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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-27A0153 Original Issue: May 09, 2012 ATA System: 2721 SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod Bolt Replacement 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 © 2012 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Unpublished Work.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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management Company.
Original Issue: May 09, 2012 757-27A0153 1 of 45
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2012 757-27A0153 2 of 45 BOEING SERVICE BULLETIN 757-27A0153
ALERTALERT
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 3 E. Compliance .............................................. 1 3 F. Approval ............................................... 1 5 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 1 8 J. References .............................................. 1 8
1. Existing Data: ......................................... 1 8
2. Data Supplied with this Service Bulletin: ........................... 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8 K. Publications Affected ........................................ 1 8 L. Interchangeability and Intermixability of Parts ........................... 1 9 M. Software Accomplishment Summary ................................ 1 9
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 1 C. Parts Necessary for Each Airplane ................................. 2 1
1. Kits/Parts ............................................ 2 1
2. Parts and Materials Supplied by the Operator ........................ 2 2
3. Parts Modified and Reidentified ................................ 2 2
4. Parts Removed and Not Replaced .............................. 2 3 D. Parts Necessary to Change Spares ................................. 2 3 E. Special Tooling - Price and Availability ............................... 2 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: REMOVAL OF THE RUDDER PEDAL PUSHROD BOLT, WASHER, NUT, AND COTTER PIN
AND INSPECTION OF THE HOLE IN EACH OF THE CAPTAIN AND THE FIRST OFFICER RUDDER PEDAL ARM ASSEMBLIES ............................ 3 0 FIGURE 2: INSTALLATION OF THE NEW RUDDER PEDAL PUSHROD BOLT FOR EACH RUDDER PEDAL ARM ASSEMBLY ................................... 3 4 FIGURE 3: REPAIR OF ONE HOLE IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING ONE BUSHING ............................................ 3 8 FIGURE 4: REPAIR OF THE TWO HOLES IN THE RUDDER PEDAL ARM ASSEMBLY BY INSTALLING TWO BUSHINGS ........................................ 4 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2012 757-27A0153 3 of 45 BOEING SERVICE BULLETIN 757-27A0153
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2012 757-27A0153 4 of 45 BOEING SERVICE BULLETIN 757-27A0153
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-27A0153Original Issue: May 09, 2012 ATA System: 2721 SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod Bolt Replacement
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 Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND This service bulletin gives the instructions and a kit of parts to inspect the rudder pedal arm assembly holes, install stronger rudder pedal pushrod bolt, and provides an option to replace the rudder pedal assembly or repair the rudder pedal arm assembly if the holes are worn. If the change in this service bulletin is not done, a bolt fracture under heavy braking during a high-speed takeoff (RTO) may result in a loss of control of the airplane and subsequent runway excursion.
Boeing received three reports of fractured rudder pedal pushrod bolts in the rudder pedal assembly on 757 aircraft. In one incident, the operator found a fractured bolt during the airplane pushback when the captain applied brakes. The operator reported that the rudder pedal shifted when applying brakes and the rudder moved to the hard left. The left rudder sudden movement occurred after the bolt fractured. Investigation and analysis of the three incidents has shown that the rudder pedal pushrod bolts are under strength for high loading applications.
Accomplishment of this service bulletin installs new stronger rudder pedal pushrod bolts. The installation of the new bolts will prevent runway excursion under heavy braking during a high-speed takeoff (RTO) due to bolt fracture.
Boeing Service Related Problem (SRP) 757-SRP-27-0209 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 757 FTD 27-09004 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2012 757-27A0153 5 of 45
ReferenceAffectedPlanning Data Paragraph 1.E., ComplianceNoAD 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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 54530-295RS) Get access to the rudder pedal assembly for the captain and first officer and remove the rudder pedal pushrod bolt, washer, nut, and cotter pin. Inspect the rudder pedal arm assembly holes for wear. If holes are worn, replace the rudder pedal assembly or repair the rudder pedal arm assembly by installing bushings as necessary. Install the new rudder pedal pushrod bolt, washer, nut, and cotter pin.
EFFECTIVITY All 757 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
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 available for airplanes in warranty as of October 16, 1997. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 757-27A0153
ALERT ALERT RUDDER
RUDDER PEDAL ARMS PEDAL
PUSHRODS
REMOVE BOLTS,
INSPECT THE HOLES,
REPLACE THE RUDDER
PEDAL ARM ASSEMBLY
OR INSTALL BUSHINGS AS NECESSARY.
INSTALL NEW BOLTS.
FIRST OFFICER'S RUDDER PEDALS SIMILAR CAPTAIN'S RUDDER PEDALS SHOWN 2104633 Original Issue: May 09, 2012 Export Controlled ECCN: 9E991 - BOEING 757-27A0153 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 45
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-27A0153 Original Issue: May 09, 2012 ATA System: 2721 SUBJECT: FLIGHT CONTROL - Rudder and Rudder Trim Control System - Rudder Pedal Pushrod Bolt Replacement
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 This service bulletin is for the airplane(s) shown below. Refer to PRR 54530-295RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP All 757 airplanes line numbers 1 through 1050.-1 Airplane Models:
757-200, 757-200CB, 757-200PF, 757-300 GroupVariable Number 1NA001 - NA028 1NA191 - NA199 1NA201 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 1NA401 - NA408 1NA441 - NA447 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 09, 2012 757-27A0153 9 of 45
GroupVariable Number 1NA501 - NA586 1NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 1NB221 - NB228 1NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 1NB571 1NB581 - NB583 1NC001 - NC033 1NC041 - NC042 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NC151 1NC161 1NC901 - NC951 1NC971 - NC974 1ND001 - ND007 1ND011 - ND059 1ND111 - ND113 1ND161 - ND199 1ND201 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND322 1ND401 1ND891 1ND895 1NE001 - NE008 1NE011 - NE088 1NE091 - NE094 1NE141 - NE150 1NE161 - NE177 1NE201 - NE204 1NE301 - NE302 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 1NL001 - NL002 1NL006 - NL017 1NL101 - NL109 1NL141 1NL601 - NL616 1NN001 - NN002 1NN051 - NN052 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NP901 - NP904 1NS601 - NS616 1NT001 - NT009 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 1NT281 - NT289 1NT341 - NT347 1NT351 - NT360 1NT371 - NT373 1NT375 - NT379 1NT381 - NT386 1NT401 - NT409 1NT411 - NT412 1NT426 - NT427 1NT431 - NT432 1NT436 - NT438 1NT441 - NT442 1NT446 1NT701 - NT769 1NT791 - NT796 1NT861 - NT862 1NT881 - NT885 1NT901 - NT916 1NT971 - NT985 1NU031 - NU038 1NU701 - NU705 1NU721 - NU728 1NU731 - NU732 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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