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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0099 Original Issue: September 18, 2014 ATA System: 5363 SUBJECT: FUSELAGE - Section 43 and 46 - Structure - Inspection for Cracks in Fuselage Frames at Stringer S-24 and S-25, Left and Right 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 © 2014 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Unpublished Work.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.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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 4 F. Approval ............................................... 2 1 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 4 I. Electrical Load Data ......................................... 2 4 J. References .............................................. 2 4
1. Existing Data: ......................................... 2 4
2. Data Supplied with this Service Bulletin: ........................... 2 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 5 K. Publications Affected ........................................ 2 5 L. Interchangeability and Intermixability of Parts ........................... 2 5 M. Software Accomplishment Summary ................................ 2 5
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 7
1. Kits/Parts ............................................ 2 7
2. Parts and Materials Supplied by the Operator ........................ 2 7
3. Parts Modified and Reidentified ................................ 2 7
4. Parts Removed and Not Replaced .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 1 FIGURE 1: FUSELAGE FRAME - DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTIONS ......................................... 5 4 FIGURE 2: FUSELAGE FRAME - DETAILED AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTIONS - SECTION 43 [Group 1-2, 5-6] ....................... 5 9 APPENDIX A: SCOPE OF INSPECTION [Group 1] ............................. 6 4 APPENDIX B: SCOPE OF INSPECTION [Group 2] ............................. 6 5 APPENDIX C: SCOPE OF INSPECTION [Group 3] ............................. 6 6 APPENDIX D: SCOPE OF INSPECTION [Group 4] ............................. 6 7 APPENDIX E: SCOPE OF INSPECTION [Group 5] ............................. 6 8 APPENDIX F: SCOPE OF INSPECTION [Group 6] ............................. 6 9 APPENDIX G: SCOPE OF INSPECTION [Group 7] ............................. 7 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0099Original Issue: September 18, 2014 ATA System: 5363 SUBJECT: FUSELAGE - Section 43 and 46 - Structure - Inspection for Cracks in Fuselage Frames at Stringer S-24 and S-25, Left and Right
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 One operator has reported a 0.60 inch long crack in the fuselage frame at Station (STA) 1440, stringer S-24L.
The airplane had 36,890 total flight cycles and 78,922 total flight hours. The crack was discovered while doing unrelated local repairs. An investigation has determined the crack may have been caused by fatigue. The crack initiated in the fuselage frame at the corner radius of the fuselage frame opening for the stringer. It continued to the fastener hole common to fuselage frame, splice plate, and fail safe chord. The crack was not visible because it was completely hidden by the splice plate on one side and the fail safe chord on the other side. If this service bulletin is not done, such fatigue cracking could adversely affect the structural integrity of the airplane.
Similar design details and stresses exist at multiple fuselage frame stations in Section 43 and Section 46. This service bulletin gives instructions to inspect for cracks in the fuselage frames at S-24 and S-25, left and right at multiple fuselage frame stations.
The fuselage frames have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Boeing Service Related Problem (SRP) 757-53-0429 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data 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/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION This service bulletin gives instructions to do detailed and High Frequency Eddy Current (HFEC) inspections for cracks in the fuselage frames at the identified Station (STA) locations and Stringer (S) locations.
If any crack is found, contact Boeing for repair instructions and do the repair.
EFFECTIVITY All 757-200, -200CB, -200PF, -300 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 not available for the inspections given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 757-53A0099
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A LEFT SIDE
RIGHT SIDE
SIDE SIDE
FRAME DO DETAILED AND HIGH FREQUENCY EDDY FRAME
CURRENT (HFEC) INSPECTIONS FOR CRACKS
SPLICE SPLICE
PLATE PLATE S-25R - S-25L (SECTION 43) (SECTION 43) S-24R S-24L (SECTION 46) (SECTION 46)
INBD INBD
LOWER LOWER
TYPICAL FUSELAGE FRAME FRAME FRAME TYPICAL FUSELAGE FRAME (RIGHT SIDE, VIEW LOOKING AFT) (LEFT SIDE, VIEW LOOKING AFT) Original Issue: September 18, 2014 Export Controlled ECCN: 9E991 - BOEING 757-53A0099 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 70
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: 757-53A0099 Original Issue: September 18, 2014 ATA System: 5363 SUBJECT: FUSELAGE - Section 43 and 46 - Structure - Inspection for Cracks in Fuselage Frames at Stringer S-24 and S-25, Left and Right
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 Service Bulletin Index D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 757-200 Airplanes with 2 Cargo Doors-1 757-200 Airplanes with 3 Cargo Doors-2 757-200PF Airplanes (Freighter)-3 757-200SF Airplanes (Special Freighter Boeing Supplemental Type Certificate) -4 757-300 Airplanes with Cargo Net Support Structure Installation (STA 720-STA 740) -5 757-300 Airplanes without Cargo Net Support Structure Installation (STA 720-STA 740) -6 757-200CB Airplane (Convertible)-7 Airplane Models:
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757-200, 757-200CB, 757-200PF, 757-300 GroupVariable Number 1NA001 - NA028 1NA191 - NA199 4NA201 - NA204 2NA205 4NA206 - NA213 2NA214 4NA215 - NA236 1NA237 - NA239 1NA301 - NA305 2NA341 - NA352 2NA391 - NA399 1NA401 - NA408 1NA441 - NA447 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 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 1NC151 1NC161 3NC901 - NC951 3NC971 - NC974 1ND001 - ND007 1ND011 - ND059 1ND111 - ND113 1ND161 - ND199 1ND201 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND322 1ND401 1ND891 7ND895 1NE001 - NE008 1NE011 - NE088 1NE091 - NE094 1NE141 - NE150 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NE161 - NE177 1NE201 - NE204 1NE301 - NE302 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 5NL001 - NL002 6NL006 - NL017 6NL101 - NL109 6NL141 6NL601 - NL616 1NN001 - NN002 1NN051 - NN052 1NP901 - NP904 3NS601 - NS616 3NT001 - 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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