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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0012 Original Issue: October 05, 1984 Revision 1: January 25, 2017 ATA System: 5363 SUBJECT: FUSELAGE - Section 46 - Structure - Cargo Deck Attachment Inspection and Modification 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 © 1989 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Unpublished Work.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: October 05, 1984 757-53A0012Revision 1: January 25, 2017 1 of 169
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 2 of 169 BOEING SERVICE BULLETIN 757-53A0012
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y9
1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3
1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F . A p p r o v a l ............................................... 3 0 G. Manpower .............................................. 3 0 H. Weight and Balance Changes .................................... 3 2 I. Electrical Load Data ......................................... 3 2 J . R e f e r e n c e s .............................................. 3 2
1. Existing Data: ......................................... 3 2
2. Data Supplied with this Service Bulletin: ........................... 3 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 2 K. Publications Affected ........................................ 3 3 L. Interchangeability and Intermixability of Parts ........................... 3 3 M. Software Accomplishment Summary ................................ 3 3
2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 B. Industry Support Information .................................... 3 5 C. Parts Necessary for Each Airplane ................................. 3 5 1 . K i t s / P a r t s ............................................ 3 5
2. Parts and Materials Supplied by the Operator ........................ 3 8
3. Parts Modified and Reidentified ................................ 3 8
4. Parts Removed and Not Replaced .............................. 3 8 D. Parts Necessary to Change Spares ................................. 3 8 E. Special Tooling - Price and Availability ............................... 3 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 1 FIGURE 1: DETAILED INSPECTION AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION OF FRAME INNER CHORD FROM STA 1200 TO STA 1620 [Group 1, 3] ......... 5 4 F I G U R E 2 : T H I S F I G U R E I S D E L E T E D.................................. 5 6 FIGURE 3: SIDE PANEL AND FRAME MODIFICATION AT STA 1640 FRAME [Group 1, 3] ..... 5 7 FIGURE 4: MODIFICATION OF SIDE PANEL, FRAME, AND INTERCOSTAL AT STA 1380 ..... 6 2 FIGURE 5: MODIFICATION OF SIDE PANEL ATTACHMENT FROM STA 1200 TO STA 1300 . . . 71 FIGURE 6: MODIFICATION OF SIDE PANEL ATTACHMENT FROM STA 1320 TO STA 1620 [Group 1, 3 ] ................................................ 7 4 FIGURE 7: REMOVE SIDE PANEL SPLICE AND CARGO TIEDOWN FITTING ATTACH SCREWS . 77 FIGURE 8: INSTALL SIDE PANEL SPLICE AND CARGO TIEDOWN FITTING ............ 8 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 3 of 169 BOEING SERVICE BULLETIN 757-53A0012
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FIGURE 9: GENERAL VISUAL INSPECTION FOR MODIFICATION [Group 1] ............ 8 6 FIGURE 10: GENERAL VISUAL INSPECTION FOR MODIFICATION [Group 2] ............ 9 4 FIGURE 11: MODIFICATION OF SIDE PANEL, FRAME, AND INTERCOSTAL AT STA 1440 [Group 2] . 103 FIGURE 12: DETAILED INSPECTION AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION OF FRAME INNER CHORD FROM STA 1200 TO STA 1580 [Group 2] ......... 1 1 2 FIGURE 13: SIDE PANEL AND FRAME MODIFICATION AT STA 1640 FRAME [Group 2] ...... 1 1 4 FIGURE 14: MODIFICATION OF SIDE PANEL ATTACHMENT FROM STA 1320 AND STA 1580 [Group 2] ................................................. 1 1 7 FIGURE 15: SIDE PANEL ATTACH TAB AND FRAME AT 1380 - DETAILED INSPECTION AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION .................. 1 2 0 FIGURE 16: SIDE PANEL ATTACH TAB AND FRAME AT 1440 - DETAILED INSPECTION AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 2-3] ........... 1 2 2 FIGURE 17: FRAME AT STA 1640 - LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1 , 3 ] .............................................. 1 2 4 FIGURE 18: FRAME AT STA 1640 - LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 2 ] ................................................ 1 2 6 FIGURE 19: GENERAL VISUAL INSPECTION FOR MODIFICATION [Group 3] ............ 1 2 8 FIGURE 20: SIDE PANEL, STANCHION, AND INTERCOSTAL MODIFICATION FROM STA 1440 TO STA 1500 [Group 3] ........................................ 1 3 9 APPENDIX A: TABLE 1: INSPECTION AND MODIFICATION OF AFT CARGO SIDE PANEL TO FRAME ATTACHMENTS FROM STA 1200 TO STA 1640 [Group 1] ................ 1 4 9 APPENDIX B: TABLE 2: INSPECTION AND MODIFICATION OF AFT CARGO SIDE PANEL TO FRAME ATTACHMENTS FROM STA 1200 TO STA 1640 [Group 2] ................ 1 5 5 APPENDIX C: TABLE 3: INSPECTION AND MODIFICATION OF AFT CARGO SIDE PANEL TO FRAME ATTACHMENTS FROM STA 1200 TO STA 1640 [Group 3] ................ 1 6 2 APPENDIX D: BOEING PART DEMAND INTENT .............................. 1 6 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 4 of 169 BOEING SERVICE BULLETIN 757-53A0012
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Commercial Airplanes 757 Service Bulletin ALERT Revision Transmittal SheetNumber: 757-53A0012Original Issue: October 05, 1984 Revision 1: January 25, 2017 ATA System: 5363 SUBJECT: FUSELAGE - Section 46 - Structure - Cargo Deck Attachment Inspection and Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION 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.
Effects of this Revision on airplanes on which the Original Issue was previously done:
ActionConditionGroup Do a general visual inspection to make sure that the modifications are complete.
All airplanes.1, 2, 3 Airplanes line numbers 37 to 49 and 51 were added to Group 1, and airplane line number 50 was added to Group 2 of this service bulletin effectivity. Airplanes line numbers 2 to 5 were removed from Group 1 and airplane line number 1 to 5 were added to new Group 3.
REASON FOR REVISION Revision 1 is sent to add a general visual inspection to verify modification status and if the modification is not complete, do Low Frequency Eddy Current (LFEC) inspections and a mandatory modification that is required to comply with the Widespread Fatigue Damage (WFD) rule. The release classification of this service bulletin has been changed to Alert Service Bulletin.
These sections were changed:
1. In Summary, Background, the paragraph has been updated, a Widespread Fatigue Damage (WFD) statement, a reference to Boeing Fleet Team Digest, and a Summary evaluation table have been added.
2. In Summary, Action, the paragraph has been updated.
3. In Summary, Compliance, a paragraph has been added.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 5 of 169
4. In Summary, Industry Support Information, a paragraph has been added.
5. In Summary, Manpower, a paragraph has been updated and tables have been added.
6. In Summary, Material Information, the paragraph has been updated.
7. In Summary, the illustration has been updated.
8. In Paragraph 1.A., Effectivity, line numbers 37 to 49 and 51 have been added to Group 1, and line number 50 has been added to Group 2, line numbers 2 to 5 were removed from Group 1, and line numbers 1 to 5 were added to new Group 3.
9. In Paragraph 1.C., Reason, the paragraph has been updated, and a Widespread Fatigue Damage (WFD) statement, and a reference to Boeing Fleet Team Digest have been added.
10. In Paragraph 1.D., Description, paragraph has been updated, a group configuration table, and a maintenance zone table have been added.
11. In Paragraph 1.E., Compliance, compliance tables have been added.
12. In Paragraph 1.F., Approval, the paragraph has been updated.
13. In Paragraph 1.G., Manpower, manpower tables have been added.
14. In Paragraph 1.J., References, the reference list has been updated.
15. In Paragraph 1.K.1., Publications, a paragraph has been added.
16. In Paragraph 1.K.2., Damage Tolerance Based Structural Inspections, a paragraph has been added.
17. In Paragraph 1.L., Interchangeability and Intermixability of parts, paragraph has been added.
18. In Paragraph 1.M., Software Accomplish Summary, a paragraph has been added.
19. In Paragraph 2.A., Material - Price and Availability, the paragraphs and table have been updated.
20. In Paragraph 2.B., Industry Support Information, a paragraph has been added.
21. In Paragraph 2.C.1., Kits/Parts, the table has been updated.
22. In Paragraph 2.C.2., Parts and Materials Supplied by the operator, table has been updated.
23. In Paragraph 2.C.3., Parts Modified and Reidentified, a paragraph has been added.
24. In Paragraph 2.C.4., Parts Removed and Not Replaced, a paragraph has been added.
25. In Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin, the paragraph has been updated.
26. In Paragraph 3.A., General Information, paragraphs have been updated and notes have been added.
27. In Paragraph 3.B., Work Instructions, new work instructions have been added.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 6 of 169 BOEING SERVICE BULLETIN 757-53A0012
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28. In Figures 1, 3, 4, 5, 6, 7 and 8, the Illustrations have been updated and step tables added.
29. Figure 2 has been deleted.
30. Figure 9 has been added do inspection for modification on Group 1 airplanes.
31. Figure 10 has been added do inspection for modification on Group 2 airplanes.
32. Figure 11 has been added to do modification of the side panel, frame, and intercostal at STA 1440 for Group 2 airplanes.
33. Figure 12 has been added to do inspection of frame inner chord for Group 2 airplanes.
34. Figure 13 has been added to do modification of aft wall at STA 1640 for Group 2 airplanes.
35. Figure 14 has been added to do modification of side panel attachment from STA 1320 to STA 1580 for Group 2 airplanes.
36. Figure 15 has been added to do inspection of side panel attach tabs and frame at STA 1380.
37. Figure 16 has been added to do inspection of side panel attach tabs and frame at STA 1440 for Group 2 and Group 3 airplanes.
38. Figure 17 has been added to do inspection of frame at STA 1640 for Group 1 and Group 3 airplanes.
39. Figure 18 has been added to do inspection of frame at STA 1640 for Group 2 airplanes.
40. Figure 19 has been added do inspection for modification on Group 3 airplanes.
41. Figure 20 has been added to do modification of the side panel, stanchions, and intercostals from STA 1440 to STA 1500 on Group 3 airplanes.
42. Appendix A, new Logic Diagram has been added for Group 1 airplanes.
43. Appendix B, new Logic Diagram has been added for Group 2 airplanes.
44. Appendix C, new Logic Diagram has been added for Group 3 airplanes.
45. Appendix D, Boeing Part Demand Intent added.
The data given in Notice of Status Change 757-53-0012 NSC1 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY October 05, 1984Original Issue:
January 25, 2017Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 7 of 169 BOEING SERVICE BULLETIN 757-53A0012
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 8 of 169 BOEING SERVICE BULLETIN 757-53A0012
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BLANK PAGE
Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0012Original Issue: October 05, 1984 Revision 1: January 25, 2017 ATA System: 5363 SUBJECT: FUSELAGE - Section 46 - Structure - Cargo Deck Attachment Inspection and Modification
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.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions to inspect that a modification to the aft cargo side panel attach tabs and frames; STA 1640 frame; and STA 1380 and STA 1440 intercostals, clips and angles is complete. If modification is not complete, this service bulletin gives instructions to inspect for any crack on the frames from STA 1200 to STA 1640 at the cargo floor interfaces between stringers S-26 and S-27; and to modify the attachments between the frames and the cargo floor. Accomplishment of the work in this service bulletin will make sure that the modification of the body frames at the aft cargo compartment panel attach points and intercostals are complete, to reduce the probability of cracks in the lower lobe frames and side panels. If the work given in this service bulletin is not accomplished, a frame crack at the panel attach point may go undetected and grow in length. An undetected crack could result in reduced structural integrity of the body frames at the aft cargo panel attachment points. Failure of multiple frames could lead to rapid decompression of the airplane.
Fatigue testing of two 757 airframes indicates body frames in the aft cargo compartment may crack at the side panel to frame attachment.
In one fatigue test airframe, numerous fractured cargo compartment side panel attach fasteners, cracked side panel attach tabs at right side STA 1380, cracked frames at left side STA 1320, 1400, 1500, 1540, 1560 and right side STA 1540 were found at 34,600 equivalent flight cycles.
In the second fatigue test airframe, several fractured side panel attach fasteners and cracked frames at right side STA 1580 and 1600 were found at 62,500 equivalent flight cycles. These frame cracks originated at the side panel to frame attach fastener rivet hole and propagated from fastener hole to fastener hole through the frame inner chord, web and fail-safe chord.
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Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 9 of 169
Cracks have already been reported in fuselage frames in the aft cargo compartment at STA 1340, 1400, 1420, 1500, 1520 and 1580 between S-26 and S-27 on the left and right sides, at the intersection with the side cargo compartment panel installation. The cracking has been attributed to fatigue at the associated frame attachment fastener hole, as a result of an unmodified or de-modified interface between the affected frame and the cargo floor.
These cracks may be associated with airplanes that have had the modification removed. Widespread Fatigue Damage (WFD) analysis identified the need for the inspections and modifications of frames from STA 1320 through STA 1620.
The modification as given in the original issue of this service bulletin was not mandated, and has been removed on two airplanes that were converted, and may have been removed on more. Airplane line numbers 37 - 51 should have been reworked in production but the rework may not have been accomplished or may have been de-modified.
The fuselage frames from STA 1320 through STA 1620 in this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Boeing Fleet Team Digest (FTD) 757 FTD 53-14001 is related to this service bulletin.
Boeing Service Related Problem (SRP) 757-SRP-53-0488 is related to this service bulletin.
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 AffectedNoPublications 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 Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 53068-R) Do a general visual inspection to make sure that a modification has been done and remains complete. If no modification has been done, or is not complete, do a Low Frequency Eddy Current (LFEC) inspection for any crack and do the modification of the aft cargo compartment side panel to frame attachments. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If the modification has been done, and remains complete, no further inspection or modification is required.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 10 of 169 BOEING SERVICE BULLETIN 757-53A0012
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Group 1 airplanes, which have two cargo doors, have the E-6 electrical equipment rack aft of the number 2 cargo door and do not require inspection or modification of side panel attach tabs at STA 1440 right side. Group 2 airplanes, which have three cargo doors, have the E-6 rack aft of the number 3 cargo door and do not require inspection or modification on the right side, aft of STA 1520.
Group 3 airplanes are similar to Group 1 airplanes, and also require inspection or modification of the side panel, stanchions, stringer clips, and intercostals from STA 1440 right side, to STA 1500 right side.
EFFECTIVITY 757-200 Airplanes. Refer to Paragraph 1.A., Effectivity, 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 This service bulletin was first released before October of 1994. Thus industry support for affected airplanes depends upon whether the operator previously filed a warranty claim with Boeing on this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX D of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 05, 1984 757-53A0012Revision 1: January 25, 2017 11 of 169 BOEING SERVICE BULLETIN 757-53A0012
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BOEING SERVICE BULLETIN 757-53A0012
ALERT ALERT NO. 2 CARGO DOOR NO. 3 CARGO DOOR STA 1380
SIDEWALL LINING
SIDE PANEL STA 1440
CARGO STA DECK 1460 STA 1480 STA 1500
SIDE PANEL TO FRAME ATTACHMENT (40 LOCATIONS ON GROUP 1 AND GROUP 3) (33 LOCATIONS ON GROUP 2) NO. 2
SIDE PANEL AND INTERCOSTAL CARGO DOOR
ATTACHMENT
SIDE PANEL, STANCHION
AND INTERCOSTAL (GROUP 3 ONLY)
DO A GENERAL VISUAL INSPECTION OF THE SIDE PANELS, SIDE PANEL ATTACH TABS, FRAME INNER
COMPLETEND INTERCOSTALS IN THE CARGO COMPARTMENT, TO MAKE SURE THAT MODIFICATION IS
IF THE MODIFICATION IS NOT COMPLETE, DO A LOW FREQUENCY EDDY CURRENT INSPECTION FOR ANY
FRAME CRACK, AND DO THE MODIFICATION
IF ANY CRACK IS FOUND, CONTACT THE BOEING COMPANY FOR REPAIR INSTRUCTIONS AND DO THE RETHE MODIFICATION IS COMPLETE, NO FURTHER INSPECTION OR MODIFICATIONIS REQUIRED. 2450205 Original Issue: October 05, 1984 Revision 1: January 25, 2017 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-53A0012 Work - See page 1 for details. 12 of 169