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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0103 Original Issue: June 22, 2016 ATA System: 5333 5363 SUBJECT: FUSELAGE - Section 43 and Section 46 - Structure - Inspection and Modification of Open Holes on Frame Webs Between Stringers S-20 and S-25 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Unpublished Work.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: June 22, 2016 757-53A0103 1 of 41
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 2 of 41 BOEING SERVICE BULLETIN 757-53A0103
ALERTALERT
BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected10
B. Concurrent Requirements10
C. Reason10
D. Description11
E. Compliance11
F. Approval13
G. Manpower13
H. Weight and Balance Changes14
I. Electrical Load Data14
J. References14
1. Existing Data:14
2. Data Supplied with this Service Bulletin:14
3. Installation Drawings Used in the Preparation of this Service Bulletin:15
K. Publications Affected15
L. Interchangeability and Intermixability of Parts15
M. Software Accomplishment Summary15
2. MATERIAL INFORMATION17
A. Material - Price and Availability17
B. Industry Support Information17
C. Parts Necessary for Each Airplane17
1. Kits/Parts17
2. Parts and Materials Supplied by the Operator17
3. Parts Modified and Reidentified17
4. Parts Removed and Not Replaced17
D. Parts Necessary to Change Spares18
E. Special Tooling - Price and Availability18
F. Special Tooling Necessary to do this Service Bulletin18
3. ACCOMPLISHMENT INSTRUCTIONS19
A. GENERAL INFORMATION19
B. WORK INSTRUCTIONS20
FIGURE 1: OPEN HOLE HIGH FREQUENCY EDDY CURRENT INSPECTIONS BETWEEN STRINGERS S-20 AND S-25 FROM STA 440 TO STA 820 AND FROM STA 1300 TO STA 1701 [Group 1]
.24
FIGURE 2: OPEN HOLE HIGH FREQUENCY EDDY CURRENT INSPECTIONS BETWEEN STRINGERS S-20 AND S-25 FROM STA 440 TO STA 820 AND FROM STA 1300 TO STA 1701 [Group 2]
.28
FIGURE 3: MODIFICATION OF FRAME WEB BETWEEN STRINGERS S-20 AND S-25 FROM STA 440
TO STA 820 AND FROM STA 1300 TO STA 1701 [Group 1]32
FIGURE 4: MODIFICATION OF FRAME WEB BETWEEN STRINGERS S-20 AND S-25 FROM STA 440
TO STA 820 AND FROM STA 1300 TO STA 1701 [Group 2]36
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 3 of 41 BOEING SERVICE BULLETIN 757-53A0103
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APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE, TABLE 1: INSPECTION AND MODIFICATION OF OPEN HOLES ON FRAME WEBS BETWEEN STRINGERS S-20 AND
S-2540
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 4 of 41 BOEING SERVICE BULLETIN 757-53A0103
ALERTALERT
Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0103Original Issue: June 22, 2016 ATA System: 5333 5363 SUBJECT: FUSELAGE - Section 43 and Section 46 - Structure - Inspection and Modification of Open Holes on Frame Webs Between Stringers S-20 and S-25
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 is sent to inspect the frame webs for any open coordinating holes, tooling holes and insulation blanket attachment holes. The affected frame webs are between stringers S-20 and S-25 on the left side and right side, from STA 440 to STA 820 and from STA 1300 to STA 1701. Do an open hole eddy current inspection of all open coordinating holes, tooling holes and insulation blanket attachment holes found during the general visual inspection. If this service bulletin is not done, fatigue cracking could adversely affect the structural integrity of the airplane.
Boeing found that 757 airplanes, line number 1 through 174, have open coordinating holes, tooling holes and insulation blanket attachment holes in the frame webs which were not filled during production. A Widespread Fatigue Damage (WFD) analysis on the open holes identified a need for inspections at these locations.
There have been no reports of frame web cracking at open hole locations from operators. Cracking was found on a fatigue test article, where WFD analysis identified the need for the inspection.
Boeing Fleet Team Digest (FTD) 757 FTD 53-15004 is related to this service bulletin.
The frame webs have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 5 of 41
ReferenceAffectedPlanning Data Paragraph 1.H., Weight and Balance ChangesYesWeight 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 YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Do an Inspection of the frame webs for any open coordinating holes, tooling holes and insulation blanket attachment holes. Do an open hole eddy current inspection for any crack on all open coordinating holes, tooling holes and insulation blanket attachment holes between stringers S-20 and S-25 on the left side and right side, from STA 440 to STA 820 and from STA 1300 to STA 1701. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, repeat the inspections and do the preventative modification at the compliance time given in Paragraph 1.E., Compliance.
EFFECTIVITY 757-200/200PF 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 inspection and modification given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 6 of 41 BOEING SERVICE BULLETIN 757-53A0103
ALERTALERT
BOEING SERVICE BULLETIN 757-53A0103
ALERT ALERT STA 440 STA 820 STA 1300 STA 1701 BETWEEN STF S S-20 TO S-25, FROM STA 440 TO STA 820 AND FROM STA 1300 TA 1701, INSPECT THE FRAME WEBS FOR ANY
OPEN COORDINA GHOLES, TOO LING HOLES AND INSULATION BLANKET AT NT HOLES. DO I OPEN HOLE HIGH
FREQUENCY EDDY CURRENT INSPECTION OF ALL OPEN HOLES FOR
ANY CRACK 2482883 Original Issue: June 22, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 757-53A0103 Work - See page 1 for details. 7 of 41
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 8 of 41 BOEING SERVICE BULLETIN 757-53A0103
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BLANK PAGE
Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0103 Original Issue: June 22, 2016 ATA System: 5333 5363 SUBJECT: FUSELAGE - Section 43 and Section 46 - Structure - Inspection and Modification of Open Holes on Frame Webs Between Stringers S-20 and S-25
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 Refer to Service Bulletin Index D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is applicable to 757-200/-200PF Airplanes, line numbers 1 - 174 in 2 Groups.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP Airplane line numbers 1 through 174 without a number 3 cargo door.-1 Airplane line numbers 1 through 174 with a number 3 cargo door.-2 Airplane Models:
757-200, 757-200PF GroupVariable Number 1NA001 - NA028 1NA191 - NA197 2NA201 - NA231 2NA391 - NA394 1NA401 - NA408 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 9 of 41
GroupVariable Number 1NA441 - NA443 1NA501 - NA537 1NB001 - NB004 1NB021 - NB023 1NB036 - NB038 1NB051 - NB053 1NB061 - NB063 1NB071 - NB072 1NC001 - NC028 1NC041 - NC042 1NC901 - NC905 1ND001 - ND002 1ND891
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason This service bulletin is sent to inspect the frame webs for any open coordinating holes, tooling holes and insulation blanket attachment holes. The affected frame webs are between stringers S-20 and S-25 on the left side and right side, from STA 440 to STA 820 and from STA 1300 to STA 1701. Do an open hole eddy current inspection of all open coordinating holes, tooling holes and insulation blanket attachment holes found during the general visual inspection. If this service bulletin is not done, fatigue cracking could adversely affect the structural integrity of the airplane.
Boeing found that 757 airplanes, line number 1 through 174, have open coordinating holes, tooling holes and insulation blanket attachment holes in the frame webs which were not filled during production.
A Widespread Fatigue Damage (WFD) analysis on the open holes identified a need for inspections at these locations.
There have been no reports of frame web cracking at open hole locations from operators. Cracking was found on a fatigue test article, where WFD analysis identified the need for the inspection.
Boeing Fleet Team Digest (FTD) 757 FTD 53-15004 is related to this service bulletin.
The frame webs 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: June 22, 2016 757-53A0103 10 of 41 BOEING SERVICE BULLETIN 757-53A0103
ALERTALERT
D. Description Do an Inspection of the frame webs for any open coordinating holes, tooling holes and insulation blanket attachment holes. Do an open hole eddy current inspection for any crack on all open coordinating holes, tooling holes and insulation blanket attachment holes between stringers S-20 and S-25 on the left side and right side, from STA 440 to STA 820 and from STA 1300 to STA 1701. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, repeat the inspections and do the preventative modification at the compliance time given in Paragraph
1.E., Compliance.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 119, 121, 122, 153, 154, 161, 162, 165, 166757-200, 757-200PF Group 2:
Affected Maintenance Zones ZoneModel 119, 121, 122, 153, 154, 161, 162, 165, 166757-200 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.
A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX A.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 11 of 41 BOEING SERVICE BULLETIN 757-53A0103
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Table 1: Inspection and Modification of Open Holes on Frame Webs Between Stringers S-20 and S-25 Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the original issue date of this service bulletin.
Before 28,000 total flight cycles.
Do PART 2: INSPEC-
TION OF THE FRAME
WEBS BETWEEN STRINGERS S-20 AND S-25 for any crack. (a) All Airplanes.
--Before further flight.
CONDITION 1 (ACTION
1): Contact The Boeing Company for repair instructions and do the repair.
CONDITION 1: ANY CRACK FOUND.
12,000 flight cycles. (b) --CONDITION 1 (ACTION
2): Repeat PART 2: IN-
SPECTION OF THE
FRAME WEBS BE-
TWEEN STRINGERS S- 20 AND S-25 at all unrepaired locations. (a) --Before 59,000 total flight cycles.
CONDITION 1 (ACTION
3): Do PART 3: MODIFI-
CATION OF THE FRAME
WEBS BETWEEN STRINGERS S-20 AND S-25 at all unrepaired locations. (b) 12,000 flight cycles. (b) --CONDITION 2 (ACTION
1): Repeat PART 2: IN-
SPECTION OF THE
FRAME WEBS BE-
TWEEN STRINGERS S- 20 AND S-25 at all open hole locations. (a) CONDITION 2: NO CRACK FOUND.
--Before 59,000 total flight cycles.
CONDITION 2 (ACTION
2): Do PART 3: MODIFI-
CATION OF THE FRAME
WEBS BETWEEN STRINGERS S-20 AND S-25 at all open hole locations. (b)
(a) It is not necessary to do inspections in accordance with this service bulletin at any coordinating holes, tooling holes, and insulation blanket holes that have been filled with an aluminum rivet, filled in accordance with 757-200 SRM 53-00-07 Repair 5 or 757-200PF SRM 53-00-07 Repair 5, or have been used as part of a Boeing Company approved repair via FAA form 8100-9 or 8110-3.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 22, 2016 757-53A0103 12 of 41 BOEING SERVICE BULLETIN 757-53A0103