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Commercial Airplanes 707 Service Bulletin ALERT Number: A3539 Original Issue: April 26, 2013 ATA System: 5330 SUBJECT: FUSELAGE - Fuselage Skin - Inspection of the Fuselage Skin for Scribe Lines Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2013 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: April 26, 2013 A3539 1 of 110
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 2 of 110 BOEING SERVICE BULLETIN A3539
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 6 F. Approval ............................................... 3 6 G. Manpower .............................................. 3 6 H. Weight and Balance Changes .................................... 3 8 I. Electrical Load Data ......................................... 3 9 J. References .............................................. 3 9
1. Existing Data: ......................................... 3 9
2. Data Supplied with this Service Bulletin: ........................... 3 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 9 K. Publications Affected ........................................ 3 9 L. Interchangeability and Intermixability of Parts ........................... 3 9 M. Software Accomplishment Summary ................................ 3 9
2. MATERIAL INFORMATION ........................................ 4 1 A. Material - Price and Availability ................................... 4 1 B. Industry Support Information .................................... 4 1 C. Parts Necessary for Each Airplane ................................. 4 1
1. Kits/Parts: ........................................... 4 1
2. Parts and Materials Supplied by the Operator: ........................ 4 1
3. Parts Modified and Reidentified: ............................... 4 1
4. Parts Removed and Not Replaced: .............................. 4 1 D. Parts Necessary to Change Spares ................................. 4 2 E. Special Tooling - Price and Availability ............................... 4 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 3 A. GENERAL INFORMATION ..................................... 4 3 B. WORK INSTRUCTIONS ....................................... 4 5 FIGURE 1: FUSELAGE - SKIN LAP JOINTS - INSPECTION [Group 1] ................. 5 8 FIGURE 2: FUSELAGE - SKIN LAP JOINTS - INSPECTION [Group 2] ................. 6 2 FIGURE 3: FUSELAGE - SKIN LAP JOINTS - INSPECTION [Group 3] ................. 6 6 FIGURE 4: FUSELAGE - SKIN LAP JOINTS - INSPECTION [Group 4] ................. 7 0 FIGURE 5: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTION [Group 1] ........ 7 4 FIGURE 6: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTION [Group 2] ........ 7 7 FIGURE 7: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTION [Group 3] ........ 8 0 FIGURE 8: FUSELAGE - EXTERNAL APPROVED REPAIRS - INSPECTION [Group 4] ........ 8 3 FIGURE 9: FUSELAGE - EXTERNAL FEATURES - INSPECTION [Group 1-4] ............. 8 6 FIGURE 10: FUSELAGE - SKIN LAP JOINTS, EXTERNAL APPROVED REPAIRS, AND EXTERNAL FEATURES - NON-DESTRUCTIVE TESTING INSPECTIONS [Group 1-4] ........ 8 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 3 of 110 BOEING SERVICE BULLETIN A3539
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FIGURE 11: FUSELAGE - SKIN LAP JOINTS, EXTERNAL APPROVED REPAIRS, EXTERNAL FEATURES, SKIN BUTT JOINTS AND DECALS - INSPECTION [Group 5] ............... 9 1 Appendix A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN . 97 Appendix B: REPORTING TEMPLATE - AIRPLANES WITH SCRIBE LINES .............. 1 0 5 Appendix C: AIRPLANE FUSELAGE SCRIBE LINE MARK SUMMARY TABLES ............ 1 0 7 Appendix D: SCRIBE LINE SAMPLE .................................... 1 0 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 4 of 110 BOEING SERVICE BULLETIN A3539
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Commercial Airplanes 707 Service Bulletin ALERT SummaryNumber: A3539Original Issue: April 26, 2013 ATA System: 5330 SUBJECT: FUSELAGE - Fuselage Skin - Inspection of the Fuselage Skin for Scribe Lines
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 This service bulletin gives instructions to inspect for scribe lines in the fuselage skin. Fatigue cracks can develop at scribe line locations. If this service bulletin is not done, any crack that remains undetected could grow large and cause a rapid decompression of the airplane.
Although Boeing has not received reports of scribe line related cracks on 707 series airplanes, Boeing has received reports of scribe line related cracks on two 727 airplanes. One report was on a 727-100 airplane with 44,171 cycles. The crack was near a repair and caused rapid decompression of the airplane. Another report was on a 727-100 airplane with 51,195 cycles. The crack was at station 1090-1110, stringer 4L lap joint. This also resulted in rapid decompression of the airplane.
A scribe line is a narrow, shallow, distinct line of damage (typically up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (skin lap joints and skin butt joints, respectively). A more detailed definition of a scribe line is included in Accomplishment Instructions Paragraph 3.B. - Identification of a "Typical" Scribe Line.
A review of fleet activity yields two separate scenarios that are suspected to have caused scribe lines to the fuselage skin.
The first scenario involves the paint stripping and repainting of airplanes. In the process of stripping and preparing the airplane for paint, tools were used to remove sealant and paint buildup at lap joints, at certain external approved repair doublers or door scuff plates, or around external features. Tools like scrapers (steel, wood, hard plastic, etc.), knives, or utility knives can damage the skin. Fatigue cracks can develop at scribe line locations.
The second scenario is decal application on/or removal from the fuselage. To install the decals across lap joint steps or repairs, investigation into maintenance practices has shown that decals have been cut in place, using some form of knife, to allow the decal to lie flush to the skin at these stepped locations. This operation results in scribe lines at the decal cut location. Based on service reports, sharp tools have also been used for close trimming of decal outlines. This type of decal trimming also has left scribe lines on the fuselage skin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 5 of 110
Each of the above maintenance operations can lead to the same type of scribe line damage and subsequent premature fatigue cracks.
Boeing Service Related Problem (SRP) 707-SRP-53-0247 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION Group 1-4:
Prepare surface for inspection by removing paint and sealant at the applicable locations. Do a detailed inspection of the fuselage skin at skin lap joints, external approved repairs, and external features for any scribe line. If no scribe lines are found, no further inspections are required. If any scribe line is found, measure the depth of the scribe line. For scribe lines less than 0.001 inch deep, no repair or further inspections are required. For scribe lines greater than or equal to 0.001 inch deep, Non-Destructive Testing (NDT) inspections are required to check for cracks. If any crack is found, contact Boeing for repair instructions and do the repair.
As an alternative to immediate repair, for a scribe line that qualifies, the provided Limited Return To Service (LRTS) program may be used to allow airplanes to return to revenue flight for a limited period before scribe lines are repaired. This service bulletin contains a LRTS program.
NOTE: Further Boeing approval is not required to begin a LRTS program.
The LRTS program consists of repeat inspections to detect any crack where scribe lines were found. Total airplane flight cycles, location, and the extent of the scribe line must meet specific criteria in order for a scribe line to qualify for a LRTS program. Inspections at each affected structural location within a LRTS program will be terminated with a repair.
Since a scribe line can occur at any time during the service life of an airplane and at many locations, this program uses both total flight cycles and structural criticality of location to determine the inspection requirements.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 6 of 110 BOEING SERVICE BULLETIN A3539
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Criticality of location allows this service bulletin to address the most critical areas first and determines the inspection thresholds for each location. This service bulletin uses figures and compliance times to address all of the critical locations and their corresponding inspection thresholds. Each critical piece of structure susceptible to a scribe line is assigned to a figure. The affected structure for each group of airplanes is identified in individual figures in this service bulletin.
Group 5:
Prepare surface for inspection by removing paint and sealant at the applicable locations. Do a detailed inspection of the fuselage skin at all skin lap joints, external approved repairs, external features, skin butt joints, and decals for any scribe line. If no scribe lines are found, no further inspections are required. If any scribe line is found, measure the depth of the scribe line. For scribe lines less than 0.001 inch deep, no repair or further inspections are required. For scribe lines greater than or equal to 0.001 inch deep, contact Boeing for repair instructions and do the repair.
NOTE: There is no LRTS program for Group 5 airplanes.
EFFECTIVITY 707-100, 707-100B, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B airplanes. Refer to Paragraph
1.A.1., Airplanes for the list of affected airplanes.
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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 7 of 110 BOEING SERVICE BULLETIN A3539
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BOEING SERVICE BULLETIN A3539
ALERT ALERT GROUPS 1 THROUGH 4:
DO A DETAILED INSPECTION OF THE FUSELAGE SKIN FOR SCRIBE LINES
AT SKIN LAP JOINTS, EXTERNAL APPROVED REPAIRS, AND EXTERNAL FEATURES. IF A SCRIBE LINE GREATER THAN 0.001 INCH DEEP IS FOUND, DO A NON-DESTRUCTIVE TESTING (NDT) INSPECTION FOR ANY CRACK.
GROUP 5:
DO A DETAILED INSPECTION OF THE FUSELAGE SKIN FOR SCRIBE LINES
AT SKIN LAP JOINTS, EXTERNAL APPROVED REPAIRS, EXTERNAL FEATURES, SKIN BUTT JOINTS, AND DECALS. IF A SCRIBE LINE GREATER THAN 0.001 INCH DEEP IS FOUND, CONTACT BOEING FOR REPAIR INSTRUCTIONS AND DO THE REPAIR. 2198859 Original Issue: April 26, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING A3539 Work - See page 1 for details. 8 of 110
Commercial Airplanes 707 Service Bulletin ALERT Number: A3539 Original Issue: April 26, 2013 ATA System: 5330 SUBJECT: FUSELAGE - Fuselage Skin - Inspection of the Fuselage Skin for Scribe Lines
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 707-100B Airplanes-1 707-300 Airplanes-2 707-300B Airplanes-3 707-300C Airplanes-4 707-100, 707-200, 707-400, 720, 720B Airplanes-5 Airplane Models:
707-100, 707-100B, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B GroupVariable Number 5B0001 - B0029 5B0101 - B0125 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 9 of 110
GroupVariable Number 5B0201 - B0203 5B0301 - B0306 5B0401 - B0402 5B0501 - B0515 5B2001 - B2008 5B2091 - B2092 5B2101 - B2116 5B2191 - B2194 5B2199 5B2201 - B2227 5B2401 - B2403 5B2501 - B2502 5B2551 - B2553 5B2601 - B2608 500001 - 00004 100005 - 00006 100101 - 00156 500201 - 00205 500301 - 00305 500401 - 00415 100416 - 00451 100471 - 00475 100501 - 00513 500601 - 00602 100701 - 00703 202001 - 02020 202101 - 02121 202201 - 02207 202301 - 02303 202401 - 02418 504001 - 04005 504020 - 04022 504101 - 04106 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 10 of 110 BOEING SERVICE BULLETIN A3539
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GroupVariable Number 504201 - 04218 504271 - 04272 504301 - 04303 305001 - 05060 305101 - 05138 305201 - 05208 305301 - 05312 305401 305601 - 05605 305631 - 05635 305701 - 05703 305801 - 05802 305821 - 05827 305831 - 05833 305851 - 05854 305891 - 05892 305921 - 05923 305941 - 05942 305961 - 05970 306001 - 06002 306101 306401 - 06404 306451 306461 407001 - 07017 407041 - 07059 407071 - 07081 407101 - 07109 407181 407191 407201 - 07215 407251 - 07271 407401 - 07407 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 11 of 110 BOEING SERVICE BULLETIN A3539
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GroupVariable Number 407451 - 07458 407501 - 07504 407601 - 07626 407661 - 07662 407681 - 07684 407701 - 07702 407801 - 07821 407901 - 07907 408001 - 08008 408021 408051 - 08056 408071 - 08077 408101 - 08104 408121 - 08129 408141 - 08144 408151 - 08153 408171 - 08173 408191 - 08192 408201 - 08210 408221 - 08224 408241 - 08244 408251 408261 408271 408301 - 08320 408324 - 08330 408333 408401 - 08410 408451 - 08452 408471 - 08475 408501 - 08502 408551 - 08553 408581 - 08582 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 26, 2013 A3539 12 of 110 BOEING SERVICE BULLETIN A3539