Boeing Alert Requirements Bulletin 757-53A0120 RB: No revision named, part 1 of 2, text

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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0120 RB Original Issue: January 17, 2022 ATA System: 5360 SUBJECT: FUSELAGE - Section 46 - Fuselage Frame Web at STA 1640 between S-14 and S-15

- Liner Hole 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:

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 17, 2022 757-53A0120 RB 1 of 204

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Original Issue: January 17, 2022 757-53A0120 RB 2 of 204 REQUIREMENTS BULLETIN 757-53A0120

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Table of Contents

1. EFFECTIVITY5

A. Airplanes5

B. Spares Affected7

2. CONCURRENT REQUIREMENTS7

3. COMPLIANCE8

4. APPROVAL70

5. ACCOMPLISHMENT INSTRUCTIONS71

A. General Information71

B. Work Instructions72

FIGURE 1: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - GENERAL

VISUAL INSPECTION [Group 1-2]145

FIGURE 2: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - SURFACE

HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1-2]148

FIGURE 3: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - OPEN

HOLE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1-2]151

FIGURE 4: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - ZERO-TIME

THE PLUGGED LINER HOLE [Group 1-2]154

FIGURE 5: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - ZERO-TIME

THE OPEN LINER HOLE [Group 1-2]158

FIGURE 6: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - FASTENER

INSTALLATION [Group 1-2]162

FIGURE 7: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - GENERAL

VISUAL INSPECTION [Group 1-2]166

FIGURE 8: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - SURFACE

HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1-2]169

FIGURE 9: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - OPEN

HOLE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION [Group 1-2]172

FIGURE 10: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - ZERO-TIME

THE PLUGGED LINER HOLE [Group 1-2]175

FIGURE 11: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - ZERO-TIME

THE OPEN LINER HOLE [Group 1-2]179

FIGURE 12: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - FASTENER

INSTALLATION [Group 1-2]183

FIGURE 13: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - GENERAL

VISUAL INSPECTION [Group 3]187

FIGURE 14: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - SURFACE

HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION AROUND A PLUGGED LINER

HOLE [Group 3]190

FIGURE 15: LEFT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - SURFACE

HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION AROUND AN OPEN LINER HOLE

[Group 3]193

FIGURE 16: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - GENERAL

VISUAL INSPECTION [Group 3]196

FIGURE 17: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - SURFACE

HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION AROUND A PLUGGED LINER

HOLE [Group 3]199

Original Issue: January 17, 2022 757-53A0120 RB 3 of 204 REQUIREMENTS BULLETIN 757-53A0120

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FIGURE 18: RIGHT SIDE - FUSELAGE FRAME WEB AT STA 1640 BETWEEN S-14 AND S-15 - SURFACE

HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION AROUND AN OPEN LINER HOLE

[Group 3]202

Original Issue: January 17, 2022 757-53A0120 RB 4 of 204 REQUIREMENTS BULLETIN 757-53A0120

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- Liner Hole 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, 757-300 Airplane(s), line number(s) 1-138, 140, 142, 144-146, 148, 150-175, 177-180, 182-183, 185, 187-188, 190, 192, 194, 196, 198, 200-236, 238-257, 259-299, 301-313, 315-317, 319-321, 323-325, 327-329, 331-333, 335-339, 341-394, 396-398, 400-402, 404-406, 408-410, 412-476, 478-480, 482-484, 486-488, 490-492, 494-568, 570-572, 574-576, 578, 580, 582-624, 626-627, 629-630, 632-633, 635, 637, 639, 641, 643, 645, 647-648, 650, 652-653, 655, 657-658, 660-674, 676-678, 680-682, 684-686, 688-690, 692-727, 731-732, 735-754, 756-758, 760-762, 764, 766, 768, 770, 772-773, 775, 777, 779-812, 814, 816-822, 824-878, 880-881, 883-1050 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 757-200 and -200CB Airplanes.-1 Airplanes that have not incorporated the SB 757-53-0110 modification at or before the accomplishment of the first Requirements Bulletin 757-53A0120 RB inspection.

1 Airplanes that have incorporated the SB 757-53-0110 modification at or before the accomplishment of the first Requirements Bulletin 757-53A0120 RB inspection.

Original Issue: January 17, 2022 757-53A0120 RB 5 of 204

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DESCRIPTIONCONFIGURATIONGROUP 757-300 Airplanes.-2 Airplanes that have not incorporated the SB 757-53-0110 modification at or before the accomplishment of the first Requirements Bulletin 757-53A0120 RB inspection.

1 Airplanes that have incorporated the SB 757-53-0110 modification at or before the accomplishment of the first Requirements Bulletin 757-53A0120 RB inspection.

2 757-200 airplanes changed to the Special Freighter (SF) configuration by the Boeing Company in accordance with Supplemental Type Certificate (STC) ST00916WI-D.

-3 Airplanes that have not incorporated the SB 757-53-0110 modification at or before the accomplishment of the first Requirements Bulletin 757-53A0120 RB inspection.

1 Airplanes that have incorporated the SB 757-53-0110 modification at or before the accomplishment of the first Requirements Bulletin 757-53A0120 RB inspection.

2 Airplane Models:

757-200, 757-200CB, 757-300 GroupVariable Number 1NA001 - NA028 1NA191 - NA199 3NA201 - NA204 1NA205 3NA206 - NA213 1NA214 3NA215 - NA236 1NA237 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 1NA401 - NA408 1NA441 - NA447 GroupVariable Number 1NA501 - NA586 1NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 1NB221 - NB228 1NB230 GroupVariable Number 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 1NB571 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.

Original Issue: January 17, 2022 757-53A0120 RB 6 of 204 REQUIREMENTS BULLETIN 757-53A0120

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GroupVariable Number 1NB581 - NB583 1NC001 - NC033 1NC041 - NC042 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 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 GroupVariable Number 1NE141 - NE150 1NE161 - NE177 1NE201 - NE204 1NE301 - NE302 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 2NL001 - NL002 2NL006 - NL017 2NL101 - NL109 2NL141 2NL601 - NL616 1NN001 - NN002 1NN051 - NN052 1NP901 - NP904 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 1NT281 - NT289 1NT341 - NT347 GroupVariable Number 1NT351 - NT360 1NT371 - NT373 1NT375 - NT379 1NT381 - NT386 1NT401 - NT409 1NT411 - NT412 1NT426 - NT427 1NT431 - NT432 1NT436 - NT438 1NT441 - NT442 1NT446 1NT701 - NT769 1NT791 - NT796 1NT861 - NT862 1NT881 - NT885 1NT901 - NT916 1NT971 - NT985 1NU031 - NU038 2NU701 - NU705 2NU721 - NU728 2NU731 - NU732 -- -- B. Spares Affected Examine your spares supply for the parts or components identified below. If any parts or components are found, refer to Work Instructions for the recommended action.

Part Number 653N0001-1 653N0001-2

2. CONCURRENT REQUIREMENTS None.

Original Issue: January 17, 2022 757-53A0120 RB 7 of 204 REQUIREMENTS BULLETIN 757-53A0120

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3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 757-53A0120 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0120 RB mandatory.

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.

Accomplish the required action(s), based on the applicable condition(s) in Table 1 through Table 18, in accordance with Accomplishment Instructions.

Group 1, Configuration 1:

Table 1: STA 1640 Frame Web between S-14L and S-15L - General Visual Inspection and High Frequency Eddy Current (HFEC) Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,000 Flight Cycles after the original issue date of Requirements Bulletin 757- 53A0120 RB, or within 6,000 Flight Cycles after the last Service Bulletin 757-53A0108 Revision 1 eddy current inspections were done, whichever occurs later.

Before 20,000 Total Flight Cycles.

OPTION 1:

Do a General Visual Inspection of the STA 1640 Frame Web between S-14L and S-15L for an existing liner hole.

All Airplanes.

OPTION 2:

Do a Maintenance Records check of the STA 1640 Frame Web between S-14L and S- 15L for an existing liner hole.

--No further action required.CONDITION 1: NO LINER HOLE FOUND.

--No further action required.CONDITION 2: LINER

HOLE FOUND - LINER

HOLE WAS ZERO-

TIMED AND PLUGGED WITH A FASTENER.

Original Issue: January 17, 2022 757-53A0120 RB 8 of 204 REQUIREMENTS BULLETIN 757-53A0120

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Group 1, Configuration 1:

HOLE FOUND - LINER

HOLE WAS PLUGGED

WITH A FASTENER

DURING PRODUC- TION. (a) -Within 2,000 Flight Cycles after the original issue date of Requirements Bulletin 757- 53A0120 RB, or within 6,000 Flight Cycles after the last Service Bulletin 757-53A0108 Revision 1 eddy current inspections were done, whichever occurs later.

Before 20,000 Total Flight Cycles.

CONDITION 4 (OPTION 1):

Do a Surface High Frequency Eddy Current (HFEC) inspection of the web around the fastener (plug) for any crack.

CONDITION 4: LINER

HOLE FOUND - LINER

HOLE WAS PLUGGED

WITH A FASTENER

AND THE LINER HOLE

WAS NOT ZERO-

TIMED BEFORE BE-

ING PLUGGED OR

LINER HOLE WAS

PLUGGED WITH A

FASTENER AND THE

ZERO-TIME HISTORY IS UNKNOWN.

-CONDITION 4 (OPTION 2):

Zero-time the liner hole.

-Before further flight.Contact The Boeing Company for repair instructions and do the repair.

CONDITION 4.1: ANY

CRACK FOUND DUR-

ING SURFACE HFEC INSPECTION.

6,000 Flight Cycles.

-CONDITION 4.2 (OPTION 1):

Repeat the Surface HFEC inspection of the web around the fastener (plug) for any crack.

(b) CONDITION 4.2: NO

CRACK FOUND DUR-

ING SURFACE HFEC INSPECTION.

-Before further flight.CONDITION 4.2 (OPTION 2):

Zero-time the liner hole.

Original Issue: January 17, 2022 757-53A0120 RB 9 of 204 REQUIREMENTS BULLETIN 757-53A0120

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Group 1, Configuration 1:

CONDITION 4.3: NO

CRACK FOUND DUR-

ING CURRENT SUR-

FACE HFEC INSPEC-

TION AND HAVE IN-

CORPORATED SER- VICE BULLETIN 757- 53-0110 MODIFICA-

TION SINCE THE PRI- OR INSPECTION.

-At the times specified in Table 5.Do the actions specified in Table 5.

CONDITION 4.4: NO

CRACK FOUND DUR-

ING CURRENT SUR-

FACE HFEC INSPEC-

TION AND HAVE IN-

CORPORATED SER- VICE BULLETIN 757- 53-0110 AT THE SAME

TIME AS THE CUR- RENT INSPECTION.

(c)Before further flight.Install a fastener (plug) at the zero-time liner hole location.

(a) CONDITION 4.5: DUR-

ING ACCOMPLISH-

MENT OF CONDITION 4 (OPTION 2) OR CONDITION 4.2 (OP- TION 2), ANY CRACK

FOUND DURING ZE-

RO-TIME OF LINER

HOLE AND THE

CRACK IS REMOVED

WITHIN REPAIR LIM-

ITS OR NO CRACK

FOUND DURING ZE-

Original Issue: January 17, 2022 757-53A0120 RB 10 of 204 REQUIREMENTS BULLETIN 757-53A0120

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Group 1, Configuration 1:

Table 1: STA 1640 Frame Web between S-14L and S-15L - General Visual Inspection and High Frequency Eddy Current (HFEC) Inspection Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Contact The Boeing Company for repair instructions and do the repair.

CONDITION 4.6: DUR-

ING ACCOMPLISH-

MENT OF CONDITION 4 (OPTION 2) OR CONDITION 4.2 (OP- TION 2), ANY CRACK

FOUND DURING ZE-

RO-TIME OF LINER

HOLE AND THE

CRACK CANNOT BE

REMOVED WITHIN REPAIR LIMITS. (d) -Within 2,000 Flight Cycles after the original issue date of Requirements Bulletin 757- 53A0120 RB, or within 6,000 Flight Cycles after the last Service Bulletin 757-53A0108 Revision 1 eddy current inspections were done, whichever occurs later.

Before 20,000 Total Flight Cycles.

CONDITION 5 (OPTION 1):

Do an Open Hole HFEC inspection of the web for any crack.

CONDITION 5: LINER

HOLE FOUND - LINER

HOLE IS OPEN OR A

PLASTIC INSULATION STUD IS INSTALLED. -CONDITION 5 (OPTION 2):

Zero-time the liner hole.

-Before further flightZero-time the liner hole.CONDITION 5.1: ANY

CRACK FOUND DUR-

ING OPEN HOLE HFEC INSPECTION.

6,000 Flight Cycles.

-CONDITION 5.2 (OPTION 1):

Repeat the Open Hole HFEC inspection of the web for any crack. (b) CONDITION 5.2: NO

CRACK FOUND DUR-

ING OPEN HOLE HFEC INSPECTION.

-Before further flight.CONDITION 5.2 (OPTION 2):

Zero-time the liner hole.

Original Issue: January 17, 2022 757-53A0120 RB 11 of 204 REQUIREMENTS BULLETIN 757-53A0120

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Group 1, Configuration 1:

CONDITION 5.3: NO

CRACK FOUND DUR-

ING CURRENT OPEN

HOLE HFEC INSPEC-

TION AND HAVE IN-

CORPORATED SER- VICE BULLETIN 757- 53-0110 MODIFICA-

TION SINCE THE PRI- OR INSPECTION.

-At the times specified in Table 5.Do the actions specified in Table 5.

CONDITION 5.4: NO

CRACK FOUND DUR-

ING CURRENT OPEN

HOLE HFEC INSPEC-

TION AND HAVE IN-

CORPORATED SER- VICE BULLETIN 757- 53-0110 AT THE SAME

TIME AS THE CUR- RENT INSPECTION.

(c)Before further flight.Install a fastener (plug) at the zero-time liner hole location.

(a) CONDITION 5.5: DUR-

ING ACCOMPLISH-

MENT OF CONDITION 5 (OPTION 2), CONDI- TION 5.1, OR CONDI- TION 5.2 (OPTION 2),

ANY CRACK FOUND

BEFORE OR DURING

ZERO-TIME OF LINER

HOLE AND THE

CRACK IS REMOVED

WITHIN REPAIR LIM-

ITS OR NO CRACK

FOUND DURING ZE-

Original Issue: January 17, 2022 757-53A0120 RB 12 of 204 REQUIREMENTS BULLETIN 757-53A0120

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