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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0101 Original Issue: November 08, 2016 ATA System: 5363 SUBJECT: FUSELAGE - Section 46 - Structure - Station 1380 Frame Inner Chord Inspection Between Stringer S-23R and Lower Sill Threshold 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 © 2016 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Unpublished Work.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: November 08, 2016 757-53A0101 1 of 35
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2016 757-53A0101 2 of 35 BOEING SERVICE BULLETIN 757-53A0101
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected13
B. Concurrent Requirements13
C. Reason13
D. Description14
E. Compliance14
F. Approval16
G. Manpower16
H. Weight and Balance Changes17
I. Electrical Load Data17
J. References17
1. Existing Data:17
2. Data Supplied with this Service Bulletin:18
3. Installation Drawings Used in the Preparation of this Service Bulletin:18
K. Publications Affected18
L. Interchangeability and Intermixability of Parts18
M. Software Accomplishment Summary18
2. MATERIAL INFORMATION19
A. Material - Price and Availability19
B. Industry Support Information19
C. Parts Necessary for Each Airplane19
1. Kits/Parts19
2. Parts and Materials Supplied by the Operator19
3. Parts Modified and Reidentified19
4. Parts Removed and Not Replaced19
D. Parts Necessary to Change Spares19
E. Special Tooling - Price and Availability19
F. Special Tooling Necessary to do this Service Bulletin19
3. ACCOMPLISHMENT INSTRUCTIONS21
A. GENERAL INFORMATION21
B. WORK INSTRUCTIONS22
FIGURE 1: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - ELECTRICAL CONDUCTIVITY MEASUREMENT [Group 2]25
FIGURE 2: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - SURFACE HFEC INSPECTION28
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 1: STATION (STA) 1380 FRAME INNER CHORD AT NUMBER 2 CARGO DOOR CUTOUT - SURFACE HIGH
FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1]33
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 2: STATION (STA) 1380 FRAME INNER CHORD AT NUMBER 2 CARGO DOOR CUTOUT - MATERIAL IDENTIFICATION AND SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 2] . 34 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2016 757-53A0101 3 of 35 BOEING SERVICE BULLETIN 757-53A0101
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2016 757-53A0101 4 of 35 BOEING SERVICE BULLETIN 757-53A0101
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0101Original Issue: November 08, 2016 ATA System: 5363 SUBJECT: FUSELAGE - Section 46 - Structure - Station 1380 Frame Inner Chord Inspection Between Stringer S-23R and Lower Sill Threshold
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 do inspections for any crack in the Station (STA) 1380 frame inner chord at the number 2 cargo door cutout, between stringer S-23R and the lower sill threshold. Accomplishment of this service bulletin will make sure that any crack is found and repaired before the crack grows to a critical length. If this service bulletin is not done, an undetected crack could result in the inability of the number 2 cargo door cutout structure, a principal structural element, to sustain limit loads which could adversely affect the structural integrity of the airplane.
One operator reported finding a 0.406 inch long crack in the STA 1380 frame inner chord, originating from a fastener hole between stringers S-25R and S-26R. The crack was found during frame web corrosion removal on an airplane with a 7075-T73 aluminum alloy STA 1380 frame inner chord. Boeing received five other reports of cracking on airplanes with a 7075-T73 aluminum alloy STA 1380 frame inner chord. Boeing has determined that existing internal zonal (general visual) and detailed structural inspections of the number 2 cargo door cutout are not adequate to reliably detect a crack before it grows to a critical length. Boeing Service Bulletin 757-53A0080 addresses airplane line numbers 1 through 57. This service bulletin is applicable to airplane line numbers 176 through 1050 that were delivered with a 7075-T73 aluminum alloy STA 1380 frame inner chord, or delivered with an unknown alloy STA 1380 frame inner chord. Airplanes delivered with a 2024-T42 aluminum alloy frame inner chord are not included in the effectivity of this service bulletin.
Boeing Service Related Problem (SRP) 757-SRP-53-0520 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 757 FTD 53-02001 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2016 757-53A0101 5 of 35
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 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 Group 1:
Do a surface high frequency eddy current (HFEC) inspection for any crack in the STA 1380 frame inner chord.
If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, repeat the surface HFEC inspection.
Group 2:
Do a material identification for alloy and temper of the STA 1380 frame inner chord. If the material is 7075-T73 aluminum alloy, do a surface high frequency eddy current (HFEC) inspection for any crack in the STA 1380 frame inner chord. If any crack is found, contact The Boeing Company for repair instructions and do the repair.
If no crack is found, repeat the surface HFEC inspection. If the material is 2024-T42 aluminum alloy, no further action is required.
EFFECTIVITY 757-200, 757-200PF and 757-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes, 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection procedures 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 757-53A0101
ALERT ALERT GROUP 1:
DO A SURFACE HIGH FREQUENCY
EDDY CURRENT (HFEC) INSPECTION FOR ANY CRACK IN THE STA 1380 FRAME INNER CHORD.
GROUP 2:
DO A MATERIAL IDENTIFICATION
FOR ALLOY AND TEMPER OF THE STA 1380 FRAME INNER CHORD. IF THE MATERIAL IS 7075-T73
ALUMINUM ALLOY, DO A SURFACE
HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION FOR ANY CRACK IN THE STA 1380 FRAME INNER CHORD. IF THE MATERIAL IS 2024-T42 ALUMINUM ALLOY, NC FURTHER ACTION IS REQUIRED.
STA 1380 GROUP 1 AND GROUP 2:
IF ANY CRACK IS FOUND,
CONTACT THE BOEING COMPANY
FOR REPAIR INSTR UCTIONS AND DO THE REPAIR. IF NO CRACK IS
FOUND, REPEAT THE SURFACE HFEC INSPECTION.
S-23R
LOWER SILL
THRESHOLD NUMBER 2 CARGO DOOR CUTOUT 2523414 Original Issue: November 08, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-53A0101 Work - See page 1 for details. 8 of 35
Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0101 Original Issue: November 08, 2016 ATA System: 5363 SUBJECT: FUSELAGE - Section 46 - Structure - Station 1380 Frame Inner Chord Inspection Between Stringer S-23R and Lower Sill Threshold
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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to 757-200, 757-200PF and 757-300 Airplanes, line numbers 176, 181, 184, 186, 189, 191, 193, 195, 197, 199, and 205 through 1050, in 2 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 757-200 airplanes, 757-200 airplanes changed to the Special Freighter (SF) configuration by the Boeing Company in accordance with Supplemental Type Certificate (STC) ST00916WI-D, 757-200PF airplanes, and 757-300 airplanes between line numbers 176 and 1050, and delivered with a 7075-T73 aluminum alloy Station 1380 frame inner chord.
-1 757-200 airplanes between line numbers 257 and 277, and delivered with an unknown Station 1380 frame inner chord material.
-2 Airplane Models:
757-200, 757-200PF, 757-300 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2016 757-53A0101 9 of 35
GroupVariable Number 1NA198 - NA199 1NA234 - NA239 1NA301 - NA305 2NA341 1NA342 - NA352 1NA397 - NA398 2NA399 1NA445 - NA446 1NA542 - NA552 2NA553 - NA556 1NA557 - NA586 1NB039 - NB041 1NB066 - NB067 2NB068 1NB069 - NB070 1NB079 1NB131 - NB138 2NB139 - NB140 1NB141 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 2NB202 1NB203 - 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 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 1NC151 1NC161 1NC906 - NC951 1NC971 - NC974 1ND004 - ND007 1ND011 - ND018 2ND019 - ND021 1ND022 - ND059 1ND111 - ND113 1ND161 - ND199 2ND201 1ND202 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND322 1ND401 1NE001 - NE008 1NE011 - NE015 2NE016 - NE018 1NE019 - NE088 1NE091 - NE094 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NE141 - NE150 2NE161 - NE163 1NE164 - 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 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 08, 2016 757-53A0101 12 of 35 BOEING SERVICE BULLETIN 757-53A0101