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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-53A0108 Original Issue: November 14, 2016 Revision 1: July 17, 2019 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Unpublished Work.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.
Original Issue: November 14, 2016 757-53A0108Revision 1: July 17, 2019 1 of 252
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 14, 2016 757-53A0108Revision 1: July 17, 2019 2 of 252 BOEING SERVICE BULLETIN 757-53A0108
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y9
1. PLANNING INFORMATION ........................................ 1 3 A . E f f e c t i v i t y ............................................... 1 3
1. Airplanes ............................................ 1 3 2 . S p a r e s A f f e c t e d ........................................ 1 8 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 2 0 E. Compliance .............................................. 2 1 F . A p p r o v a l ............................................... 8 6 G. Manpower .............................................. 8 7 H. Weight and Balance Changes .................................... 8 8 I. Electrical Load Data ......................................... 8 8 J . R e f e r e n c e s .............................................. 8 9
1. Existing Data: ......................................... 8 9
2. Data Supplied with this Service Bulletin: ........................... 8 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 8 9 K. Publications Affected ........................................ 9 0 L. Interchangeability and Intermixability of Parts ........................... 9 0 M. Software Accomplishment Summary ................................ 9 0
2. MATERIAL INFORMATION ........................................ 9 1 A. Material - Price and Availability ................................... 9 1 B. Industry Support Information .................................... 9 1 C. Parts Necessary for Each Airplane ................................. 9 1 1 . K i t s / P a r t s ............................................ 9 1
2. Parts and Materials Supplied by the Operator ........................ 9 1
3. Parts Modified and Reidentified ................................ 9 1
4. Parts Removed and Not Replaced .............................. 9 1 D. Parts Necessary to Change Spares ................................. 9 1 E. Special Tooling - Price and Availability ............................... 9 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 9 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 9 3 A. GENERAL INFORMATION ..................................... 9 3 B. WORK INSTRUCTIONS ....................................... 9 6 FIGURE 1: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 A ND LOWER HINGE INTERCOSTAL HFEC AND LFEC INSPECTION [Group 1-3] ............... 1 0 7 FIGURE 2: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 AND LOWER HINGE INTERCOSTAL - HFEC AND LFEC INSPECTION [Group 1-3] .............. 1 1 2 FIGURE 3: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 A ND LOWER HINGE INTERCOSTAL - HFEC INSPECTION [Group 1-3] ..................... 1 1 7 FIGURE 4: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 AND LOWER HINGE INTERCOSTAL - HFEC INSPECTION [Group 1-3] ..................... 1 2 1 FIGURE 5: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-11 A ND S-13 INTERCOSTAL AREAS - HFEC INSPECTION [Group 1-3] ......................... 1 2 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 6: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-11 AND S-13 INTERCOSTAL AREAS - HFEC INSPECTION [Group 1-3] ......................... 1 2 9 FIGURE 7: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 I NTERCOSTAL AREA - HFEC AND LFEC INSPECTION [Group 4-5] ........................ 1 3 3 FIGURE 8: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 INTERCOSTAL AREA - HFEC AND LFEC INSPECTION [Group 4-5] ........................ 1 3 7 FIGURE 9: LEFT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 I NTERCOSTAL AREA - HFEC INSPECTION [Group 4-5] ............................... 1 4 1 FIGURE 10: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT STRINGER S-14 INTERCOSTAL AREA - HFEC INSPECTION [Group 4-5] ............................... 1 4 5 FIGURE 11: LEFT SIDE - STA 1640 FUSELAGE FRAME AT LOWER HINGE INTERCOSTAL, STRINGERS S-11 AND S-13 - HFEC INSPECTION [Group 4-5] ..................... 1 4 9 FIGURE 12: RIGHT SIDE - STA 1640 FUSELAGE FRAME AT LOWER HINGE INTERCOSTAL, STRINGERS S-11 AND S-13 - HFEC INSPECTION [Group 4-5] ..................... 1 5 4 FIGURE 13: LEFT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD - DETAILED INSPECTION . 159 FIGURE 14: RIGHT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD - DETAILED INSPECTION . 161 FIGURE 15: LEFT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD FASTENER HOLES AND FLANGE RADIUS - HFEC INSPECTION ............................... 1 6 3 FIGURE 16: RIGHT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD FAST ENER HOLES AND FLANGE RADIUS - HFEC INSPECTION .......................... 1 6 7 FIGURE 17: LEFT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD FASTE NER HOLES - HFEC INSPECTION [Group 1-3] .................................. 1 7 1 FIGURE 18: RIGHT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD FAST ENER HOLES - HFEC INSPECTION [Group 1-3] .................................. 1 7 4 FIGURE 19: LEFT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD FASTE NER HOLES - HFEC INSPECTION [Group 4-5] .................................. 1 7 7 FIGURE 20: RIGHT SIDE - STA 1640 FUSELAGE FRAME INNER CHORD FAST ENER HOLES - HFEC INSPECTION [Group 4-5] .................................. 1 8 0 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2 [Group 1, Configuration 1 - 2 ] ............................................... 1 8 3 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 3 [Group 1, Configuration 3 ] ................................................ 1 9 0 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 4 [Group 2, Configuration 1 ] ................................................ 1 9 7 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 5 [Group 2, Configuration 2 ] ................................................ 2 0 4 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 6 [Group 3, Configuration 1 - 2 ] ............................................... 2 1 1 APPENDIX F: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 7 [Group 3, Configuration 3 ] ................................................ 2 1 8 APPENDIX G: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 8 [Group 4, Configuration 1 ] ................................................ 2 2 5 APPENDIX H: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 9 [Group 4, Configuration 2 ] ................................................ 2 3 2 APPENDIX I: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 10 [Group 5, Configuration 1 ] ................................................ 2 3 9 APPENDIX J: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 11 [Group 5, Configuration 2 ] ................................................ 2 4 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 14, 2016 757-53A0108Revision 1: July 17, 2019 4 of 252 BOEING SERVICE BULLETIN 757-53A0108
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Commercial Airplanes 757 Service Bulletin ALERT Revision Transmittal SheetNumber: 757-53A0108Original Issue: November 14, 2016 Revision 1: July 17, 2019 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Body Station 1640 Fuselage Frame Inspection This revision includes all pages of the service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 14, 2016 757-53A0108Revision 1: July 17, 2019 5 of 252
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2018-06-07 is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue was previously done:
ActionConditionGroup Do PART 6 inspection for any crack, nick or gouge.
Airplanes that have accomplished OPTION 1 PART 2 inspections in Service Bulletin 757-53A0108 Original Issue with no crack found.
Groups 1-5 Do PART 2, PART 7 and PART 8 inspection for any crack.
Do PART 6 inspection for any crack, nick or gouge.
Airplanes that have accomplished OPTION 2 PART 3 inspections in Service Bulletin 757-53A0108 Original Issue with no crack found. Do PART 3, PART 7 and PART 8 inspections for any crack.
Do PART 6 inspection for any crack, nick or gouge.
Airplanes that have accomplished the inspections in accordance with Service Bulletin 757-53A0108 Original Issue and have installed a repair or local frame replacement that does not contain a reinforcement repair or repair splice member between S-11 and S-16 and the repair or replacement is Boeing Organization Designation Authorization (ODA) approved via an FAA form 8100-9.
Do PART 2, PART 7 and PART 8 inspections for any crack.
OR Do PART 3, PART 7 and PART 8 inspections for any crack.
Contact The Boeing Company for alternative inspection(s) and do the inspection(s) and any corrective actions as applicable.
Airplanes that have accomplished the inspections in accordance with Service Bulletin 757-53A0108 Original Issue and have installed a repair or local frame replacement that contains a reinforcement repair or repair splice member between S-11 and S-16.
Contact The Boeing Company for alternative inspection(s) and do the inspection(s) and any corrective actions as applicable.
Airplanes that have accomplished the inspections in accordance with Service Bulletin 757-53A0108 Original Issue and have installed a repair or local frame replacement that is not Boeing Organization Designation Authorization (ODA) approved.
REASON FOR REVISION This revision is sent to provide the following:
– Added a reference to Airworthiness Directive AD 2018-06-07 – Added new instructions to do a one time inspection of maintena nce records for any repairs or local frame replacements installed as a result of damage found during inspections in the original issue of service bulletin 757-53A0108.
– Added a one time Detailed Inspection of the frame inner chord forward return flange edge for cracks, nicks and gouges.
– Added initial and repetitive High Frequency Eddy Current (HFEC ) inspections around the fasteners of the frame inner chord, and of the inner chord forward return flange radius.
– Changed Low Frequency Eddy Current (LFEC) inspections for six fasteners in the inner chord from LFEC to HFEC inspections, and the inspection direction is changed from the outboard side of the frame inner chord to the inboard side of the frame inner chord.
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– Added LFEC inspections of the frame inner chord around the upp ermost fastener common to the frame inner chord long strap (Groups 1-3) These sections were changed:
1. Summary, Illustration, added new detailed and HFEC inspection s.
2. In Paragraph 1.A., Effectivity, updated paragraph that lists airplane minor models, line numbers and groups.
3. In Paragraph 1.C., Reason, updated paragraph to add new crack information and reason for revision statement added.
4. In Paragraph 1.D., Description, added more work table and new paragraph that includes the new Detailed and HFEC inspections.
5. In Paragraph 1.E., Compliance, changed existing compliance Ta bles 1-7, added new Tables 8-11, added Part - Title Index table, and added paragraph to reference Airworthiness Directive (AD).
6. In Paragraph 1.F., Approval, added new AMOC statement.
7. In Paragraph 1.G., Manpower, added manpower for figures 13-18 for Groups 1-3 and figures 13-16 and Figures 19-20 for Groups 4-5.
8. In Paragraph 1.J., References, Airworthiness Directive AD 2018-06-07, Boeing Service Related Problem 757-SRP-53-0594 and Multi-Operator Message MOM-MOM-17-0037-01C.
9. In Paragraph 3.A., General Information, added notes 18 and 19 , and changed notes 9 and 10.
10. In Paragraph 3.B., Work Instructions, Changed existing Part 2 and Part 3 inspections, added new Part 6 detailed inspection and Part 7 and Part 8 HFEC inspections.
11. In Paragraph 3.B., Work Instructions, changed the inspection areas in Figures 1, 2.
12. In Paragraph 3.B., Work Instructions, removed the HFEC inspe ction from Figures 7, 8.
13. In Paragraph 3.B., Work Instructions, added Figures 13 and 14 for the new Part 6 detailed inspection.
14. In Paragraph 3.B., Work Instructions, added Figures 15 and 1 6 for the new Part 7 HFEC inspections.
15. In Paragraph 3.B., Work Instructions, added Figures 17, 18, 19, 20, for the new Part 8 HFEC inspections.
16. In Appendices A to G, updated logic diagram to incorporate c hanges in the associated Compliance Tables.
17. In Appendices H, I and J, new logic diagrams added for Compl iance Tables 9, 10 and 11.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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REVISION HISTORY November 14, 2016Original Issue:
July 17, 2019Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 14, 2016 757-53A0108Revision 1: July 17, 2019 8 of 252 BOEING SERVICE BULLETIN 757-53A0108
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-53A0108Original Issue: November 14, 2016 Revision 1: July 17, 2019 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-16, 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.
During inspections in Service Bulletin 757-53A0108 Original Issue an operator found a STA 1640 frame with a crack starting from the third fastener below the S-14 intercostal on the right side. The crack was approximately 3 inches long and had grown into an insulation stud hole in the web near the outer chord. The crack was not in the 757-53A0108 Original Issue inspection area. There have also been instances of cracks found growing out of the fastener holes in the inner chord in the aft direction, towards the web away from the original inspection areas.
In addition, after the original issue of this service bulletin, there have been a total of 23 cracks reported in the STA 1640 frames resulting from SB 757-53A0108 Original Issue inspections. These reports were from airplanes with 20,500 to 39,850 flight cycles, and with 62,100 to 89,150 flight hours. The crack lengths reported ranged from 0.10 inch to a completely severed frame with some reporting cracking in the outer chord.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 14, 2016 757-53A0108Revision 1: July 17, 2019 9 of 252
Boeing Service Related Problem (SRP) 757-SRP-53-0525 and 757-SRP-53-0594 are related to this service bulletin.
Multi-Operator Message (MOM) MOM-MOM-17-0037-01C 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 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-16, on the left and right side of the airplane. Do the one time general visual inspection for repairs and the one-time detailed inspection for any crack, nick or gouge in the STA 1640 fuselage frame, on the left and right side of the airplane. If any repair, crack, nick or gouge is found, contact The Boeing Company for alternate inspections, repairs and any corrective actions as applicable. If no crack, nick or gouge is found, do the High Frequency Eddy Current (HFEC) inspections and Low Frequency Eddy Current (LFEC) for any crack in the STA 1640 fuselage frame, between stringers S-11 and S-16, 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 HFEC and LFEC inspections in unrepaired areas at the times given in Paragraph 1.E., Compliance. If no crack is found, repeat the HFEC and LFEC 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 Federal Aviation Administration (FAA) Airworthiness Directive AD 2018-06-07 is related to this service bulletin.
The effective date of AD 2018-06-07 is May 03, 2018.
Refer to Paragraph 1.E., Compliance.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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.
Original Issue: November 14, 2016 757-53A0108Revision 1: July 17, 2019 11 of 252 BOEING SERVICE BULLETIN 757-53A0108
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BOEING SERVICE BULLETIN 757-53A0108
ALERT ALERT STA 1640 STA 1620 ... - S-8
• S-10 S-11 -DO A ONE TIME GENERAL
VISUAL INSPECTION FOR
REPAIRS
- DO REPEAT HIGH FREQUENCY
EDDY CURRENT (HFEC) AND
LOW FREQUENCY
EDDY CURRENT (LFEC) INSPECTIONS FOR ANY CRACK - S-13
- DO A ONE-TIME DETAILED - LOWER HINGE INSPECTION FOR ANY CRACK, • S-14 STRAP INTERCOSTAL
NICK OR GOUGE
• DO REPEAT HIGH FREQUENCY
EDDY CURRENT (HFEC
NSPECTIONS FOR ANY CRACK FWD
LEFT SIDE SHOWN, RIGHT SIDE SIMILAR 2522109 Original Issue: November 14, 2016 Revision 1: July 17, 2019 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-53A0108 Work - See page 1 for details. 12 of 252