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Commercial Airplanes 707 Requirements Bulletin ALERT Number: A3544 RB Original Issue: November 01, 2021 ATA System: 5706 SUBJECT: WINGS - Center Section - Lower Skin and Rear Spar Lower Chord between LBBL 40 and RBBL 40 - Inspection 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:
Copyright © 2021 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Unpublished Work.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: November 01, 2021 A3544 RB 1 of 27
5.0
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 2 of 27 REQUIREMENTS BULLETIN A3544
ALERTALERT
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Table of Contents
1 . E F F E C T I V I T Y5
A . A i r p l a n e s5
B . S p a r e s A f f e c t e d7
2. CONCURRENT REQUIREMENTS7
3 . C O M P L I A N C E7
4. APPROVAL ................................................ 1 3
5. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 5 A. General Information ......................................... 1 5 B. Work Instructions ........................................... 1 6 FIGURE 2: CENTER WING BOX, LOWER SKIN AND REAR SPAR LOWER CHORD - INSPECTION . 19 FIGURE 3: CENTER WING BOX, LOWER SKIN AND REAR SPAR LOWER CHORD - SEALANT APPLICATION ......................................... 2 4 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 3 of 27 REQUIREMENTS BULLETIN A3544
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 4 of 27 REQUIREMENTS BULLETIN A3544
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Commercial Airplanes 707 Requirements Bulletin ALERT Number: A3544 RB Original Issue: November 01, 2021 ATA System: 5706 SUBJECT: WINGS - Center Section - Lower Skin and Rear Spar Lower Chord between LBBL 40 and RBBL 40 - Inspection
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING
PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1. Effectivity A. Airplanes This bulletin is applicable to 707-100 LONG BODY, 707-100B LONG BODY, 707-100B SHORT BODY, 707-200, 707-300, 707-300B, 707-300C, 707-400 Airplane(s), line number(s) 1-2, 4-7, 9-35, 37-84, 86-94, 96-108, 110-118, 121-129, 133-140, 144-145, 151-155, 159-164, 167-171, 175-176, 192, 200-201, 205, 209, 212, 216-217, 227-229, 264, 266, 268-272, 274-277, 280, 282-283, 286-287, 291-294, 296, 299, 301-303, 305-306, 308-309, 311-313, 315-318, 320, 323, 325-336, 341-346, 348-350, 352-360, 362-373, 375-379, 383, 385-389, 391-400, 402-409, 411-413, 415-422, 424-426, 428, 430-432, 434-441, 443-469, 471-472, 475-480, 482-511, 513, 515-580, 582-596, 598-614, 616-620, 622-623, 625-770, 772-776, 778-786, 788-793, 795-800, 802-855, 857, 859-897, 899-900, 903, 905-906, 908, 910-912, 914-915, 917-919, 922-923, 925, 928-929, 936, 938, 941 in 4 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 707-100 LONG BODY, -100B LONG BODY, -100B SHORT BODY, -200 Airplanes -1 707-300/-400 Airplanes-2 707-300B Airplanes-3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 5 of 27
DESCRIPTIONCONFIGURATIONGROUP 707-300C Airplanes-4 Passenger Airplanes1 Cargo Airplanes2 Airplane Models:
707-100 LONG BODY, 707-100B LONG BODY, 707-100B SHORT BODY, 707-200, 707-300, 707-300B, 707-300C, 707-400 GroupVariable Number 100001 - 00002 100004 - 00006 100101 100103 - 00113 100115 - 00153 100201 - 00205 100301 - 00305 100401 - 00449 100471 - 00475 100501 - 00513 100601 100701 - 00703 202001 - 02020 202101 - 02121 202201 - 02207 202301 - 02303 202401 - 02418 204001 - 04005 204020 - 04022 204101 - 04106 204201 - 04218 204271 - 04272 204301 - 04303 GroupVariable Number 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 GroupVariable Number 407071 - 07081 407101 - 07109 407181 407191 407201 - 07215 407251 - 07271 407401 - 07407 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 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 6 of 27 REQUIREMENTS BULLETIN A3544
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GroupVariable Number 408171 - 08173 408191 - 08192 408201 - 08210 408221 - 08224 408241 - 08244 408251 408261 408271 408301 - 08320 408324 - 08330 408333 GroupVariable Number 408401 - 08410 408451 - 08452 408471 - 08475 408501 - 08502 408551 - 08553 408581 - 08582 409001 - 09006 409101 - 09107 409161 - 09167 409201 - 09204 409221 - 09223 GroupVariable Number 409227 409231 - 09232 409251 409271 409281 409286 - 09290 409411 409421 409438 409441 -- B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 707A3544 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 707A3544 RB mandatory.
Group 1: Accomplish the required action(s), based on the applicable condition(s) in Table 1, in accordance with Accomplishment Instructions.
Group 2: Accomplish the required action(s), based on the applicable condition(s) in Table 2, in accordance with Accomplishment Instructions.
Group 3: Accomplish the required action(s), based on the applicable condition(s) in Table 3, in accordance with Accomplishment Instructions.
Group 4: Accomplish the required action(s), based on the applicable condition(s) in Table 4, in accordance with Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 7 of 27 REQUIREMENTS BULLETIN A3544
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Group 1:
Table 1: Center Wing Box, Rear Spar Lower Chord and Lower Skin Between LBBL 40 and RBBL 40, Inspection.
Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight cycles after the original issue date of Requirements Bulletin 707A3544 RB.
Before 15,000 total flight cycles.
Do an internal Detailed Inspection of the center wing box lower skin between LBBL 40 and RBBL 40, do an internal surface High Frequency Eddy Current (HFEC) Inspection and an internal Ultrasonic (UT) Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack.
All airplanes.
-Before further flight.CONDITION 1 (ACTION 1):
Apply sealant.
CONDITION 1: NO CRACK FOUND.
4,400 flight cycles -CONDITION 1 (ACTION 2):
Repeat internal Detailed Inspection of the lower skin and internal surface HFEC and UT Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack. (a) --Before further flight.
CONDITION 2 (ACTION 1):
Contact the Boeing Company for repair instructions and do the repair.
CONDITION 2: ANY CRACK FOUND.
CONDITION 2 (ACTION 2):
Apply sealant.
4,400 flight cycles -CONDITION 2 (ACTION 3):
Repeat internal Detailed Inspection of the lower skin and internal surface HFEC and UT Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack at the unrepaired areas. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 8 of 27 REQUIREMENTS BULLETIN A3544
ALERTALERT
Group 1:
Table 1: Center Wing Box, Rear Spar Lower Chord and Lower Skin Between LBBL 40 and RBBL 40, Inspection.
Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition
(a) It is not required to do the inspection in areas where a repair covers the affected inspection area if the repair meets the conditions that follow:
1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 707A3544 RB and installed after the original issue date of Requirements Bulletin 707A3544 RB.
2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
Group 2:
Table 2: Center Wing Box, Rear Spar Lower Chord and Lower Skin Between LBBL 40 and RBBL 40, Inspection.
Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight cycles after the original issue date of Requirements Bulletin 707A3544 RB.
Before 15,000 total flight cycles.
Do an internal Detailed Inspection of the center wing box lower skin between LBBL 40 and RBBL 40, do an internal surface High Frequency Eddy Current (HFEC) Inspection and an internal Ultrasonic (UT) Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack.
All airplanes.
-Before further flight.CONDITION 1 (ACTION 1):
Apply sealant.
CONDITION 1: NO CRACK FOUND.
5,700 flight cycles -CONDITION 1 (ACTION 2):
Repeat internal Detailed Inspection of the lower skin and internal surface HFEC and UT Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 9 of 27 REQUIREMENTS BULLETIN A3544
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Group 2:
Table 2: Center Wing Box, Rear Spar Lower Chord and Lower Skin Between LBBL 40 and RBBL 40, Inspection.
Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition --Before further flight.
CONDITION 2 (ACTION 1):
Contact the Boeing Company for repair instructions and do the repair.
CONDITION 2: ANY CRACK FOUND.
CONDITION 2 (ACTION 2):
Apply sealant.
5,700 flight cycles -CONDITION 2 (ACTION 3):
Repeat internal Detailed Inspection of the lower skin and internal surface HFEC and UT Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack at the unrepaired areas. (a)
(a) It is not required to do the inspection in areas where a repair covers the affected inspection area if the repair meets the conditions that follow:
1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 707A3544 RB and installed after the original issue date of Requirements Bulletin 707A3544 RB.
2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 10 of 27 REQUIREMENTS BULLETIN A3544
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Group 3; Group 4, Configuration 1:
Table 3: Center Wing Box, Rear Spar Lower Chord and Lower Skin Between LBBL 40 and RBBL 40, Inspection.
Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight cycles after the original issue date of Requirements Bulletin 707A3544 RB.
Before 15,000 total flight cycles.
Do an internal Detailed Inspection of the center wing box lower skin between LBBL 40 and RBBL 40, do an internal surface High Frequency Eddy Current (HFEC) Inspection and an internal Ultrasonic (UT) Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack.
All airplanes.
-Before further flight.CONDITION 1 (ACTION 1):
Apply sealant.
CONDITION 1: NO CRACK FOUND.
5,000 flight cycles -CONDITION 1 (ACTION 2):
Repeat internal Detailed Inspection of the lower skin and internal surface HFEC and UT Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack. (a) --Before further flight.
CONDITION 2 (ACTION 1):
Contact the Boeing Company for repair instructions and do the repair.
CONDITION 2: ANY CRACK FOUND.
CONDITION 2 (ACTION 2):
Apply sealant.
5,000 flight cycles -CONDITION 2 (ACTION 3):
Repeat internal Detailed Inspection of the lower skin and internal surface HFEC and UT Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack at the unrepaired areas. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 11 of 27 REQUIREMENTS BULLETIN A3544
ALERTALERT
Group 3; Group 4, Configuration 1:
Table 3: Center Wing Box, Rear Spar Lower Chord and Lower Skin Between LBBL 40 and RBBL 40, Inspection.
Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition
(a) It is not required to do the inspection in areas where a repair covers the affected inspection area if the repair meets the conditions that follow:
1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 707A3544 RB and installed after the original issue date of Requirements Bulletin 707A3544 RB.
2. The installed repair was approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
Group 4, Configuration 2:
Table 4: Center Wing Box, Rear Spar Lower Chord and Lower Skin Between LBBL 40 and RBBL 40, Inspection.
Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,100 flight cycles after the original issue date of Requirements Bulletin 707A3544 RB.
Before 15,000 total flight cycles.
Do an internal Detailed Inspection of the center wing box lower skin between LBBL 40 and RBBL 40, do an internal surface High Frequency Eddy Current (HFEC) Inspection and an internal Ultrasonic (UT) Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack.
All airplanes.
-Before further flight.CONDITION 1 (ACTION 1):
Apply sealant.
CONDITION 1: NO CRACK FOUND.
2,200 flight cycles -CONDITION 1 (ACTION 2):
Repeat internal Detailed Inspection of the lower skin and internal surface HFEC and UT Inspection of the rear spar lower chord located between LBBL 40 and RBBL 40 for any crack. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 01, 2021 A3544 RB 12 of 27 REQUIREMENTS BULLETIN A3544