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
STA
600K
— S-12
→FWD
- S-18
A-A  J23038
FIGURE 4: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K.
(SHEET 2 OF 3)
July 18, 2007
Revision 1 September 18, 2008  A3524
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  47 of 68

### Page 48

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
If present to enable detection of any crack
or corrosion on the surface. Refer to
SOPM 20-41-05 as an accepted
procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Remove1
Do a Detailed Inspection of the visible
surfaces of the entire fitting, including the
web, flanges, ribs and all repairs on it for
any crack or corrosion. (a)
150-5345-4 or
50-5345-12
Body Terminal FittingInspect2
To the entire fitting after inspection if no
crack or corrosion is found. Refer to SOPM
20-41-05 as an accepted procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Apply3
(a) Pay particular attention to fastener locations. Removal of fasteners or structure is not required.
FIGURE 4: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 600K.
(SHEET 3 OF 3)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1 September 18, 2008
48 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 49 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
STA
820
WL 202.
SEE
BL
FWD <  • INBD
LEFT SIDE CABIN FLOOR
(VIEW FROM BELOW, LOOKING FORWARD)
STA  J22969
820
FIGURE 5: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 1 OF 4)
July 18, 2007
Revision 1 September 18, 2008  A3524
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### Page 50 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
•
WL 202
TYPICAL
CRACKS
STA 820
BULKHEAD  S-18-
1) 2) 3
UP
— INBD
A)
VIEW LOOKING FORWARD
UP
→ INBD  WL 150
A-A
FIGURE 5: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 2 OF 4)
July 18, 2007
Revision 1 September 18, 2008  A3524
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### Page 51 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
- 5-9
WL 270-
S-17
(WL 208)
WL 202 -
123  S-18 -
UP
WL 150-
FWD <  J35883
B~B
FIGURE 5: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 3 OF 4)
July 18, 2007
Revision 1 September 18, 2008  A3524
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  51 of 68

### Page 52

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
If present to enable detection of any crack
or corrosion on the surface. Refer to SOPM
20-41-05 as an accepted procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Remove1
Do a Detailed Inspection of the visible
surfaces of the entire fitting, including
webs, flanges and ribs for any crack or
corrosion. Pay particular attention to
fastener locations. Removal of fasteners
or structure is not required. (a)
165-1903-1 or
65-1903-3, or
65-1903-5, or
50-6827-1, or
50-6827-3, or
50-6827-5, or
50-6827-7, or
50-6827-9, or
50-6827-11
Body Terminal FittingInspect2
To the entire fitting after inspection if no
crack or corrosion is found. Refer to SOPM
20-41-05 as an accepted procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Apply3
(a) If there are existing repairs, do a Detailed Inspection of the repairs on the fitting for any crack or corrosion.
Pay particular attention to fastener locations.
FIGURE 5: LEFT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 4 OF 4)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1 September 18, 2008
52 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 53 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
STA
820
WL 202
SEE
BL 0.
INBD  • FWD
LEFT SIDE CABIN FLOOR  STA  J23048
(VIEW FROM BELOW, LOOKING FORWARD)  820
FIGURE 6: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 1 OF 4)
July 18, 2007
Revision 1 September 18, 2008  A3524
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### Page 54 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
• B
- S-9
WL 202
TYPICAL
CRACKS
+ +
STA 820•
- S-18
BULKHEAD
INBD
(A)
VIEW LOOKING FORWARD
UP
INBD <
WL 150 -
• B
A-A
FIGURE 6: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 2 OF 4)
July 18, 2007
Revision 1 September 18, 2008  A3524
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### Page 55 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
S-9 -
- WL 270
S-17
(WL 208)
- WL 202
- S-18
UP
→FWD  - WL 150
B-B  9889EГ
FIGURE 6: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 3 OF 4)
July 18, 2007
Revision 1 September 18, 2008  A3524
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  55 of 68

### Page 56

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
If present to enable detection of any crack
or corrosion on the surface. Refer to
SOPM 20-41-05 as an accepted
procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Remove1
Do a Detailed Inspection of the visible
surfaces of the entire fitting, including
webs, flanges and ribs for any crack or
corrosion. Pay particular attention to
fastener locations. Removal of fasteners
or structure is not required. (a)
165-1903-2 or
65-1903-4, or
65-1903-6, or
50-6827-2, or
50-6827-4, or
50-6827-6, or
50-6827-8, or
50-6827-10, or
50-6827-12
Body Terminal FittingInspect2
To the entire fitting after inspection if no
crack or corrosion is found. Refer to SOPM
20-41-05 as an accepted procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Apply3
(a) If there are existing repairs, do a Detailed Inspection of the repairs on the fitting for any crack or corrosion.
Pay particular attention to fastener locations.
FIGURE 6: RIGHT BODY TERMINAL FITTING INSPECTION - BODY STATION 820.
(SHEET 4 OF 4)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1 September 18, 2008
56 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 57 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
This Figure applies only to: Group 1.
STA
820
WL 202
BL
UP
FWD *  • INBD
LEFT SIDE CABIN FLOOR
(VIEW FROM BELOW, LOOKING FORWARD)
STA
820
FIGURE 7: LEFT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820.
(SHEET 1 OF 3)
July 18, 2007
Revision 1 September 18, 2008  A3524
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### Page 58 (OCR)

BOEING SERVICE BULLETIN А3524
ALERT  ALERT
+ + +
- S-18
7.0
S-18A -
S-18 -
10.0
WL 150
ULTRASONIC
INSPECTION
A-A  - AREA
UP
> INBD  1563960
FIGURE 7: LEFT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820.
(SHEET 2 OF 3)
July 18, 2007
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### Page 59

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
If present, from the outer flange. Refer to
SOPM 20-41-05 as an accepted
procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Remove1
Do an Ultrasonic Inspection of the entire
outboard flange from 7 inches above
Stringer 18A down to 10 inches below
Stringer 18A for internal cracking.
Determine the end locations of each crack
that is found. (a) (b)
165-1903-1 or
65-1903-3, or
65-1903-5, or
50-6827-1, or
50-6827-3, or
50-6827-5, or
50-6827-7, or
50-6827-9, or
50-6827-11
Body Terminal FittingInspect2
To the outer flange if no crack or corrosion
is found. Refer to SOPM 20-41-05 as an
accepted procedure.
-BMS 3-23, Type IICorrosion Inhibiting
Compound
Apply3
(a) Do the inspection as given in 707, 720 NDT Part 4, 53-10-07 Figure 1.
(b) 707, 720 NDT Part 4, 53-10-07 Figure 1 was intended for use in monitoring crack propagation, but can
also be used for crack detection.
FIGURE 7: LEFT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820.
(SHEET 3 OF 3)
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
July 18, 2007
A3524Revision 1 September 18, 2008
59 of 68
BOEING SERVICE BULLETIN A3524
ALERTALERT

### Page 60 (OCR)

BOEING SERVICE BULLETIN A3524
ALERT  ALERT
This Figure applies only to: Group 1.
STA
820
- WL 202
BL 0.
UP
INBD
LEFT SIDE CABIN FLOOR  1563927
STA
(VIEW FROM BELOW, LOOKING FORWARD)  820
FIGURE 8: RIGHT BODY TERMINAL FITTING ULTRASONIC INSPECTION - BODY STATION 820.
(SHEET 1 OF 3)
July 18, 2007
Revision 1 September 18, 2008  A3524
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.  60 of 68

The text continues at https://openairdocs.org/service-documents/boeing/a3524/file/8f7c5d9713f1.md?from=61

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