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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-54A0047 Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 1 of 79
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 2 of 79 BOEING SERVICE BULLETIN 757-54A0047
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 9 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 4 G. Manpower .............................................. 2 5 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 8
1. Existing Data: ......................................... 2 8
2. Data supplied with this Service Bulletin: ........................... 2 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 9 K. Publications Affected ........................................ 2 9 L. Interchangeability and Intermixability of Parts ........................... 2 9
2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 1 C. Parts Necessary For Each Airplane ................................. 3 1
1. Kits/Parts: ........................................... 3 1
2. Parts and Materials Supplied by the Operator: ........................ 3 2
3. Parts Modified and Reidentified: ............................... 3 3
4. Parts Removed and Not Replaced: .............................. 3 3 D. Parts Necessary to Change Spares ................................. 3 3 E. Special Tooling - Price and Availability ............................... 3 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: ACCESS FOR INSPECTION ................................. 4 1 FIGURE 2: INSPECTION - FASTENERS AND SHIM - VERTICAL FLANGE .............. 4 4 FIGURE 3: INSPECTION - HORIZONTAL FLANGE FASTENERS AND TORQUE BULKHEAD .... 4 6 FIGURE 4: INTERIM REPAIR I - SHIM REPLACEMENT - VERTICAL FLANGE ............ 4 9 FIGURE 5: INTERIM REPAIR II - OVERSIZE FASTENERS - VERTICAL FLANGE .......... 5 2 FIGURE 6: INTERIM REPAIR III - OVERSIZE FASTENERS - HORIZONTAL FLANGE ........ 5 4 FIGURE 7: THIS FIGURE HAS BEEN DELETED ............................. 5 7 FIGURE 8: REPAIR - SEALANT AND LEVELING COMPOUND ..................... 5 8 FIGURE 9: INTERIM REPAIR V - SHIM - VERTICAL FLANGE ..................... 6 0 FIGURE 10: SEAL COVER PLATES .................................... 6 2 FIGURE 11: INSPECTION - CRITICAL HORIZONTAL FLANGE FASTENER LOCATIONS ....... 6 4
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Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 3 of 79 BOEING SERVICE BULLETIN 757-54A0047
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FIGURE 12: NACELLE/PYLONS - ALTERNATIVE ACCESS TO THE CRITICAL HORIZONTAL FLANGE FASTENERS .......................................... 6 7 FIGURE 13: NACELLE/PYLONS - ULTRASONIC INSPECTION OF THE CRITICAL FASTENERS . . 68 FIGURE 14: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 1 STRUT . 70 FIGURE 15: FASTENER REPLACEMENT - HORIZONTAL AND VERTICAL FLANGE - NO. 2 STRUT . 75
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 4 of 79 BOEING SERVICE BULLETIN 757-54A0047
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Commercial Airplanes 757 Service Bulletin ALERT Revision Transmittal SheetNumber: 757-54A0047Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and Change This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplanes changed in accordance with the original issue, Revision 1, Revision 2, Revision 3 or Revision 4 of this service bulletin. Replace the fasteners on the horizontal and vertical flange as given in this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive (AD) AD 2004-12-07 and AD 2008-05-10 are related to this service bulletin.
No airplanes were added or removed from this service bulletin effectivity.
REASON FOR REVISION This revision is sent to revise the compliance information and to give terminating action details.
These sections were changed:
1. Subject revised.
2. Summary Background and Action - More information is added.
3. Summary Compliance - New AD information added
4. Summary Industry Support Information - Reimbursement details added.
5. Summary Manpower terminating action hours added.
6. Summary Material Information Revised.
7. Paragraph 1.C., Reason - Terminating action added.
8. Paragraph 1.D., Description - Terminating action added.
9. Paragraph 1.E., Compliance - Terminating action compliance information and new AD information added.
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Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 5 of 79
10. Paragraph 1.G., Manpower - New manpower tables added.
11. Paragraph 1.H., Weight and Balance Changes - Table added.
12. Paragraph 1.J.1., Existing Data - PRR and Boeing Service Letter reference added.
13. Paragraph 1.K., Publications Affected - Table added.
14. Paragraph 2.A., Material - Price and Availability - New kit supply information added.
15. Paragraph 2.B., Industry Support Information - Reimbursement details added.
16. Paragraph 2.C.1., Kit/Parts - New kit added.
17. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Alternatives information revised.
18. Paragraph 3.A., General Information - Notes revised.
19. Paragraph 3.B., Work Instructions - Part I, Step 4.b. and Step 5.a.1. Revised. Part II, Step 2.a.1. Revised.
Part III, Step 5. Revised. Part IV, Step 2.b.1 note added. Part V added.
20. FIGURE 4, 5 and 6 - Fastener code illustration added.
21. FIGURE 8 - Alternatives information revised.
22. FIGURE 9 - Alternatives information revised.
23. FIGURE 11- Fastener code illustration added.
24. FIGURE 14 and 15 added.
The data given in Information Notice 757-54A0047 IN 02 is included in this revision. The information notice gives the removal of the common nozzle exhaust collector as an option to the removal of the engine.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY November 13, 2003Original Issue:
March 24, 2005Revision 1:
January 31, 2007Revision 2:
June 27, 2007Revision 3:
June 24, 2010Revision 4:
Revision 5:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 6 of 79 BOEING SERVICE BULLETIN 757-54A0047
ALERTALERT
Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-54A0047Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and Change
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 This service bulletin gives the instructions to inspect the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting for a loose shim, and/or loose, missing, or damaged fasteners. Instructions are also given to make repairs if loose fasteners or migrated shims are found during the inspections and to do an inspection and repair of the four critical fastener holes on the horizontal flange. Terminating Instructions replace the fasteners on the horizontal and vertical flange with larger fasteners.
Since 1993, Boeing has eighteen reports of cracks, loose and broken bolts, and shim migration in the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting.
Service History ReportStrutCyclesHoursDate One bolt sheared in horizontal flange. Four bolts loose in vertical flange.
-10,28429,45112/93 Four bolts loose in vertical flange of both struts.No. 1 & 29,35825,76811/96 One bolt loose in vertical flange of Strut No. 1. Four bolts loose in vertical flange of Strut No. 2.
No. 1 & 2--06/98 Four bolts loose in vertical flange of both struts. Two bolts sheared in horizontal flange of both struts. All remaining bolts loose in horizontal flange of both struts.
No. 1 & 221,74955,78911/99 Sixteen bolts loose in horizontal flange.No. 1 & 220,16146,45901/01 Two bolts loose in vertical flange.No. 113,66249,01909/01
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Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 7 of 79
Service History ReportStrutCyclesHoursDate Two bolt heads cracked.-14,63323,42301/02 Two bolts loose in horizontal flange of Strut No. 1.
Three bolts loose in horizontal flange of Strut No. 2.
No. 1 & 212,49316,60104/02 Migrated shim between bulkhead and vertical flange of fitting.
No. 1 & 215,52243,82205/02 Four bolts loose in vertical flange. Five bolts loose in horizontal flange.
No. 215,90046,75806/02 One bolt missing and one bolt loose in horizontal flange. Cracks in the aluminum bulkhead at three hole locations.
No. 120,09049,80712/02 Two loose bolts in vertical flange.-22,11150,84104/03 Three loose bolts in vertical flange.No. 19,99130,07209/03 Migrated shims between bulkhead and vertical flange of fitting.
No. 1 & 226,91460,71509/03 Three loose bolts in vertical flange.No. 215,00444,98510/03 Three loose bolts in vertical flange.No. 27,92212,36801/04 Four loose bolts in vertical flange.No. 17,59212,11902/04 One loose fastener in the vertical flange. Cracks in the aluminum bulkhead at two hole locations and web at one hole location common to the horizontal flange.
No. 113,08344,42304/06 In addition, one operator found a strut torque bulkhead fitting with loose fasteners and cracks at the joint common to the strut diagonal brace fitting on two airplanes with the Strut Improvement Program (SIP) incorporated during production. One airplane had been inspected for loose fasteners in 2006 per service bulletin 75-54A0047 Revision 01 with no findings. Since that inspection, the airplane had accumulated less than 3000 flight cycles. The loose fasteners and cracks were found during an engine change while the area was exposed.
Continued operation with cracks, and/or loose and broken fasteners, could cause separation of the joint between the aft torque bulkhead and the strut-to-diagonal brace fitting. With separation of these components, the diagonal brace would not transmit the engine loads through to the wing structure. Continued safe flight, as related to this characteristic of the strut installation, would then have dependence on the upper link load path of the strut. The upper link load path is designed with sufficient strength to carry the load redistribution. However, if a separation in the diagonal brace load path goes undetected for a long enough period, loss of the strut could occur.
Boeing Service Related Problems (SRP) 757-SRP-54-0095, 757-SRP-54-0118 and 757-SRP-54-0130 are related to this service bulletin.
ACTION (PRR 54530-291RS) Get access to the forward and aft surfaces of the torque bulkhead assembly. Do an inspection of the shims between the vertical flange of the strut-to-diagonal brace fitting and the torque bulkhead. Also, do an inspection of the four fasteners through the vertical flange of the fitting and the torque bulkhead. If shim migration and/or loose bolts are found in the diagonal brace load path, make the applicable interim repairs.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 8 of 79 BOEING SERVICE BULLETIN 757-54A0047
ALERTALERT
Get more access for the inspection of the horizontal flange of the strut-to-diagonal brace fitting. Do an inspection of the sixteen fasteners through the horizontal flange of the fitting. A borescope, or other inspections aids, can be necessary for this inspection. If necessary remove the engine and install oversize fasteners.
If loose fasteners are found or shim migration is beyond limits, do an inspection and repair of the four critical fastener holes on the horizontal flange.
For service bulletin terminating action, replace the fasteners on the horizontal and the vertical flange with larger fasteners.
As necessary, apply new sealant to the fasteners and leveling compound to the strut structure. As necessary install the engine, diagonal brace, and other components removed to get access. Put the airplane back to a serviceable condition and schedule the repeat inspections.
EFFECTIVITY 757-200/-200CB and -200PF airplanes line numbers 1 thru 1048, powered by Rolls Royce engines.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directives (AD) AD 2004-12-07 and AD 2008-05-10 are related to this service bulletin.
The FAA will possibly release another Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin. For customers who have already ordered and/or, installed the 757 SIP Top Kit 012N8041-1 please submit a claim for reimbursement of your purchase of Supplemental Kit 012N8931-23. When submitting your claim, please include your SIP (SB 757-54-0035) Top Kit incorporation date.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
22.0 (a)44.0 (a)All
26.0 (b)74.0 (b)All (Engine Removed)
23.0 (b)46.0 (b)All (Common Nozzle Exhaust Removed)
(a) Inspections only. Does not include time to make repairs if loose fasteners or cracks are found.
(b) For increased diameter fastener installation terminating action.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 9 of 79 BOEING SERVICE BULLETIN 757-54A0047
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BOEING SERVICE BULLETIN 757-54A0047
ALERT ALERT
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
INSTALL OVERSIZE FASTENERS
TO TERMINATE INSPECTIONS (8 LOCATIONS).
INSPECT FASTENERS IN
HORIZONTAL FLANGE OF FITTING (16 LOCATIONS).
FWD A-A
INSPECT THE ACCESS DOOR CUTOUT FOR FADI CRACKING.
INSPECT SHIM
INSPECT FASTENERS INSTALL OVERSIZE FASTENERS INSTALLATION. IN VERTICAL FLANGE TO TERMINATE INSPECTIONS OF FITTING (4 LOCATIONS).
(4 LOCATIONS).
INSPECT THE BULKHEAD FOR CRACKING.
W38926 Original Issue: November 13, 2003 Revision 5: June 09, 2011 BOEING PROPRIETARY - 757-54A0047 Copyright © Unpublished Work - See page 1 for details. 10 of 79
Commercial Airplanes 757 Service Bulletin ALERT Number: 757-54A0047 Original Issue: November 13, 2003 Revision 5: June 09, 2011 ATA System: 5451 SUBJECT: NACELLE/PYLONS - Nacelle Strut - Rolls Royce RB 211 Powered Airplanes - Loose and/or Broken Fasteners on the Strut-to-Diagonal Brace Fitting - Inspection and Change
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 Document D6-24N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP 757-200/-200CB/-200PF airplanes line number 1 thru 735, powered by Rolls Royce engines.
-1 Airplanes without SB 757-54-0035 incorporation.1 Airplanes with SB 757-54-0035 incorporation.2 757-200/-200PF airplanes line number 736 thru 1048, powered by Rolls Royce engines.
-2 Airplane Models:
757-200, 757-200CB, 757-200PF GroupVariable Number 1NA002 - NA028
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Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 11 of 79
GroupVariable Number 1NA191 - NA199 1NA201 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 1NA401 - NA408 1NA441 - NA447 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB201 - NB204 1NB221 - NB225 2NB226 - NB228 2NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 2NB571 2NB581 - NB583 1NC058 - NC061
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Original Issue: November 13, 2003 757-54A0047Revision 5: June 09, 2011 12 of 79 BOEING SERVICE BULLETIN 757-54A0047