# Boeing Alert Service Bulletin 757-53A0101: No revision named

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- Document: [Boeing Alert Service Bulletin 757-53A0101](https://openairdocs.org/service-documents/boeing/757-53a0101.md)
- Title as filed: SB-757-53A0101-00
- Pages: 35
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## Text

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### Page 1

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Unpublished Work.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
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3.0

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ALERTALERT
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### Page 3

Table of Contents
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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 Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 19
3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 19
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 28
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
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### Page 5

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
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### Page 6

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 Air-
plane 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.
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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.
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### Page 8 (OCR)

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
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### Page 9

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
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### Page 10

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
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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
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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
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GroupVariable Number
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
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
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.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: November 08, 2016
757-53A0101
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ALERTALERT

### Page 14

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.
D. Description
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.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
154757-200, 757-200PF, 757-300
Group 2:
Affected Maintenance Zones
ZoneModel
154757-200
E. 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.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When
more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION
numbers for that CONDITION number or OPTION number.
Accomplish the required actions, based on the applicable conditions in Tables 1 and 2, in accordance
with Paragraph 3. Accomplishment Instructions.
Logic diagrams showing compliance tasks and compliance times is included as an aid in APPENDIX
A and APPENDIX B.
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### Page 15

Group 1:
Table 1: Station (STA) 1380 Frame Inner Chord at Number 2 Cargo Door Cutout - Surface High Frequency
Eddy Current (HFEC) Inspection
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3,300 flight
cycles after the
original issue date
of this service bul-
letin.
Before 22,000 to-
tal flight cycles.
Do PART 3: STA 1380
FRAME INNER CHORD
SURFACE HFEC INSPEC-
TION for any crack.
All Airplanes.
-Before further flight.CONDITION 1 (ACTION 1):
Contact The Boeing Com-
pany for repair instructions
and do the repair.
CONDITION 1: ANY
CRACK FOUND.
6,000 flight cycles.-CONDITION 1 (ACTION 2):
Repeat PART 3: STA 1380
FRAME INNER CHORD
SURFACE HFEC INSPEC-
TION for any crack.
6,000 flight cycles.-Repeat PART 3: STA 1380
FRAME INNER CHORD
SURFACE HFEC INSPEC-
TION for any crack.
CONDITION 2: NO
CRACK FOUND.
Group 2:
Table 2: Station (STA) 1380 Frame Inner Chord at Number 2 Cargo Door Cutout - Material Identification
Inspection and Surface High Frequency Eddy Current (HFEC) Inspection
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 3,300 flight
cycles after the
original issue date
of this service bul-
letin.
Before 22,000 to-
tal flight cycles.
Do PART 2: STA 1380
FRAME INNER CHORD
MATERIAL IDENTIFICA-
TION to find the alloy and
temper (7075-T73 or 2024-
T42 Aluminum).
All Airplanes.
-Before further flight.Do PART 3: STA 1380
FRAME INNER CHORD
SURFACE HFEC INSPEC-
TION for any crack.
CONDITION 3: STA
1380 FRAME INNER
CHORD MATERIAL
IS 7075-T73 ALU-
MINUM ALLOY.
--No further action required.CONDITION 4: STA
1380 FRAME INNER
CHORD MATERIAL
IS 2024-T42 ALU-
MINUM ALLOY.
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Group 2:
Table 2: Station (STA) 1380 Frame Inner Chord at Number 2 Cargo Door Cutout - Material Identification
Inspection and Surface High Frequency Eddy Current (HFEC) Inspection
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Before further flight.CONDITION 5 (ACTION 1):
Contact The Boeing Com-
pany for repair instructions
and do the repair.
CONDITION 5: ANY
CRACK FOUND.
6,000 flight cycles.-CONDITION 5 (ACTION 2):
Repeat PART 3: STA 1380
FRAME INNER CHORD
SURFACE HFEC INSPEC-
TION for any crack.
6,000 flight cycles.-Repeat PART 3: STA 1380
FRAME INNER CHORD
SURFACE HFEC INSPEC-
TION for any crack.
CONDITION 6: NO
CRACK FOUND.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the structural
inspection methods with the corresponding compliance times defined in Paragraph 1.E., Compliance
of this service bulletin as an Alternative Method of Compliance (AMOC) to the requirements of paragraph
(h) of AD 2006-11-11, for the supplemental structural inspections of Structural Significant Item 53-60-11
(No. 2 Cargo Door Cutout BS 1380 Edge Frame Inner Chord S-23 to Lower Sill, L/N 58 and on) listed
in Boeing 757 Maintenance Planning Data (MPD) Document D622N001-9. This AMOC only applies
to structural inspections common to the Inner Chord. All provisions of AD 2006-11-11 that are not
specifically referenced in the above statement remain fully applicable and must be complied with.
G. Manpower
The table below shows an estimate of the task hours necessary to do this inspection for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
• Time to adjust to the workplace
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• Time to schedule the work
• Time to inspect the work
• Time to cure the materials
• Time to make the parts
• Time to find the tools
Group 1:
Elapsed HoursTask HoursNumber of PersonsTask
0.750.751OPEN ACCESS
3.203.201FIGURE 2
0.750.751CLOSE ACCESS
4.704.70TOTAL FOR EACH AIRPLANE
Group 2:
Elapsed HoursTask HoursNumber of PersonsTask
0.750.751OPEN ACCESS
1.601.601FIGURE 1
3.203.201FIGURE 2
0.750.751CLOSE ACCESS
6.306.30TOTAL FOR EACH AIRPLANE (a)
(a) The total includes the task hours and elapsed hours necessary for electrical conductivity measure-
ment and surface high frequency eddy current inspection of the STA 1380 frame inner chord.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Boeing Service Bulletin 757-53A0080
b. Boeing Service Letter 757-SL-51-022
c. Boeing Service Related Problem (SRP) 757-SRP-53-0520
d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2006-11-11
e. Service Bulletin Index D624N001
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f. 757 Aircraft Maintenance Manual (AMM) 25-50-02, 25-50-07, 52-34-00
g. 757 Fleet Team Digest (FTD) 53-02001
h. 757 Maintenance Planning Data (MPD) Appendix A
i. 757 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01, Part 6, 51-00-18, Part 6, 51-00-19
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
SUPT INSTL - DECK, STA 1200 TO 1640, AFT CARGO COMPT146N5390
FWD FRAME INSTL - STA 1380, NO. 2 CARGO DOOR CUTOUT.146N8511
LWR MAIN SILL INSTL - NO. 2 CARGO DOOR CUTOUT.146N8522
SIDEWALL SUPPORT INSTL - AFT CARGO COMPT RIGHT SIDE.453N1230
The table above lists applicable drawings used to prepare this service bulletin. The drawings are
not necessary to make the specified changes, and are not supplied with this service bulletin. The
drawings may not be applicable to all airplane configurations or operators.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
M. Software Accomplishment Summary
Not affected.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
None.
B. Industry Support Information
Boeing warranty remedies are not available for the inspection procedures given in this service bulletin.
C. Parts Necessary for Each Airplane
1. Kits/Parts
None.
2. Parts and Materials Supplied by the Operator
No special parts or materials are necessary to do the change in this service bulletin. But, parts
and materials in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator part and material supply to make sure all necessary parts and materials are available.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
– Angular tolerance is plus or minus 2 degrees
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
– Torque Values:
— Values for structural fasteners are given in 757 Structural Repair Manual,
Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 757
Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of
Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 757
Aircraft Maintenance Manual (AMM).
— Non-standard torque values for maintenance tasks are included in the
applicable installation step.
4. Use the approved fastener, process and material substitutions in accordance with
SRM Chapter 51.
5. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
6. Boeing Service Letter 757-SL-51-022, Damage Reporting and Repair Plan/Design
Guidelines, is an acceptable procedure to request information from Boeing for
additional structural repair instructions. The Service Letter describes what information
must be provided to Boeing before a structural repair can be provided.
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7. Refer to Appendix APPENDIX A and APPENDIX B for logic diagrams. Logic diagrams
are provided as an aid only. Information contained in Paragraph 1.E., Compliance
is the primary source for compliance times. Information in Paragraph 3.B., Work
Instructions is the primary source for tasks required for compliance.
8. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
9. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
10. Use of colors in Figures is based on guidance from the ATA e-Business Program
(ATA) iSpec 2200.
11. When more than one OPTION is given for a CONDITION, do only one of the OPTION
numbers. When more than one ACTION is given for a CONDITION number or an
OPTION number, do all of the ACTION numbers for that CONDITION number or
OPTION number.
12. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS
are in Paragraph 1.E., Compliance.
13. Some steps in the Work Instructions are labeled as Required for Compliance (RC).
If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps
labeled as RC, including sub-steps under an RC step and any figures identified in
an RC step, must be done to comply with the AD. If a step or sub-step is labeled
"RC Exempt," then the RC requirement is removed from that step or sub-step. An
Alternative Method of Compliance (AMOC) is required for any deviations to RC steps,
including sub-steps and identified figures. Steps not labeled as RC may be deviated
from using accepted methods in accordance with the operator's maintenance or
inspection program without obtaining approval of an AMOC. This is provided that
the RC steps, including sub-steps and identified figures, can still be done as specified,
and the airplane can be put back in an airworthy condition.
B. WORK INSTRUCTIONS
Group 1:
1. Do PART 1: OPEN ACCESS.
2. RC - Do PART 3: STA 1380 FRAME INNER CHORD SURFACE HFEC INSPECTION for any
crack.
a. CONDITION 1: ANY CRACK FOUND.
(1) CONDITION 1 (ACTION 1): Contact The Boeing Company for repair instructions and do
the repair.
(2) CONDITION 1 (ACTION 2): Repeat PART 3: STA 1380 FRAME INNER CHORD
SURFACE HFEC INSPECTION for any crack, at the times specified in Paragraph 1.E.,
Compliance.
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b. CONDITION 2: NO CRACK FOUND.
(1) Repeat PART 3: STA 1380 FRAME INNER CHORD SURFACE HFEC INSPECTION for
any crack, at the times specified in Paragraph 1.E., Compliance.
3. Do PART 4: CLOSE ACCESS.
4. Put the airplane back to a serviceable condition.
Group 2:
1. Do PART 1: OPEN ACCESS.
2. RC - Do PART 2: STA 1380 FRAME INNER CHORD MATERIAL IDENTIFICATION to find the
alloy and temper (7075-T73 or 2024-T42 Aluminum).
a. CONDITION 3: STA 1380 FRAME INNER CHORD MATERIAL IS 7075-T73 ALUMINUM
ALLOY.
(1) Do PART 3: STA 1380 FRAME INNER CHORD SURFACE HFEC INSPECTION for any
crack.
(a) CONDITION 5: ANY CRACK FOUND.
1) CONDITION 5 (ACTION 1): Contact The Boeing Company for repair instructions
and do the repair.
2) CONDITION 5 (ACTION 2): Repeat PART 3: STA 1380 FRAME INNER CHORD
SURFACE HFEC INSPECTION for any crack, at the times specified in Paragraph
1.E., Compliance.
(b) CONDITION 6: NO CRACK FOUND.
1) Repeat PART 3: STA 1380 FRAME INNER CHORD SURFACE HFEC
INSPECTION for any crack, at the times specified in Paragraph 1.E., Compliance.
b. CONDITION 4: STA 1380 FRAME INNER CHORD MATERIAL IS 2024-T42 ALUMINUM
ALLOY.
(1) No further action required.
3. Do PART 4: CLOSE ACCESS.
4. Put the airplane back to a serviceable condition.
PART 1: OPEN ACCESS
1. Open the number 2 cargo door to get access to the aft cargo compartment. Refer to 757 AMM
52-34-00 as an accepted procedure.
2. Remove and keep the right side aft cargo compartment sidewall lining panel 154FW to get access
to the Station (STA) 1380 frame inner chord in the area between stringer S-23R and the lower sill
threshold. Refer to 757 MPD Appendix A and 757 AMM 25-50-02 as an accepted procedure.
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3. Remove and keep the insulation blankets from behind the removed sidewall lining. Refer to 757
AMM 25-50-07 as an accepted procedure.
Group 2:
PART 2: STA 1380 FRAME INNER CHORD MATERIAL IDENTIFICATION
1. Do one of the two options that follow to find the STA 1380 frame inner chord alloy and temper
(7075-T73 or 2024-T42 Aluminum):
a. OPTION 1: Inspect the STA 1380 frame inner chord in the area from stringer S-23R to the
lower sill threshold for the part number.
Table 1 shows the relation between part number, and Aluminum alloy and temper for each
Station (STA) 1380 frame inner chord that could be installed on the airplane:
Table 1: STA 1380 Frame Inner Chord Part Number, Alloy and Temper
Aluminum Alloy and TemperPart Number
7075-T73146N8511-2
2024-T42146N8511-23
(1) If the part number of the STA 1380 frame inner chord is found, use Table 1 to find the
alloy and temper of the STA 1380 frame inner chord.
(2) If the part number of the STA 1380 frame inner chord is not found, do OPTION 2.
b. OPTION 2: Do an electrical conductivity measurement to find the alloy and temper (7075-T73
or 2024-T42 Aluminum) of the STA 1380 frame inner chord in accordance with FIGURE 1.
PART 3: STA 1380 FRAME INNER CHORD SURFACE HFEC INSPECTION
1. Do a surface high frequency eddy current (HFEC) inspection for any crack in the Station (STA)
1380 frame inner chord in accordance with FIGURE 2.
PART 4: CLOSE ACCESS
1. Install the kept insulation blankets. Refer to 757 AMM 25-50-07 as an accepted procedure.
2. Install the kept right side aft cargo compartment sidewall lining panel 154FW. Refer to 757 MPD
Appendix A and 757 AMM 25-50-02 as an accepted procedure.
3. Close the number 2 cargo door to close access to the aft cargo compartment. Refer to 757 AMM
52-34-00 as an accepted procedure.
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BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
This Figure applies only to: Group 2.
S-23R
LOWER SILL
THRESHOLD
NUMBER 2 CARGO DOOR CUTOUT
FIGURE 1: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - ELECTRICAL CONDUCTIVITY MEASUREMENT
(SHEET 1 OF 3)
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### Page 26 (OCR)

BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
REVEAL STRIP
INNER CHORD C
WEB
S-22R
B-B
S-23R
OUTER CHORD
S-24R
S-25R
S-26R
S-27R
• INBD
FRAME INSTALLATION, STA 1380,
NUMBER 2 CARGO DOOR CUTOUT  A-A  2522877
FIGURE 1: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - ELECTRICAL CONDUCTIVITY MEASUREMENT
(SHEET 2 OF 3)
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### Page 27

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataQtyIdentificationNameTaskStep
(a)--CHORD - INNERInspect1
(a) Do an electrical conductivity measurement to find the STA 1380 frame inner chord alloy and temper (7075-
T73 or 2024-T42 Aluminum) in accordance with 757 NDT Manual Part 6, 51-00-18.
FIGURE 1: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - ELECTRICAL CONDUCTIVITY MEASUREMENT
(SHEET 3 OF 3)
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BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
STA
1380
S-23R
LOWER SILL
THRESHOLD
NUMBER 2 CARGO DOOR CUTOUT
2521116
FIGURE 2: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - SURFACE HFEC INSPECTION
(SHEET 1 OF 5)
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### Page 29 (OCR)

BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
STRIP  REVEAL  1 INNER CHORD
WEB
INNER CHORD O  S-22R
FWD
B-B
S-23R
OUTER CHORD
LOWER SILL
THRESHOLD  B  S-24R
S-25R
B\
S-26R
INBD
FRAME INSTALLATION, STA 1380,
NUMBER 2 CARGO DOOR CUTOUT
• INSPECTION AREA  A-A  2521117
FIGURE 2: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - SURFACE HFEC INSPECTION
(SHEET 2 OF 5)
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### Page 30 (OCR)

BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
1 INCH
• INSPECTION AREA
BACKUP FITTING
2) INNER CHORD
INNER RADIUS
WEB  1 INCH
LATCH GUIDE
S-22R
S-23R
OUTER CHORD
S-24R
S-25R
S-26R
S-27R
INBD
RAME INSTALLATION. STA 1380
JUMBER 2 CARGO DOOR CUTOU  C-C  2521937
FIGURE 2: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - SURFACE HFEC INSPECTION
(SHEET 3 OF 5)
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
REVEAL
STRIP  LATCH GUIDE
INNER
CHORD
BACKUP
FITTING
FWD
D-D
INNER CHORD
INNER RADIUS
2521985
FIGURE 2: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - SURFACE HFEC INSPECTION
(SHEET 4 OF 5)
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### Page 32

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
More DataQtyIdentificationNameTaskStep
(a)-146N8511-2 OR
146N1027-8
CHORD - INNERInspect1
(b)-146N8511-2 OR
146N1027-8
CHORD - INNERInspect2
(a) Do a surface HFEC inspection for any crack in the STA 1380 frame inner chord, between stringer S-23R
and the lower sill threshold, from the aft side of the frame installation, in accordance with 757 NDT Man-
ual Part 6, 51-00-01 or 757 NDT Manual Part 6, 51-00-19. It is not necessary to inspect the area underneath
the latch guide.
(b) Do a surface HFEC inspection for any crack in the STA 1380 frame inner chord inner radius, above the
backup fitting and latch guide nutplates, from the forward side of the frame installation, in accordance
with 757 NDT Manual Part 6, 51-00-01 or 757 NDT Manual Part 6, 51-00-19.
FIGURE 2: RIGHT SIDE - STA 1380 - FRAME INNER CHORD - STRINGER S-23R TO LOWER SILL
THRESHOLD - SURFACE HFEC INSPECTION
(SHEET 5 OF 5)
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BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
This Appendix applies only to: Group 1.
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the logic diagrams.
Title  Description
PART 3  STA 1380 FRAME INNER CHORD SURFACE HFEC INSPECTION.
CONDITION 1  ANY CRACK FOUND.
CONDITION 2  NO CRACK FOUND.
WHICHEVER OCCURS LATER
WITHIN 3,300 FLIGHT CYCLES AFTER THE
BEFORE 22,000 TOTAL FLIGHT CYCLES  ORIGINAL ISSUE DATE OF THIS SERVICE
BULLETIN
DO PART 3
CONDITION  CONDITION 2
BEFORE
FURTHER FLIGHT
NOT TO
EXCEED 6,000
FLIGHT CYCLES
ACTION 1: CONTACT THE
BOEING COMPANY FOR
REPAIR INSTRUCTIONS
AND DO THE REPAIR
REPEAT PART 3
NOT TO
EXCEED 6.000
FLIGHT CYCLES
ACTION 2:
REPEAT PART 3  2530540
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
(SHEET 1 OF 1)
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### Page 34

This Appendix applies only to: Group 2.
Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
The table below gives the description for the parts and conditions called out in the logic diagrams.
DescriptionTitle
STA 1380 FRAME INNER CHORD MATERIAL IDENTIFICATION.PART 2
STA 1380 FRAME INNER CHORD SURFACE HFEC INSPECTION.PART 3
INNER CHORD MATERIAL IS 7075-T73 ALUMINUM ALLOY.CONDITION 3
INNER CHORD MATERIAL IS 2024-T42 ALUMINUM ALLOY.CONDITION 4
ANY CRACK FOUND.CONDITION 5
NO CRACK FOUND.CONDITION 6
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
(SHEET 1 OF 2)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN 757-53A0101
ALERT  ALERT
WHICHEVER OCCURS LATER
WITHIN 3,300 FLIGHT CYCLES AFTER THE
BEFORE 22,000 TOTAL FLIGHT CYCLES  ORIGINAL ISSUE DATE OF THIS SERVICE
BULLETIN
DO PART 2
CONDITION 3  CONDITION 4
BEFORE
NO FURTHER
FURTHER FLIGHT
ACTION REQUIRED
DO PART 3
CONDITION 5  CONDITION 6
BEFORE
FURTHER FLIGHT
NOT TO
EXCEED 6,000
FLIGHT CYCLES
ACTION 1: CONTACT THE
BOEING COMPANY FOR
REPAIR INSTRUCTIONS
AND DO THE REPAIR
REPEAT PART 3
NOT TO
EXCEED 6,000
FLIGHT CYCLES
ACTION 2:
REPEAT PART 3  2530542
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
(SHEET 2 OF 2)
Original Issue: November 08, 2016
PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  757-53A0101
Work - See page 1 for details.  35 of 35

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