### Commercial **Airplanes** 

# 707 Service Bulletin **Number: 3532** Original Issue: January 12, 2012 ATA System: 2802 **SUBJECT:** FUEL - Integral Fuel Tanks - Access doors Inspection/Replacement 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 1 of 31 11.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 2 of 31 **BOEING SERVICE BULLETIN 3532**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 7 A. Effectivity................................................ 7 1. Airplanes............................................. 7 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 14 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 15 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 15 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FIGURE 1: ACCESS DOOR INSPECTION - LEFT WING [Group 1]. . . . . . . . . . . . . . . . . . . 20 FIGURE 2: ACCESS DOOR INSPECTION - RIGHT WING [Group 1]. . . . . . . . . . . . . . . . . . 22 FIGURE 3: ACCESS DOOR INSPECTION - LEFT WING [Group 2]. . . . . . . . . . . . . . . . . . . 24 FIGURE 4: ACCESS DOOR INSPECTION - RIGHT WING [Group 2]. . . . . . . . . . . . . . . . . . 26 APPENDIX A: PROCEDURE FOR ACCESS DOOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 28

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 3 of 31 **BOEING SERVICE BULLETIN 3532**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 4 of 31 **BOEING SERVICE BULLETIN 3532**

BLANK PAGE

### Commercial **Airplanes** 

# 707 Service Bulletin **Summary Number: 3532**  Original Issue: January 12, 2012 ATA System: 2802 **SUBJECT:** FUEL - Integral Fuel Tanks - Access doors Inspection/Replacement **CONCURRENT REQUIREMENTS** Refer to Paragraph 1.B., Concurrent Requirements. **BACKGROUND** This service bulletin provides instructions to inspect the Wing Fuel Tank Access Doors to make sure that Impact Resistant Access Doors are installed in the correct locations and stencils and index markers are applied. Fire can result from damage to a standard access door if it is located where an Impact Resistant Access Door is required. An operator identified a standard access door located where an Impact Resistant Access Door is required. In addition, the operator examined its spares stock and found that some Impact Resistant Access Doors were without stencils. These findings have raised a concern about the possibility of more standard access doors being installed at locations where Impact Resistant Access Doors are required. Impact Resistant Access Doors minimize risk of penetration from engine debris or objects thrown by airplane tires. By accomplishing the inspection in this service bulletin, operators can make sure that stencils and index markers are applied and Impact Resistant Access Doors are installed at the correct locations, providing increased resistance to Wing Fuel Tank penetration. Boeing Service Related Problem (SRP) 707-SRP-57-0225is related to this service bulletin. **ACTION** Identify the Wing Fuel Tank Access Doors. Do a General Visual Inspection or an ultrasonic Non-Destructive Test (NDT) to make sure that Impact Resistant Access Doors are installed in the correct locations. If a standard access door is identified in a location where an Impact Resistant Access Door is required, replace the door with an Impact Resistant Access Door. Do a General Visual Inspection to make sure that stencils and index markers are applied. If a stencil and/or index marker is missing, apply new stencil and/or index marker. **EFFECTIVITY** All 707-100 Long Body/100B Long Body/100B Short Body/200/300/300B/300C/400, 720 and 720B Airplanes. Refer to Paragraph 1.A.1, Effectivity. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 5 of 31Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Refer to Paragraph 2.B., Industry Support Information. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 6 of 31 **BOEING SERVICE BULLETIN 3532**

### Commercial **Airplanes** 

# 707 Service Bulletin **Number: 3532** Original Issue: January 12, 2012 ATA System: 2802 **SUBJECT:** FUEL - Integral Fuel Tanks - Access doors Inspection/Replacement
**1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** All 707-300/300B/300C/400 airplanes. These airplanes have nine impact resistant door locations on each wing. - 1
All 707-100 Long Body/100B Long Body/100B Short Body/200, 720, 720B airplanes. These airplanes have eight impact resistant door locations on each wing. - 2

Airplane Models: 707-100 Long Body, 707-100B Long Body, 707-100B Short Body, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B **Group Variable Number**  2 B0001 - B0029 2 B0101 - B0125 2 B0201 - B0203 2 B0301 - B0306 2 B0401 - B0402 2 B0501 - B0515 2 B2001 - B2008 2 B2091 - B2092

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 7 of 31**Group Variable Number**  2 B2101 - B2116 2 B2191 - B2194 2 B2199 2 B2201 - B2227 2 B2401 - B2403 2 B2501 - B2502 2 B2551 - B2553 2 B2601 - B2608 2 00001 - 00006 2 00101 - 00156 2 00201 - 00205 2 00301 - 00305 2 00401 - 00451 2 00471 - 00475 2 00501 - 00513 2 00601 - 00602 2 00701 - 00703 1 02001 - 02020 1 02101 - 02121 1 02201 - 02207 1 02301 - 02303 1 02401 - 02418 1 04001 - 04005 1 04020 - 04022 1 04101 - 04106 1 04201 - 04218 1 04271 - 04272 1 04301 - 04303 1 05001 - 05060 1 05101 - 05138 1 05201 - 05208 1 05301 - 05312 1 05401

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 8 of 31 **BOEING SERVICE BULLETIN 3532 Group**  **Variable Number** 1 05601 - 05605 1 05631 - 05635 1 05701 - 05703 1 05801 - 05802 1 05821 - 05827 1 05831 - 05833 1 05851 - 05854 1 05891 - 05892 1 05921 - 05923 1 05941 - 05942 1 05961 - 05970 1 06001 - 06002 1 06101 1 06401 - 06404 1 06451 1 06461 1 07001 - 07017 1 07041 - 07059 1 07071 - 07081 1 07101 - 07109 1 07181 1 07191 1 07201 - 07215 1 07251 - 07271 1 07401 - 07407 1 07451 - 07458 1 07501 - 07504 1 07601 - 07626 1 07661 - 07662 1 07681 - 07684 1 07701 - 07702 1 07801 - 07821 1 07901 - 07907

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 9 of 31 **BOEING SERVICE BULLETIN 3532 Group**  **Variable Number** 1 08001 - 08008 1 08021 1 08051 - 08056 1 08071 - 08077 1 08101 - 08104 1 08121 - 08129 1 08141 - 08144 1 08151 - 08153 1 08171 - 08173 1 08191 - 08192 1 08201 - 08210 1 08221 - 08224 1 08241 - 08244 1 08251 1 08261 1 08271 1 08301 - 08320 1 08324 - 08330 1 08333 1 08401 - 08410 1 08451 - 08452 1 08471 - 08475 1 08501 - 08502 1 08551 - 08553 1 08581 - 08582 1 09001 - 09006 1 09101 - 09107 1 09161 - 09167 1 09201 - 09204 1 09221 - 09223 1 09227 1 09231 - 09232 1 09251

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 10 of 31 **BOEING SERVICE BULLETIN 3532 Group**  **Variable Number** 1 09271 1 09281 1 09286 - 09290 1 09411 1 09421 1 09438 1 09441 2. Spares Affected None. **B. Concurrent Requirements** The service bulletin listed below must be done before or at the same time as this service bulletin: **Description Service Bulletin**  **Company** Fuel Tank Access Door Replacement 707-3473 Revision 1 Boeing
**C. Reason** This service bulletin provides instructions to inspect the Wing Fuel Tank Access Doors to make sure that Impact Resistant Access Doors are installed in the correct locations and stencils and index markers are applied. Fire can result from damage to a standard access door if it is located where an Impact Resistant Access Door is required. An operator identified a standard access door located where an Impact Resistant Access Door is required. In addition, the operator examined its spares stock and found that some Impact Resistant Access Doors were without stencils. These findings have raised a concern about the possibility of more standard access doors being installed at locations where Impact Resistant Access Doors are required. Impact Resistant Access Doors minimize risk of penetration from engine debris or objects thrown by airplane tires. By accomplishing the inspection in this service bulletin, operators can make sure that stencils and index markers are applied and Impact Resistant Access Doors are installed at the correct locations, providing increased resistance to Wing Fuel Tank penetration. Boeing Service Related Problem (SRP) 707-SRP-57-0225is related to this service bulletin. **D. Description** Identify the Wing Fuel Tank Access Doors. Do a General Visual Inspection or an ultrasonic Non-Destructive Test (NDT) to make sure that Impact Resistant Access Doors are installed in the correct locations. If a standard access door is identified in a location where an Impact Resistant Access Door is required, replace the door with an Impact Resistant Access Door. Do a General Visual Inspection to make sure that stencils and index markers are applied. If a stencil and/or index marker is missing, apply new stencil and/or index marker.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 11 of 31 **BOEING SERVICE BULLETIN 3532**The work in this service bulletin is done in the maintenance zone(s) given below. **Group 1:**
**Affected Maintenance Zones Zone**  **Model** 5-71, 5-72, 6-73, 6-74 707-300, 707-300B, 707-300C, 707-400 **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 5-71, 5-72, 6-73, 6-74 707-100 Long Body, 707-100B Long Body, 707-100B Short Body, 707-200, 720, 720B **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Boeing recommends that the inspection given in this service bulletin be done within 72 months after the original issue date of this service bulletin. **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 man-hours necessary to do this change for each airplane. This estimate is for direct labor only, done by experienced crews. Adjust the estimate with operator man-hour data if necessary. The estimate does not include lost time. These are examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 12 of 31 **BOEING SERVICE BULLETIN 3532**— Time to make the parts — Time to find the tools. **Group 1: OPTION 1: MAN-HOURS FOR GENERAL VISUAL INSPECTION PROCEDURE** 
**More Data Elapsed Hours**  **Task Hours Number of Persons**  **Task** (a) 6.0 6.0 1 Figure 1 (a) 6.0 6.0 1 Figure 2 (a) 12.0 12.0 TOTAL FOR EACH AIRPLANE (a) Does not include time to defuel/refuel. **Group 1: OPTION 2: MAN-HOURS FOR ULTRASONIC NON-DESTRUCTIVE TEST (NDT) INSPECTION PROCEDURE** 
**More Data Elapsed Hours**  **Task Hours Number of Persons**  **Task** (a) 5.0 5.0 1 Figure 1 (a) 5.0 5.0 1 Figure 2 (a) 10.0 10.0 TOTAL FOR EACH AIRPLANE (a) Does not include time to defuel/refuel. **Group 2: OPTION 1: MAN-HOURS FOR GENERAL VISUAL INSPECTION PROCEDURE** 
**More Data Elapsed Hours**  **Task Hours Number of Persons**  **Task** (a) 6.0 6.0 1 Figure 3 (a) 6.0 6.0 1 Figure 4 (a) 12.0 12.0 TOTAL FOR EACH AIRPLANE (a) Does not include time to defuel/refuel. **Group 2: OPTION 2: MAN-HOURS FOR ULTRASONIC NON-DESTRUCTIVE TEST (NDT) INSPECTION PROCEDURE** 
**More Data Elapsed Hours**  **Task Hours Number of Persons**  **Task** (a) 5.0 5.0 1 Figure 3 (a) 5.0 5.0 1 Figure 4 (a) 10.0 10.0 TOTAL FOR EACH AIRPLANE (a) Does not include time to defuel/refuel. **H. Weight and Balance Changes** None

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 13 of 31 **BOEING SERVICE BULLETIN 3532 I. Electrical Load Data**  Not applicable **J. References** 1. Existing Data: a. Boeing Service Related Problem (SRP) 707-SRP-57-0225 b. Boeing Service Bulletin 707-3473 c. Standard Overhaul Practices Manual (SOPM) 20-50-10 d. 707-400 Illustrated Parts Catalog (IPC) 28-03, 57-03 e. 707 Airplane Maintenance Manual (AMM) 28-2-1, 28-0 f. 707/720 Non-Destructive Testing (NDT) Manual 707, 720 NDT Part 4, 51-00-00 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None **K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary. **L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 14 of 31 **BOEING SERVICE BULLETIN 3532 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Refer to Paragraph 2.C., Parts Necessary For Each Airplane. **B. Industry Support Information** Boeing warranty remedies are available for 707 airplanes in warranty as of June 19, 2008. For inspection man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Warranty & Product Assurance Contracts. If the condition described in this service bulletin is found during the initial inspection for airplanes in warranty as of that date and additional man-hours or parts are required, send a warranty claim to Boeing Warranty & Product Assurance Contracts. Warranty remedies are not available for continued inspections as described in this Service Bulletin as these actions are considered routine maintenance. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None 2. Parts and Materials Supplied by the Operator: Refer to Illustrated Parts Catalog (IPC) 28-03, 57-03. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 15 of 31 **BOEING SERVICE BULLETIN 3532**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 16 of 31 **BOEING SERVICE BULLETIN 3532**

BLANK PAGE**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. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees 4. If the length of any fastener specified in this service bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. 5. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access doors or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 6. A Non-Destructive Test (NDT) is an inspection/testing procedure used to determine the condition of a material in such a manner as to not damage or destroy the material under investigation. The material is examined for flaws or conditions that could be detrimental to the integrity of the structure. 7. These work instructions refer to procedures included in 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 "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 17 of 31 **BOEING SERVICE BULLETIN 3532 B. WORK INSTRUCTIONS** 
1. **Group 1:** Do a General Visual Inspection or an ultrasonic Non-Destructive Test (NDT) of the left wing fuel tank access doors to make sure that Impact Resistant Access Doors are installed in the correct locations, in accordance with FIGURE 1.
2. **Group 1:** If one or more standard access doors are found, replace each standard access door with an Impact Resistant access door. Refer to 707 AMM 28-2-1 as an accepted procedure. 3. **Group 1:** Do a General Visual Inspection of the left wing fuel tank access doors to verify stencils and index markers are applied in accordance with FIGURE 1.
4. **Group 1:** If a stencil and/or index marker is missing, apply stencil and/or index marker in accordance with FIGURE 1.
5. **Group 1:** Do a General Visual Inspection or an ultrasonic NDT of the right wing fuel tank access doors to make sure that Impact Resistant Access Doors are installed in the correct locations, in accordance with FIGURE 2. 6. **Group 1:** If one or more standard access doors are found, replace each standard access door with an Impact Resistant access door. Refer to 707 AMM 28-2-1 as an accepted procedure.
7. **Group 1:** Do a General Visual Inspection of the right wing fuel tank access doors to verify stencils and index markers are applied in accordance with FIGURE 2. 8. **Group 1:** If a stencil and/or index marker is missing, apply stencil and/or index marker in accordance with FIGURE 2. 9. **Group 2:** Do a General Visual Inspection or an ultrasonic Non-Destructive Test (NDT) of the left wing fuel tank access doors to make sure that Impact Resistant Access Doors are installed in the correct locations, in accordance with FIGURE 3. 10. **Group 2:** If one or more standard access doors are found, replace each standard access door with an Impact Resistant access door. Refer to 707 AMM 28-2-1 as an accepted procedure.
11. **Group 2:** Do a General Visual Inspection of the left wing fuel tank access doors to verify stencils and index markers are applied in accordance with FIGURE 3.
12. **Group 2:** If a stencil and/or index marker is missing, apply stencil and/or index marker in accordance with FIGURE 3.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 18 of 31 **BOEING SERVICE BULLETIN 3532**13. **Group 2:** Do a General Visual Inspection or an ultrasonic NDT of the right wing fuel tank access doors to make sure that Impact Resistant Access Doors are installed in the correct locations, in accordance with FIGURE 4.
14. **Group 2:** If one or more standard access doors are found, replace each standard access door with an Impact Resistant access door. Refer to 707 AMM 28-2-1 as an accepted procedure. 15. **Group 2:** Do a General Visual Inspection of the right wing fuel tank access doors to verify stencils and index markers are applied in accordance with FIGURE 4. 16. **Group 2:** If a stencil and/or index marker is missing, apply stencil and/or index marker in accordance with FIGURE 4. 17. If one or more access doors were replaced and a leak check has not been done, refuel the applicable fuel tank and check for leaks. Repair if necessary. Refer to 707 AMM 28-2-1 as an accepted procedure. 18. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 19 of 31 **BOEING SERVICE BULLETIN 3532 This Figure applies only to: Group 1.** 

**FIGURE 1: ACCESS DOOR INSPECTION - LEFT WING (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 20 of 31 **BOEING SERVICE BULLETIN 3532**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 each wing.
**NOTE QTY**  **PART NUMBER NAME**  **TASK STEP**  (a) 9
- Access Door Inspect 1 (b)

- - Stencil and Index Marker Inspect 2 (b)

- - Stencil Inspect 3 (b)

- - Index Marker Inspect 4 (a) In accordance with APPENDIX A. (b) If a stencil and/or index marker is missing, apply stencil and/or index marker with BMS 10-60, Polyurethane Gloss Enamel, matching color to existing stencil and/or index marker. Refer to SOPM 20-50-10.

**FIGURE 1: ACCESS DOOR INSPECTION - LEFT WING (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 21 of 31 **BOEING SERVICE BULLETIN 3532 This Figure applies only to: Group 1.** 

**FIGURE 2: ACCESS DOOR INSPECTION - RIGHT WING (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 22 of 31 **BOEING SERVICE BULLETIN 3532**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 each wing.
**NOTE QTY**  **PART NUMBER NAME**  **TASK STEP**  (a) 9
- Access Door Inspect 1 (b)

- - Stencil and Index Marker Inspect 2 (b)

- - Stencil Inspect 3 (b)

- - Index Marker Inspect 4 (a) In accordance with APPENDIX A. (b) If a stencil and/or index marker is missing, apply stencil and/or index marker with BMS 10-60, Polyurethane Gloss Enamel, matching color to existing stencil and/or index marker. Refer to SOPM 20-50-10.

**FIGURE 2: ACCESS DOOR INSPECTION - RIGHT WING (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 23 of 31 **BOEING SERVICE BULLETIN 3532 This Figure applies only to: Group 2.** 

**FIGURE 3: ACCESS DOOR INSPECTION - LEFT WING (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 24 of 31 **BOEING SERVICE BULLETIN 3532**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 each wing.
**NOTE QTY**  **PART NUMBER NAME**  **TASK STEP**  (a) 8
- Access Door Inspect 1 (b)

- - Stencil and Index Marker Inspect 2 (b)

- - Stencil Inspect 3 (b)

- - Index Marker Inspect 4 (a) In accordance with APPENDIX A. (b) Do a general visual inspection to verify stencils and index markers are applied. If missing, apply stencil and/or index marker with BMS 10-60, Polyurethane Gloss Enamel, matching color to existing stencil and/or index marker. Refer to SOPM 20-50-10.

**FIGURE 3: ACCESS DOOR INSPECTION - LEFT WING (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 25 of 31 **BOEING SERVICE BULLETIN 3532 This Figure applies only to: Group 2.** 

**FIGURE 4: ACCESS DOOR INSPECTION - RIGHT WING (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 26 of 31 **BOEING SERVICE BULLETIN 3532**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 each wing.
**NOTE QTY**  **PART NUMBER NAME**  **TASK STEP**  (a) 8
- Access Door Inspect 1 (b)

- - Stencil and Index Marker Inspect 2 (b)

- - Stencil Inspect 3 (b)

- - Index Marker Inspect 4 (a) In accordance with APPENDIX A. (b) Do a general visual inspection to verify stencils and index markers are applied. If missing, apply stencil and/or index marker with BMS 10-60, Polyurethane Gloss Enamel, matching color to existing stencil and/or index marker. Refer to SOPM 20-50-10.

**FIGURE 4: ACCESS DOOR INSPECTION - RIGHT WING (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 27 of 31 **BOEING SERVICE BULLETIN 3532**Use one of these two procedures to inspect each of the specified access doors. **OPTION 1: GENERAL VISUAL INSPECTION PROCEDURE** 1. General Visual Inspection Procedure: a. Defuel the applicable fuel tank. Refer to 707 AMM 28-0 as an accepted procedure. b. Remove the access door. Refer to 707 AMM 28-2-1 as an accepted procedure. c. Do a General Visual Inspection of the internal surface of the access door. If the internal surface of the access door has protruding cast aluminum integral ribs, then the door is a standard access door (Figure A1). If the internal surface is smooth (no ribs showing), then the door is an impact resistant access door (Figure A1).

**APPENDIX A: PROCEDURE FOR ACCESS DOOR INSPECTION (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 28 of 31 **BOEING SERVICE BULLETIN 3532**Figure A1

**APPENDIX A: PROCEDURE FOR ACCESS DOOR INSPECTION (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 29 of 31 **BOEING SERVICE BULLETIN 3532 OPTION 2: ULTRASONIC NON-DESTRUCTIVE TEST (NDT) INSPECTION PROCEDURE**  1. General: a. This procedure is permitted with or without fuel in the tanks. b. Refer to Non-Destructive Testing Manual (NDT) 707, 720 NDT Part 4, 51-00-00as an accepted procedure. 2. Equipment: a. Digital thickness gage: Kramer Branson CL300, or equivalent. b. Aluminum step wedge standard with a range that includes 0.08 to 0.50 inch. c. A 0.25 inch, 15mhz delay tip or equivalent transducer. d. Couplant: A low viscosity oil or UT couplant which will not damage the airplane structure. 3. Preparation: Clean fuel tank access door external skin. 4. Calibration: Calibrate the gage between 0.08 and 0.50 inch. 5. Inspection: a. Along the center line of the long axis, slowly scan the fuel tank access door from one end to the other end (Figure A2). b. If a rib is detected and the rib thickness is greater than 0.50 inch, then the door is a standard access door. c. If the access door has a thickness between 0.08 and 0.10 inch and no ribs are detected, then the access door is an impact resistant access door.

**APPENDIX A: PROCEDURE FOR ACCESS DOOR INSPECTION (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 30 of 31 **BOEING SERVICE BULLETIN 3532**Figure A2

**APPENDIX A: PROCEDURE FOR ACCESS DOOR INSPECTION (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 3532 31 of 31 **BOEING SERVICE BULLETIN 3532**