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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0104 Original Issue: November 06, 2017 ATA System: 5330 5340 5360 SUBJECT: FUSELAGE - Section 43, Section 44, and Section 46 - Fuselage Skin Lap Splice 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:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2017 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Unpublished Work.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.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
S u m m a r y5
1. PLANNING INFORMATION9
A . E f f e c t i v i t y9
1. Airplanes9
2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 5 1 G. Manpower .............................................. 5 2 H. Weight and Balance Changes .................................... 5 5 I. Electrical Load Data ......................................... 5 5 J . R e f e r e n c e s .............................................. 5 5
1. Existing Data: ......................................... 5 5
2. Data Supplied with this Service Bulletin: ........................... 5 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 6 K. Publications Affected ........................................ 5 6 L. Interchangeability and Intermixability of Parts ........................... 5 6 M. Software Accomplishment Summary ................................ 5 6
2. MATERIAL INFORMATION ........................................ 5 7 A. Material - Price and Availability ................................... 5 7 B. Industry Support Information .................................... 5 7 C. Parts Necessary for Each Airplane ................................. 5 7 1 . K i t s / P a r t s ............................................ 5 7
2. Parts and Materials Supplied by the Operator ........................ 5 7
3. Parts Modified and Reidentified ................................ 5 7
4. Parts Removed and Not Replaced .............................. 5 7 D. Parts Necessary to Change Spares ................................. 5 7 E. Special Tooling - Price and Availability ............................... 5 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 9 A. GENERAL INFORMATION ..................................... 5 9 B. WORK INSTRUCTIONS ....................................... 6 1 FIGURE 1: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 1] ............................................ 6 7 FIGURE 2: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 1] ............................... 7 0 FIGURE 3: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 1] . . 73 FIGURE 4: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 2] ............................................ 7 6 FIGURE 5: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 2] ............................... 7 9 FIGURE 6: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 2] . . 82 FIGURE 7: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 3] ............................................ 8 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 8: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 3] ............................... 8 8 FIGURE 9: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 3] . . 91 FIGURE 10: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 4] ............................................ 9 4 FIGURE 11: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 4] ............................... 9 7 FIGURE 12: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 4] . . 100 FIGURE 13: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 5] ............................................ 1 0 3 FIGURE 14: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 5] ............................... 1 0 6 FIGURE 15: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 5] . . 109 FIGURE 16: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 6] ............................................ 1 1 2 FIGURE 17: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 6] ............................... 1 1 5 FIGURE 18: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 6] . . 119 FIGURE 19: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 7] ............................................ 1 2 3 FIGURE 20: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 7] ............................... 1 2 6 FIGURE 21: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 7] . . 129 FIGURE 22: EXTERNAL HFEC AND DETAILED INSPECTION OF THE OUTER SKIN UPPER LAP ROW [Group 8] ............................................ 1 3 2 FIGURE 23: EXTERNAL DFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW AND GENERAL VISUAL INSPECTION [Group 8] ............................... 1 3 5 FIGURE 24: INTERNAL HFEC INSPECTION OF THE INNER SKIN LOWER LAP ROW [Group 8] . . 137 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: FUSELAGE SKIN LONGITUDINAL LAP SPLICE INSPECTION ........................ 1 3 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0104Original Issue: November 06, 2017 ATA System: 5330 5340 5360 SUBJECT: FUSELAGE - Section 43, Section 44, and Section 46 - Fuselage Skin Lap Splice 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 The fuselage skin longitudinal lap splices on 757 model airplanes have been determined to be susceptible to Widespread Fatigue Damage (WFD). No cracking was found on the fatigue test article, but WFD analysis has identified the need for more frequent repeat inspections. Existing Maintenance Planning Data (MPD) inspections are not sufficient to detect widespread fatigue cracks before they become critical. Currently, there have been no reports of WFD cracking on airplanes in service. Inspections will mitigate a safety issue, allowing continued operation to the Limit of Validity (LOV). Accomplishment of the inspections in this service bulletin will make sure that any crack in the fuselage skin longitudinal lap splices is found. Continued operation with any undetected crack in the fuselage skin longitudinal lap splices could adversely affect the structural integrity of the airplane.
The fuselage skin longitudinal lap splices have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Boeing Fleet Team Digest (FTD) 757 FTD 53-15006 is related to this service bulletin.
Boeing Service Related Problem (SRP) 757-SRP-53-0487 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 AffectedYesPublications 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 Do visual and eddy current inspections of the fuselage skin longitudinal lap splices in Section 43, Section 44, and Section 46, for any crack and any protruding head fastener.
If no crack is found and no protruding head fastener is found, repeat the inspections at the interval specified in Paragraph 1.E., Compliance.
If any crack is found or any protruding head fastener found, contact The Boeing Company for crack repair instructions or alternate inspection instructions for the protruding head fastener and do the repair or inspection and any corrective actions as applicable.
EFFECTIVITY All 757-200/-200CB/-200PF/-300 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
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.
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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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.
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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0104 Original Issue: November 06, 2017 ATA System: 5330 5340 5360 SUBJECT: FUSELAGE - Section 43, Section 44, and Section 46 - Fuselage Skin Lap Splice 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to all 757-200/-200CB/-200PF/-300 Airplanes, line numbers 1-1050 in 8 Group(s). 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.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP 757-200 passenger airplanes with 2 lower cargo doors with no Aft Potable Water Service Panel -1 757-200 passenger airplanes with 2 lower cargo doors with Aft Potable Water Service Panel -2 757-200 passenger airplanes with 2 lower cargo doors with Aft Potable Water Service Panel, and Door 4 lavatory service panel (166AR Access Door) -3 757-200 passenger airplanes with 3 lower cargo doors-4 757-200CB combi airplanes-5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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DESCRIPTIONCONFIGURATIONGROUP 757-200PF package freighter airplanes-6 757-200 special freighter airplanes-7 757-300 airplanes-8 Airplane Models:
757-200, 757-200CB, 757-200PF, 757-300 GroupVariable Number 1NA001 - NA028 1NA191 - NA199 7NA201 - NA204 4NA205 7NA206 - NA213 4NA214 7NA215 - NA236 1NA237 - NA239 1NA301 - NA305 4NA341 - NA352 4NA391 - NA399 1NA401 - NA408 1NA441 - NA447 3NA501 - NA586 3NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NB221 - NB228 1NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 1NB571 1NB581 - NB583 1NC001 - NC033 1NC041 - NC042 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 1NC151 1NC161 6NC901 - NC951 6NC971 - NC974 3ND001 - ND007 3ND011 - ND059 3ND111 - ND113 3ND161 - ND199 3ND201 - ND203 3ND221 - ND225 3ND241 - ND248 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 3ND301 - ND322 3ND401 3ND891 5ND895 3NE001 - NE008 3NE011 - NE088 3NE091 - NE094 3NE141 - NE150 3NE161 - NE177 3NE201 - NE204 3NE301 - NE302 3NE311 - NE325 2NJ001 - NJ004 2NJ031 - NJ032 2NJ551 - NJ555 8NL001 - NL002 8NL006 - NL017 8NL101 - NL109 8NL141 8NL601 - NL616 2NN001 - NN002 2NN051 - NN052 1NP901 - NP904 6NS601 - NS616 6NT001 - NT009 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 1NT281 - NT289 1NT341 - NT347 1NT351 - NT360 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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