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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0106 RB Original Issue: January 03, 2023 ATA System: 5331 SUBJECT: FUSELAGE - Structural Inspections - Main Deck Cargo Door Hinge Attachment Holes Inspection EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.
9E991ECCN:
Copyright © 2023 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Unpublished Work.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: January 03, 2023 757-53A0106 RB 1 of 32
3.0
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 2 of 32 REQUIREMENTS BULLETIN 757-53A0106
ALERTALERT
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Table of Contents
1. EFFECTIVITY5
A. Airplanes5
B. Spares Affected6
2. CONCURRENT REQUIREMENTS6
3. COMPLIANCE6
4. APPROVAL11
5. ACCOMPLISHMENT INSTRUCTIONS13
A. General Information13
B. Work Instructions14
FIGURE 1: HIGH FREQUENCY EDDY CURRENT INSPECTION AT THE MAIN DECK CARGO DOOR
FORWARD HINGE ATTACHMENT21
FIGURE 2: HIGH FREQUENCY EDDY CURRENT INSPECTION AT THE MAIN DECK CARGO DOOR
AFT HINGE ATTACHMENT25
APPENDIX C: MAINTENANCE RECORDS CHECK FOR ANY REPAIR AT THE FORWARD AND AFT HINGE
AREAS OF THE MAIN DECK CARGO DOOR CUTOUT29
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 3 of 32 REQUIREMENTS BULLETIN 757-53A0106
ALERTALERT
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 4 of 32 REQUIREMENTS BULLETIN 757-53A0106
ALERTALERT
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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0106 RB Original Issue: January 03, 2023 ATA System: 5331 SUBJECT: FUSELAGE - Structural Inspections - Main Deck Cargo Door Hinge Attachment Holes 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. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING
PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1. Effectivity A. Airplanes This bulletin is applicable to 757-200, 757-200CB, 757-200PF Airplane(s), line number(s) 9-11, 13, 16, 23-25, 29-30, 32-33, 50, 52, 54, 58, 63, 77-78, 81, 89-90, 93, 98, 123, 139, 141, 143, 145, 147, 149, 160, 166, 168, 175-176, 179, 181-182, 184, 186, 189, 191, 193, 195, 197, 199, 210-211, 214, 237, 258, 300, 314, 318, 322, 326, 330, 334, 340, 395, 399, 403, 407, 411, 477, 481, 485, 489, 493, 569, 573, 577, 579, 581, 625, 628, 631, 634, 636, 638, 640, 642, 644, 646, 649, 651, 654, 656, 659, 675, 679, 683, 687, 691, 728-730, 733-734, 755, 759, 763, 765, 767, 769, 771, 774, 776, 778, 813, 815, 823, 879, 882 in 3 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g.
line numbers 1-9 means line numbers 1 through 9 inclusive.
The Variable Numbers and Group Information for the applicable airplanes is given below.
DESCRIPTIONCONFIGURATIONGROUP 757-200PF Package Freighter Airplanes.-1 757-200 airplanes that have been converted into Special Freighters (SF) in accordance with Boeing STC ST00916WI-D.
-2 757-200CB Combination Freighter Airplane.-3 Airplane Models:
757-200, 757-200CB, 757-200PF Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 5 of 32
GroupVariable Number 2NA201 - NA204 2NA206 - NA213 2NA215 - NA236 GroupVariable Number 1NC901 - NC951 1NC971 - NC974 3ND895 GroupVariable Number 1NS601 - NS616 1NT001 - NT009 -- B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 757-53A0106 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0106 RB mandatory.
Accomplish the required action(s), based on the applicable condition(s) in Tables 1 and 2, in accordance with 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 or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Group 1, 3:
Table 1: Inspection of Bear Strap, Skin, Doubler, and Upper Sill Chord at the Main Deck Cargo Door Hinge Attachment Holes Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,800 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0106 RB.
Before 27,500 total flight cycles.
Do a Maintenance Records Check (MRC) for any repair at the forward and aft hinge areas of the main deck cargo door cutout.
All Airplanes.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 6 of 32 REQUIREMENTS BULLETIN 757-53A0106
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Group 1, 3:
Table 1: Inspection of Bear Strap, Skin, Doubler, and Upper Sill Chord at the Main Deck Cargo Door Hinge Attachment Holes Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 500 flight cycles or 6 months, whichever comes first, after the MRC has been performed.
CONDITION 1 (ACTION 1):
Contact The Boeing Company for alternative inspection and corrective action instructions.
CONDITION 1:
ANY REPAIR FOUND.
-At times provided in CONDI- TION 1 (ACTION 1).
CONDITION 1 (ACTION 2):
Do the alternative inspections and applicable corrective actions.
-Within 3,300 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0106 RB.
Before 28,000 total flight cycles.
CONDITION 1 (ACTION 3):
Do an open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) -Before further flight.CONDITION 1.1 (ACTION 1):CONDITION 1.1:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK FOUND.
7,000 flight cycles.-CONDITION 1.1 (ACTION 2):
Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) 7,000 flight cycles.-Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) CONDITION 1.2:
NO CRACK FOUND.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 7 of 32 REQUIREMENTS BULLETIN 757-53A0106
ALERTALERT
Group 1, 3:
Table 1: Inspection of Bear Strap, Skin, Doubler, and Upper Sill Chord at the Main Deck Cargo Door Hinge Attachment Holes Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,300 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0106 RB.
Before 28,000 total flight cycles.
Do an open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack.
CONDITION 2:
NO REPAIR FOUND.
-Before further flight.CONDITION 2.1 (ACTION 1):CONDITION 2.1:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK FOUND.
7,000 flight cycles.-CONDITION 2.1 (ACTION 2):
Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) 7,000 flight cycles.-Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) CONDITION 2.2:
NO CRACK FOUND.
(a) It is not required to do the open hole High Frequency Eddy Current (HFEC) inspection in accordance with Requirements Bulletin 757-53A0106 RB in the repair affected area if the repair meets all of the conditions that follow:
1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0106 RB.
2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0106 RB.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 8 of 32 REQUIREMENTS BULLETIN 757-53A0106
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Group 2:
Table 2: Inspection of Bear Strap, Skin, Doubler, and Upper Sill Chord at the Main Deck Cargo Door Hinge Attachment Holes Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,800 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0106 RB.
Within 27,500 flight cycles after the airplane is converted into a Special Freighter (SF).
Do a Maintenance Records Check (MRC) for any repair at the forward and aft hinge areas of the main deck cargo door cutout.
All Airplanes.
-Within 500 flight cycles or 6 months, whichever comes first, after the MRC has been performed.
CONDITION 3 (ACTION 1):
Contact The Boeing Company for alternative inspection and corrective action instructions.
CONDITION 3:
ANY REPAIR FOUND.
-At times provided in CONDI- TION 3 (ACTION 1).
CONDITION 3 (ACTION 2):
Do the alternative inspections and applicable corrective actions.
-Within 3,300 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0106 RB.
Within 28,000 flight cycles after the airplane is converted into a Special Freighter (SF).
CONDITION 3 (ACTION 3):
Do an open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) -Before further flight.CONDITION 3.1 (ACTION 1):CONDITION 3.1:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK FOUND.
7,000 flight cycles.-CONDITION 3.1 (ACTION 2):
Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 9 of 32 REQUIREMENTS BULLETIN 757-53A0106
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Group 2:
Table 2: Inspection of Bear Strap, Skin, Doubler, and Upper Sill Chord at the Main Deck Cargo Door Hinge Attachment Holes Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 7,000 flight cycles.-Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) CONDITION 3.2:
NO CRACK FOUND.
-Within 3,300 flight cycles after the Original Issue date of Requirements Bulletin 757- 53A0106 RB.
Within 28,000 flight cycles after the airplane is converted into a Special Freighter (SF).
Do an open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack.
CONDITION 4:
NO REPAIR FOUND.
-Before further flight.CONDITION 4.1 (ACTION 1):CONDITION 4.1:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK FOUND.
7,000 flight cycles.-CONDITION 4.1 (ACTION 2):
Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) 7,000 flight cycles.-Repeat the open hole High Frequency Eddy Current (HFEC) inspection of the bear strap, skin, doubler and upper sill chord at the main deck cargo door hinge attachment holes for any crack in the unrepaired areas. (a) CONDITION 4.2:
NO CRACK FOUND.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 10 of 32 REQUIREMENTS BULLETIN 757-53A0106
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Group 2:
Table 2: Inspection of Bear Strap, Skin, Doubler, and Upper Sill Chord at the Main Deck Cargo Door Hinge Attachment Holes Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition
(a) It is not required to do the open hole High Frequency Eddy Current (HFEC) inspection in accordance with Requirements Bulletin 757-53A0106 RB in the repair affected area if the repair meets all of the conditions that follow:
1. The repair inspection plan was approved after the Original Issue date of Requirements Bulletin 757-53A0106 RB.
2. The repair plan is approved by the Boeing Organization Designation Authorization (ODA) via a FAA Form 8100-9.
3. The FAA Form 8100-9 approval defines the repair affected area, states the inspection plan for the repair affected area, and approves the inspection plan as an alternative inspection method to the inspections recommended in Requirements Bulletin 757-53A0106 RB.
4. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document comply with the applicable regulations and are FAA approved, as well as European Union Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in this Requirements Bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 11 of 32 REQUIREMENTS BULLETIN 757-53A0106
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 03, 2023 757-53A0106 RB 12 of 32 REQUIREMENTS BULLETIN 757-53A0106