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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0118 RB Original Issue: October 22, 2021 ATA System: 5363 SUBJECT: FUSELAGE - SECTION 46 - Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web 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:
Copyright © 2021 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Unpublished Work.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: October 22, 2021 757-53A0118 RB 1 of 68
4.0
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 2 of 68 REQUIREMENTS BULLETIN 757-53A0118
ALERTALERT
BLANK PAGE
Table of Contents
1. EFFECTIVITY5
A. Airplanes5
B. Spares Affected7
2. CONCURRENT REQUIREMENTS7
3. COMPLIANCE7
4. APPROVAL25
5. ACCOMPLISHMENT INSTRUCTIONS27
A. General Information27
B. Work Instructions29
FIGURE 1: STA 1380 FRAME - BETWEEN S-22R TO THE LOWER SILL THRESHOLD - GENERAL VISUAL
INSPECTION49
FIGURE 3: STA 1380 FRAME INNER CHORD - HIGH FREQUENCY EDDY CURRENT (HFEC)
INSPECTION51
FIGURE 4: STA 1380 FRAME INNER CHORD - LOW FREQUENCY EDDY CURRENT (LFEC) INSPECTION
.57
FIGURE 5: STA 1380 FRAME WEB - HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION . 60
FIGURE 6: STA 1380 FRAME - GUIDE TRACK FITTING INSTALLATION63
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 3 of 68 REQUIREMENTS BULLETIN 757-53A0118
ALERTALERT
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 4 of 68 REQUIREMENTS BULLETIN 757-53A0118
ALERTALERT
BLANK PAGE
Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0118 RB Original Issue: October 22, 2021 ATA System: 5363 SUBJECT: FUSELAGE - SECTION 46 - Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web 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, 757-300 Airplane(s), line number(s) 1-1050 in 2 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 757-200 Airplanes, line number 1 to 57.-1 757-200/-200CB/-200PF/-300 Airplanes, line number 58 to 1050.-2 Airplane Models:
757-200, 757-200CB, 757-200PF, 757-300 GroupVariable Number 1NA001 - NA021 2NA022 - NA028 1NA191 - NA192 GroupVariable Number 2NA193 - NA199 1NA201 - NA217 2NA218 - NA239 GroupVariable Number 2NA301 - NA305 2NA341 - NA352 1NA391 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 5 of 68
GroupVariable Number 2NA392 - NA399 1NA401 - NA404 2NA405 - NA408 2NA441 - NA447 1NA501 - NA506 2NA507 - NA586 1NB001 - NB004 2NB021 - NB023 2NB036 - NB041 2NB051 - NB053 2NB061 - NB073 2NB079 2NB131 - NB148 2NB161 - NB162 2NB166 - NB168 2NB201 - NB204 2NB221 - NB228 2NB230 2NB236 2NB239 2NB261 - NB267 2NB291 - NB299 2NB301 - NB302 2NB311 - NB312 2NB321 - NB331 2NB421 - NB438 2NB446 2NB451 - NB454 2NB501 - NB523 2NB561 2NB571 2NB581 - NB583 1NC001 - NC002 GroupVariable Number 2NC003 - NC033 2NC041 - NC042 2NC051 - NC052 2NC056 - NC062 2NC066 - NC084 2NC091 - NC094 2NC151 2NC161 2NC901 - NC951 2NC971 - NC974 2ND001 - ND007 2ND011 - ND059 2ND111 - ND113 2ND161 - ND199 2ND201 - ND203 2ND221 - ND225 2ND241 - ND248 2ND301 - ND322 2ND401 2ND891 2ND895 2NE001 - NE008 2NE011 - NE088 2NE091 - NE094 2NE141 - NE150 2NE161 - NE177 2NE201 - NE204 2NE301 - NE302 2NE311 - NE325 2NJ001 - NJ004 2NJ031 - NJ032 2NJ551 - NJ555 2NL001 - NL002 GroupVariable Number 2NL006 - NL017 2NL101 - NL109 2NL141 2NL601 - NL616 2NN001 - NN002 2NN051 - NN052 2NP901 - NP904 2NS601 - NS616 2NT001 - NT009 2NT201 - NT202 2NT231 - NT234 2NT237 - NT240 2NT242 2NT245 - NT248 2NT281 - NT289 2NT341 - NT347 2NT351 - NT360 2NT371 - NT373 2NT375 - NT379 2NT381 - NT386 2NT401 - NT409 2NT411 - NT412 2NT426 - NT427 2NT431 - NT432 2NT436 - NT438 2NT441 - NT442 2NT446 2NT701 - NT769 2NT791 - NT796 2NT861 - NT862 2NT881 - NT885 2NT901 - NT916 2NT971 - NT985 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 6 of 68 REQUIREMENTS BULLETIN 757-53A0118
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GroupVariable Number 2NU031 - NU038 2NU701 - NU705 GroupVariable Number 2NU721 - NU728 2NU731 - NU732 GroupVariable Number -- -- B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2002-24-02 is related to Requirements Bulletin 757-53A0118 RB. The effective date of AD 2002-24-02 is January 7, 2003.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2017-24-10 is related to Requirements Bulletin 757-53A0118 RB. The effective date of AD 2017-24-10 is January 9, 2018.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2020-01-18 is related to Requirements Bulletin 757-53A0118 RB. The effective date of AD 2020-01-18 is March 5, 2020.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to Requirements Bulletin 757-53A0118 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0118 RB mandatory.
Group 1:
Accomplish the required action(s), based on the applicable condition(s) in Table 1, in accordance with Accomplishment Instructions.
Group 2:
Accomplish the required action(s), based on the applicable condition(s) in Table 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.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 7 of 68 REQUIREMENTS BULLETIN 757-53A0118
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Group 1:
Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 13,000 total flight cycles.
Do a General Visual Inspection or a maintenance records check of the STA 1380 frame for any repair.
All Airplanes -Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 20,000 total flight cycles or within 13,000 flight cycles after the repair was installed, whichever occurs first.
CONDITION 1 (ACTION 1):
Do a surface High Frequency Eddy Current (HFEC) inspection of the STA 1380 frame inner chord for any crack.
CONDITION 1:
ANY APPROVED
REPAIR FOUND
(a)(b) -Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 20,000 total flight cycles or within 13,000 flight cycles after the repair was installed, whichever occurs first.
CONDITION 1 (ACTION 2):
Do a sub-surface Low Frequency Eddy Current (LFEC) inspection of the STA 1380 frame inner chord for any crack.
-Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 20,000 total flight cycles or within 13,000 flight cycles after the repair was installed, whichever occurs first.
CONDITION 1 (ACTION 3):
Do a surface HFEC inspection of the STA 1380 frame web for any crack.
-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 IN THE STA 1380 FRAME
INNER CHORD AS
THE RESULT OF
THE INNER
CHORD HFEC IN-
SPECTION 3,000 flight cycles.-CONDITION 1.1 (ACTION 2):
Repeat the surface HFEC inspection of the STA 1380 frame inner chord for any crack. (c) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 8 of 68 REQUIREMENTS BULLETIN 757-53A0118
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Group 1:
Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 3,000 flight cycles.-Repeat the surface HFEC inspection of the STA 1380 frame inner chord for any crack. (c) CONDITION 1.2:
NO CRACK FOUND IN THE STA 1380
FRAME INNER
CHORD AS THE
RESULT OF THE
INNER CHORD
HFEC INSPECTION -Before further flight.CONDITION 1.3 (ACTION 1):CONDITION 1.3:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK
FOUND IN THE STA 1380 FRAME
INNER CHORD AS
THE RESULT OF
THE INNER
CHORD LFEC IN-
SPECTION 3,000 flight cycles.-CONDITION 1.3 (ACTION 2):
Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack.
(d) 3,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack.
(d) CONDITION 1.4:
NO CRACK FOUND IN THE STA 1380
FRAME INNER
CHORD AS THE
RESULT OF THE
INNER CHORD
LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 9 of 68 REQUIREMENTS BULLETIN 757-53A0118
ALERTALERT
Group 1:
Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.CONDITION 1.5 OPTION 1 (ACTION 1):
CONDITION 1.5:
ANY CRACK
FOUND IN THE STA 1380 FRAME
WEB AS THE RE-
SULT OF THE WEB
HFEC INSPECTION Do a STA 1380 frame web repair in accordance with the 757 Structural Repair Manual (SRM).
3,000 flight cycles.-CONDITION 1.5 OPTION 1 (ACTION 2):
Repeat the surface HFEC inspection of the STA 1380 frame web for any crack. (c)(e) -Before further flight.CONDITION 1.5 OPTION 2 (ACTION 1):
Contact The Boeing Company for alternative repair instructions and do the repair.
3,000 flight cycles.-CONDITION 1.5 OPTION 2 (ACTION 2):
Repeat the surface HFEC inspection of the STA 1380 frame web for any crack. (c)(e) 3,000 flight cycles.-Repeat the surface HFEC inspection of the STA 1380 frame web for any crack. (c)(e) CONDITION 1.6:
NO CRACK FOUND IN THE STA 1380
FRAME WEB AS
THE RESULT OF
THE WEB HFEC
INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 10 of 68 REQUIREMENTS BULLETIN 757-53A0118
ALERTALERT
Group 1:
Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 13,000 total flight cycles.
CONDITION 2 (ACTION 1):
Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspections and applicable corrective actions.
CONDITION 2:
ANY REPAIR
FOUND THAT
DOES NOT MEET
APPROVED RE-
PAIR CRITERIA -Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 20,000 total flight cycles.
CONDITION 2 (ACTION 2):
Do a surface HFEC inspection of the STA 1380 frame inner chord for any crack in the unrepaired areas.
-Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 20,000 total flight cycles.
CONDITION 2 (ACTION 3):
Do a sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack in the unrepaired areas.
-Within 3,000 flight cycles after the original issue date of the Requirements Bulletin 757-53A0118 RB.
Before 20,000 total flight cycles.
CONDITION 2 (ACTION 4):
Do a surface HFEC inspection of the STA 1380 frame web for any crack in the unrepaired areas.
-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 IN THE STA 1380 FRAME
INNER CHORD AS
THE RESULT OF
THE INNER
CHORD HFEC IN-
SPECTION 3,000 flight cycles.-CONDITION 2.1 (ACTION 2):
Repeat the surface HFEC inspection of the STA 1380 frame inner chord for any crack. (c) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 11 of 68 REQUIREMENTS BULLETIN 757-53A0118
ALERTALERT
Group 1:
Table 1: Number 2 Cargo Door Cutout STA 1380 Forward Edge Frame Inner Chord and Web Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition 3,000 flight cycles.-Repeat the surface HFEC inspection of the STA 1380 frame inner chord for any crack. (c) CONDITION 2.2:
NO CRACK FOUND IN THE STA 1380
FRAME INNER
CHORD AS THE
RESULT OF THE
INNER CHORD
HFEC INSPECTION -Before further flight.CONDITION 2.3 (ACTION 1):CONDITION 2.3:
Contact The Boeing Company for repair instructions and do the repair.
ANY CRACK
FOUND IN THE STA 1380 FRAME
INNER CHORD AS
THE RESULT OF
THE INNER
CHORD LFEC IN-
SPECTION 3,000 flight cycles.-CONDITION 2.3 (ACTION 2):
Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack.
(d) 3,000 flight cycles.-Repeat the sub-surface LFEC inspection of the STA 1380 frame inner chord for any crack.
(d) CONDITION 2.4:
NO CRACK FOUND IN THE STA 1380
FRAME INNER
CHORD AS THE
RESULT OF THE
INNER CHORD
LFEC INSPECTION Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 22, 2021 757-53A0118 RB 12 of 68 REQUIREMENTS BULLETIN 757-53A0118