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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0102 Original Issue: October 08, 2015 ATA System: 5330 SUBJECT: FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener Row, at S-14R, STA 440-540 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 © 2015 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Unpublished Work.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 08, 2015 757-53A0102 1 of 33
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2015 757-53A0102 2 of 33 BOEING SERVICE BULLETIN 757-53A0102
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected13
B. Concurrent Requirements13
C. Reason14
D. Description14
E. Compliance14
F. Approval16
G. Manpower17
H. Weight and Balance Changes17
I. Electrical Load Data17
J. References18
1. Existing Data:18
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: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA
440-54025
FIGURE 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT
S-14R, STA 440-54027
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: EXTERNAL DFEC INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 (OPTION
1)29
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INTERNAL HFEC SURFACE INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540
(OPTION 2)31
APPENDIX C: OPEN AND CLOSE ACCESS33
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.
Original Issue: October 08, 2015 757-53A0102 4 of 33 BOEING SERVICE BULLETIN 757-53A0102
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0102Original Issue: October 08, 2015 ATA System: 5330 SUBJECT: FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener Row, at S-14R, STA 440-540
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 The inner skin of lap splices at Stringer S-14R, lower fastener row for 757-200, and 757-200CB models have been determined to be susceptible to Widespread Fatigue Damage (WFD). Cracking was found on the fatigue test article, and WFD analysis has identified the need for inspections. Currently, there have been no reports of cracking on airplanes in service. Inspections will mitigate a safety issue, allowing continued operation to the Limit of Validity (LOV). This action is necessary to find any fatigue crack in the skin panel. Accomplishment of the inspections in this service bulletin will make sure that any fuselage skin crack at Stringer S-14R, between STA 440 and STA 540 is found. Continued operation with any undetected skin crack could adversely affect the structural integrity of the airplane.
The fuselage lap splice inner skin at the locations affected by this service bulletin have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2015 757-53A0102 5 of 33
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 This service bulletin gives instructions to do either Dual Frequency Eddy Current (DFEC) or High Frequency Eddy Current (HFEC) inspections of the fuselage lap splice, inner skin lower fastener row, at S-14R, STA 440-540 for any crack.
If any crack is found, contact The Boeing Company for repair instructions and do the repair.
If no crack is found, repeat the inspections at the interval specified in Paragraph 1.E., Compliance.
EFFECTIVITY All 757-200/-200CB 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.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections given in this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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 757-53A0102
ALERT ALERT STA 440 STA 540
OUTER SKIN OR
INNER SKIN OPTION 1: S-14R
EXTERNAL DFEC INSPECTION OF
INNER SKIN LOWER FASTENER ROW, AT S-14R, STA 440-540 STA 440 OPTION 2:
INTERNAL HFEC SURFACE
INSPECTION OF INNER SKIN LOWER FASTENER ROW, AT S-14R, S-14R STA 440-540 2403897 Original Issue: October 08, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-53A0102 Work - See page 1 for detalls. 8 of 33
Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0102 Original Issue: October 08, 2015 ATA System: 5330 SUBJECT: FUSELAGE - Skin - Section 43 - Lap Splice Inspection, Inner Skin Lower Fastener Row, at S-14R, STA 440-540
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 Refer to Service Bulletin Index D624N001 PART 2 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
This service bulletin is applicable to all 757-200/-200CB Airplanes. The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 757-200/-200CB Airplanes-1 Airplane Models:
757-200, 757-200CB GroupVariable Number 1NA001 - NA002 1NA005 1NA008 1NA021 - NA028 1NA195 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2015 757-53A0102 9 of 33
GroupVariable Number 1NA197 - NA199 1NA201 - NA213 1NA215 - NA239 1NA301 - NA305 1NA342 - NA344 1NA346 - NA352 1NA392 - NA399 1NA401 - NA408 1NA441 - NA447 1NA502 - NA505 1NA509 - NA510 1NA512 1NA514 - NA535 1NA537 - NA538 1NA541 - NA546 1NA548 - NA586 1NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB052 - NB053 1NB061 - NB068 1NB070 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB167 - NB168 1NB201 - NB202 1NB221 - NB228 1NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB424 1NB426 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 1NB571 1NB581 - NB583 1NC001 - NC003 1NC005 1NC008 1NC012 - NC013 1NC017 - NC018 1NC020 - NC022 1NC024 1NC026 1NC029 - NC033 1NC042 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 1NC151 1NC161 1ND002 1ND004 1ND011 - ND027 1ND029 - ND044 1ND046 - ND059 1ND111 - ND113 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1ND161 - ND166 1ND168 - ND199 1ND201 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND322 1ND401 1ND891 1ND895 1NE001 - NE004 1NE006 - NE008 1NE011 - NE030 1NE032 - NE081 1NE083 - NE088 1NE092 - NE094 1NE141 - NE150 1NE161 - NE177 1NE201 - NE204 1NE301 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 1NN001 - NN002 1NN051 - NN052 1NP901 - NP904 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 1NT281 - NT289 1NT341 - NT347 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 08, 2015 757-53A0102 12 of 33 BOEING SERVICE BULLETIN 757-53A0102