Boeing ASB 757-53A0100: Revision 1, text

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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0100 Original Issue: November 14, 2016 Revision 1: September 14, 2017 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Body Station 1681 Fuselage Frame 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:

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 14, 2016 757-53A0100Revision 1: September 14, 2017 1 of 188

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Original Issue: November 14, 2016 757-53A0100Revision 1: September 14, 2017 2 of 188 BOEING SERVICE BULLETIN 757-53A0100

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Table of Contents

Revision Transmittal Sheet7

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 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F . A p p r o v a l ............................................... 5 0 G. Manpower .............................................. 5 0 H. Weight and Balance Changes .................................... 5 6 I. Electrical Load Data ......................................... 5 6 J . R e f e r e n c e s .............................................. 5 6

1. Existing Data: ......................................... 5 6

2. Data Supplied with this Service Bulletin: ........................... 5 6

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 6 K. Publications Affected ........................................ 5 7 L. Interchangeability and Intermixability of Parts ........................... 5 7 M. Software Accomplishment Summary ................................ 5 7

2. MATERIAL INFORMATION ........................................ 5 9 A. Material - Price and Availability ................................... 5 9 B. Industry Support Information .................................... 5 9 C. Parts Necessary for Each Airplane ................................. 5 9 1 . K i t s / P a r t s ............................................ 5 9

2. Parts and Materials Supplied by the Operator ........................ 5 9

3. Parts Modified and Reidentified ................................ 6 0

4. Parts Removed and Not Replaced .............................. 6 0 D. Parts Necessary to Change Spares ................................. 6 0 E. Special Tooling - Price and Availability ............................... 6 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 0

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 1 A. GENERAL INFORMATION ..................................... 6 1 B. WORK INSTRUCTIONS ....................................... 6 2 FIGURE 1: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - FORWARD

INNER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] .......... 7 7 FIGURE 2: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - FORWARD

INNER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] .......... 8 0 FIGURE 3: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1, Configuration 1] ......................................... 8 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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FIGURE 4: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1, Configuration 1] ......................................... 8 6 FIGURE 5: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] .......................................... 8 9 FIGURE 6: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] .......................................... 9 2 FIGURE 7: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - FORWARD

AND AFT INNER AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 1] . 95 FIGURE 8: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - FORWARD

AND AFT INNER AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 1] . 99 FIGURE 9: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - FORWARD

AND AFT INNER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] ................................................. 1 0 3 FIGURE 10: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - FORWARD

AND AFT INNER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] ................................................. 1 0 7 FIGURE 11: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR -AFT INNER

AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 1] ............ 1 1 1 FIGURE 12: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR -AFT INNER

AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 1] ............ 1 1 5 FIGURE 13: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - AFT INNER

CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] ......... 1 1 9 FIGURE 14: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - AFT INNER

CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION [Group 1, Configuration 2-3; Group 2] ......... 1 2 3 FIGURE 15: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER

AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 1] .......................... 1 2 7 FIGURE 16: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER

AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 1] .......................... 1 3 0 FIGURE 17: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER

CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 2-3; Group 2] ............................ 1 3 3 FIGURE 18: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME ABOVE FLOOR - AFT INNER

CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 2-3; Group 2] ............................ 1 3 6 FIGURE 19: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - AFT INNER

AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 1] .......................... 1 3 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: November 14, 2016 757-53A0100Revision 1: September 14, 2017 4 of 188 BOEING SERVICE BULLETIN 757-53A0100

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FIGURE 20: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - AFT INNER

AND OUTER CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 1] .......................... 1 4 3 FIGURE 21: LEFT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - AFT INNER

CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 2-3; Group 2] ............................ 1 4 7 FIGURE 22: RIGHT SIDE - BODY STATION (STA) 1681 FUSELAGE FRAME BELOW FLOOR - AFT INNER

CHORD HIGH FREQUENCY EDDY CURRENT (HFEC) AND OPEN HOLE HFEC INSPECTION [Group 1, Configuration 2-3; Group 2] ............................ 1 5 1 APPENDIX A: LOGIC DIAGRAM FOR COMPLIANCE TABLE 1: BODY STATION (STA) 1681 FUSELAGE

FRAME HIGH FREQUENCY EDDY CURRENT (HFEC), LOW FREQUENCY EDDY CURRENT (LFEC) AND OPEN HOLE HFEC INSPECTION FOR ANY CRACK [Group 1, Configuration 1] ................................................. 1 5 5 APPENDIX B: LOGIC DIAGRAM FOR COMPLIANCE TABLE 2: BODY STATION (STA) 1681 FUSELAGE

FRAME HIGH FREQUENCY EDDY CURRENT (HFEC), LOW FREQUENCY EDDY CURRENT (LFEC) AND OPEN HOLE HFEC INSPECTION FOR ANY CRACK [Group 1, Configuration 2] ................................................. 1 6 1 APPENDIX C: LOGIC DIAGRAM FOR COMPLIANCE TABLE 3: BODY STATION (STA) 1681 FUSELAGE

FRAME HIGH FREQUENCY EDDY CURRENT (HFEC), LOW FREQUENCY EDDY CURRENT (LFEC) AND OPEN HOLE HFEC INSPECTION FOR ANY CRACK [Group 1, Configuration 3] ................................................. 1 6 8 APPENDIX D: LOGIC DIAGRAM FOR COMPLIANCE TABLE 4: BODY STATION (STA) 1681 FUSELAGE

FRAME HIGH FREQUENCY EDDY CURRENT (HFEC), LOW FREQUENCY EDDY CURRENT (LFEC) AND OPEN HOLE HFEC INSPECTION FOR ANY CRACK [Group 2, Configuration 1] ................................................. 1 7 5 APPENDIX E: LOGIC DIAGRAM FOR COMPLIANCE TABLE 5: BODY STATION (STA) 1681 FUSELAGE

FRAME HIGH FREQUENCY EDDY CURRENT (HFEC), LOW FREQUENCY EDDY CURRENT (LFEC) AND OPEN HOLE HFEC INSPECTION FOR ANY CRACK [Group 2, Configuration 2] ................................................. 1 8 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Commercial Airplanes 757 Service Bulletin ALERT Revision Transmittal SheetNumber: 757-53A0100Original Issue: November 14, 2016 Revision 1: September 14, 2017 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Body Station 1681 Fuselage Frame Inspection This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2017-NM-001-AD, is related to this service bulletin.

Effects of this Revision on airplanes on which Original Issue was previously done:

None.

REASON FOR REVISION This revision is sent to provide the operator with an option for Open Hole High Frequency Eddy Current (HFEC) inspections on the critical fasteners in order to extend repeat inspection intervals for the frames at Body Station (STA) 1681. This revision is also sent to correct fasteners to rivets in Figures 1 thru 6 and to correct conditions in the logic diagrams.

The data given in Information Notice 757-53A0100 IN 01 is included in this revision.

These sections were changed:

1. In Summary, Background, added Open Hole HFEC inspections.

2. In Summary, Action, added Open Hole HFEC inspections.

3. In Summary, Compliance, added NPRM reference.

4. In Summary, revised the summary illustration.

5. In Paragraph 1.C., Reason, added Open Hole HFEC inspections, reason for revision and Information Notice (IN) information.

6. In Paragraph 1.D., Description, added Open Hole HFEC inspections and no more work statement.

7. In Paragraph 1.E., Compliance, added options for Open Hole HFEC inspections and NPRM reference.

8. In Paragraph 1.G., Manpower, revised and added tables.

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9. In Paragraph 1.J., References, added NPRM and SRM references.

10. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added parts and footnote.

11. In Paragraph 3.B., Work Instructions, changed as follows:

a. Updated work instructions.

b. Added options for Open Hole HFEC inspections.

c. Added PART 6 and PART 7.

12. In Figures 1 thru 8, 11 and 12, revised illustrations and step tables.

13. In Figures 9 thru 12, revised figure title.

14. Added Figures 15 thru 22, Open Hole HFEC inspection figures and fastener installation figures.

15. In Appendix A thru E, revised logic diagrams and tables.

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 November 14, 2016Original Issue:

September 14, 2017Revision 1:

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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0100Original Issue: November 14, 2016 Revision 1: September 14, 2017 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Body Station 1681 Fuselage Frame 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.

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin provides instructions to do High Frequency Eddy Current (HFEC), Low Frequency Eddy Current (LFEC) and Open Hole HFEC inspections for any crack in the fuselage frame at Body Station (STA) 1681, in the area around stringer S-17, on the left and right side of the airplane. If the work given in this service bulletin is not done, undetected cracking in the fuselage frame at STA 1681 could adversely affect the structural integrity of the airplane.

One operator reported a six inch long crack in the fuselage frame web at STA 1681, below the floor line at stringer S-17L, during a routine maintenance visit. Boeing analysis has determined that the crack was caused by fatigue. The crack was not easily detected because it was significantly hidden by adjacent structure.

Accomplishment of the work given in this service bulletin will mitigate the safety issue associated with cracking in the STA 1681 fuselage frame and make sure that any crack is found and repaired before the crack grows to a critical length.

Boeing Fleet Team Digest (FTD) 757 FTD 53-14002 is related to this service bulletin.

Boeing Service Related Problem (SRP) 757-SRP-53-0489 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 YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Get access to the Body Station (STA) 1681 fuselage frame, between stringer S-16 and S-18, on the left and right side of the airplane. Inspect for any existing frame repair and for any existing floor beam repair common to the STA 1681 frame inspection area. If any existing frame repair is found common to the STA 1681 fuselage frame inspection area, contact The Boeing Company for repair evaluation and inspection instructions and do the instructions.

In areas with no existing frame repair, do High Frequency Eddy Current (HFEC) or do HFEC and Open Hole HFEC inspections for any crack in the STA 1681 fuselage frame, in the area above the floor around stringer S-17.

In areas with no existing floor beam repair, do HFEC and Low Frequency Eddy Current (LFEC) inspections or do HFEC and Open Hole HFEC inspections, from the forward and aft side of the frame, for any crack in the STA 1681 fuselage frame, in the area under the floor around stringer S-17.

In areas with any existing floor beam repair, do HFEC and LFEC inspections or do HFEC and Open Hole HFEC inspection from the aft side of the frame only, for any crack in the STA 1681 fuselage frame, in the area under the floor around stringer S-17.

If any crack is found, contact The Boeing Company for repair instructions and do the repair, and repeat the inspections in areas with no existing frame repair at the times specified in Paragraph 1.E., Compliance.

If no crack is found, repeat the inspections at the times specified in Paragraph 1.E., Compliance.

EFFECTIVITY 757-200, -200CB and -300 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2017-NM-001-AD, is related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

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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 Operator Supplied Parts/Materials.

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BOEING SERVICE BULLETIN 757-53A0100

ALERT ALERT

DO HIGH FREQUENCY EDDY CURRENT

INSPECTION (HFEC), HFEC AND LOW

FREQUENCY EDDY CURRENT (LFEC INSPECTIONS OR DO HFEC AND OPÉN HOLE TA 1681 FUSELAGE FRAME IN THE ARNATHE AROUND STRINGER S-17.

STA 1681 S-17L - S-18L - FWD

LEFT SIDE SHOWN

RIGHT SIDE IS SIMILAR 2538018 Original Issue: November 14, 2016 Revision 1: September 14, 2017 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING Work - See page 1 for details. 757-53A0100 12 of 188

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