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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0108 Original Issue: November 14, 2016 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Body Station 1640 Fuselage Frame 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 © 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Unpublished Work.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.
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4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BLANK PAGE
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 4 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 4 3 G. Manpower .............................................. 4 3 H. Weight and Balance Changes .................................... 4 4 I. Electrical Load Data ......................................... 4 4 J . R e f e r e n c e s .............................................. 4 4
1. Existing Data: ......................................... 4 4
2. Data Supplied with this Service Bulletin: ........................... 4 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 5 K. Publications Affected ........................................ 4 5 L. Interchangeability and Intermixability of Parts ........................... 4 5 M. Software Accomplishment Summary ................................ 4 5
2. MATERIAL INFORMATION ........................................ 4 7 A. Material - Price and Availability ................................... 4 7 B. Industry Support Information .................................... 4 7 C. Parts Necessary for Each Airplane ................................. 4 7 1 . K i t s / P a r t s ............................................ 4 7
2. Parts and Materials Supplied by the Operator ........................ 4 7
3. Parts Modified and Reidentified ................................ 4 7
4. Parts Removed and Not Replaced .............................. 4 7 D. Parts Necessary to Change Spares ................................. 4 7 E. Special Tooling - Price and Availability ............................... 4 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 1 FIGURE 1: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 AND LOWER HINGE INTERCOSTAL - HFEC AND LFEC INSPECTION [Group 1-3] ............... 5 6 FIGURE 2: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 AND LOWER HINGE INTERCOSTAL - HFEC AND LFEC INSPECTION [Group 1-3] ............... 6 0 FIGURE 3: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 AND LOWER HINGE INTERCOSTAL - HFEC INSPECTION [Group 1-3] ..................... 6 4 FIGURE 4: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 AND LOWER HINGE INTERCOSTAL - HFEC INSPECTION [Group 1-3] ..................... 6 7 FIGURE 5: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-11 AND S-13 INTERCOSTAL AREAS - HFEC INSPECTION [Group 1-3] .......................... 7 0 FIGURE 6: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-11 AND S-13 INTERCOSTAL AREAS - HFEC INSPECTION [Group 1-3] .......................... 7 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 7: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 INTERCOSTAL AREA - HFEC AND LFEC INSPECTION [Group 4-5] ......................... 7 8 FIGURE 8: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 INTERCOSTAL AREA - HFEC AND LFEC INSPECTION [Group 4-5] ......................... 8 1 FIGURE 9: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 INTERCOSTAL AREA- HFEC INSPECTION [Group 4-5] ................................... 8 4 FIGURE 10: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 INTERCOSTAL AREA - HFEC INSPECTION [Group 4-5] ............................... 8 7 FIGURE 11: LEFT SIDE - STA 1640 FUSELAGE FRAME AT LOWER HINGE INTERCOSTAL, STRINGERS S-11 AND S-13 - HFEC INSPECTION [Group 4-5] ...................... 9 0 FIGURE 12: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT LOWER HINGE INTERCOSTAL, STRINGERS S-11 AND S-13 - HFEC INSPECTION [Group 4-5] ...................... 9 3 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1 [Group 1, Configuration 1 ] ................................................ 9 6 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2 [Group 1, Configuration 2 ] ................................................ 1 0 2 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 3 [Group 2] ..... 1 0 7 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 4 [Group 3, Configuration 1 ] ................................................ 1 1 2 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 5 [Group 3, Configuration 2 ] ................................................ 1 1 8 APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 6 [Group 4] ..... 1 2 3 APPENDIX G: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 7 [Group 5] ..... 1 2 8 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: 757-53A0108Original Issue: November 14, 2016 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Body Station 1640 Fuselage Frame 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 This service bulletin is sent to provide instructions to do High Frequency Eddy Current (HFEC) and Low Frequency Eddy Current (LFEC) inspections for any crack in the fuselage frame at Body Station (STA) 1640, between stringers S-11 and S-14, on the left and right side of the airplane. If the work given in this service bulletin is not done, such fatigue cracking could adversely affect the structural integrity of the airplane.
One operator reported a crack finding, at 24,607 total flight cycles, in the STA 1640 fuselage frame at stringer S-14R, adjacent to door stop number 5. The crack had fully severed the inner chord and web of the STA 1640 fuselage frame. The cracking is attributed to fatigue caused by flight loads and pressurization of the fuselage.
Boeing has determined that the existing inspection programs are not sufficient to detect these cracks because most of the STA 1640 fuselage frame is obscured by adjacent structure. Accomplishment of this service bulletin will improve detection of cracking in the STA 1640 fuselage frame and make sure that any crack is found and repaired before the crack grows to a critical length.
Boeing Fleet Team Digest (FTD) 757 FTD 53-16001 is related to this service bulletin.
Boeing Service Related Problem (SRP) 757-SRP-53-0525 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 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 Get access to the Body Station (STA) 1640 fuselage frame, between stringers S-11 and S-14, on the left and right side of the airplane. Do High Frequency Eddy Current (HFEC) and Low Frequency Eddy Current (LFEC) inspections for any crack in the STA 1640 fuselage frame, between stringers S-11 and S-14, on the left and right side of the airplane. If any crack is found, contact The Boeing Company for repair instructions and do the repair, and repeat the inspections in unrepaired areas at the times given in Paragraph 1.E., Compliance. If no crack is found, repeat the inspections at the times given in Paragraph 1.E., Compliance.
EFFECTIVITY All 757-200, -200CB, and -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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BOEING SERVICE BULLETIN 757-53A0108
ALERT ALERT STA 1640 STA 1620 S-8 DO HIGH FREQUENCY EDDY CURRENT (HFEC • S-10
AND LOW FREQUENCY EDDY CURRENT (LFEC)
INSPECTIONS FOR ANY CRACK
• S
- S-13
- LOWER HINGE
INTERCOSTAL
• S-14 ..•.S-16
LEFT SIDE SHOWN, RIGHT SIDE SIMILAR 2522109 Original Issue: November 14, 2016 Export Controlled ECCN: 9E991 - BOEING 757-53A0108 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 132
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: 757-53A0108 Original Issue: November 14, 2016 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Body Station 1640 Fuselage Frame 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, and -300 Airplanes, in 5 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 and -200CB airplanes that have a long inner chord strap at the Body Station (STA) 1640 fuselage frame.
-1 757-200 and -200CB airplanes with less than 32,000 total flight cycles at the original issue date of this service bulletin, that have a long inner chord strap at the Body Station (STA) 1640 fuselage frame.
1 757-200 and -200CB airplanes with 32,000 total flight cycles or more at the original issue date of this service bulletin, that have a long inner chord strap at the Body Station (STA) 1640 fuselage frame.
2 757-200 Boeing special freighter airplanes that have a long inner chord strap at the STA 1640 fuselage frame.
-2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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DESCRIPTIONCONFIGURATIONGROUP 757-300 airplanes that have a long inner chord strap at STA 1640 fuselage frame.
-3 757-300 airplanes, with less than 16,000 total flight cycles at the original issue date of this service bulletin, that have a long inner chord strap at STA 1640 fuselage frame.
1 757-300 airplanes, with 16,000 total flight cycles or more at the original issue date of this service bulletin, that have a long inner chord strap at STA 1640 fuselage frame.
2 757-200 airplanes that have a short inner chord strap at the STA 1640 fuselage frame.
-4 757-200 Boeing special freighter airplanes that have a short inner chord strap at the STA 1640 fuselage frame.
-5 Airplane Models:
757-200, 757-200CB, 757-300 GroupVariable Number 4NA001 - NA021 1NA022 - NA028 4NA191 1NA192 - NA199 5NA201 - NA204 4NA205 5NA206 - NA213 4NA214 2NA215 - NA236 1NA237 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 4NA401 - NA403 1NA404 - NA408 1NA441 - NA447 4NA501 - NA504 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NA505 - NA586 4NB001 1NB002 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1NC091 - NC094 1NC151 1NC161 1ND001 - ND007 1ND011 - ND059 1ND111 - ND113 1ND161 - ND199 1ND201 - ND203 1ND221 - ND225 1ND241 - ND248 1ND301 - ND322 1ND401 1ND891 1ND895 1NE001 - NE008 1NE011 - NE088 1NE091 - NE094 1NE141 - NE150 1NE161 - NE177 1NE201 - NE204 1NE301 - NE302 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 3NL001 - NL002 3NL006 - NL017 3NL101 - NL109 3NL141 3NL601 - NL616 1NN001 - NN002 1NN051 - NN052 1NP901 - NP904 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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