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Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0121 RB Original Issue: September 28, 2022 ATA System: 5360 SUBJECT: FUSELAGE - Structural Inspections - STA 1640 Frame Web common to the Lower Hinge Intercostal Tee Clip - 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 © 2022 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Unpublished Work.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: September 28, 2022 757-53A0121 RB 1 of 56
3.0
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 2 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
BLANK PAGE
Table of Contents
1. EFFECTIVITY5
A. Airplanes5
B. Spares Affected7
2. CONCURRENT REQUIREMENTS7
3. COMPLIANCE7
4. APPROVAL23
5. ACCOMPLISHMENT INSTRUCTIONS25
A. General Information25
B. Work Instructions26
FIGURE 1: LEFT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP
ULTRASONIC INSPECTION43
FIGURE 2: RIGHT SIDE - STA 1640 FRAME WEB AT THE LOWER HINGE INTERCOSTAL TEE CLIP
ULTRASONIC INSPECTION47
APPENDIX I: LEFT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP
MAINTENANCE RECORDS CHECK51
APPENDIX J: RIGHT SIDE - STA 1640 FRAME AT THE LOWER HINGE INTERCOSTAL TEE CLIP
MAINTENANCE RECORDS CHECK54
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 3 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 4 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
BLANK PAGE
Commercial Airplanes 757 Requirements Bulletin ALERT Number: 757-53A0121 RB Original Issue: September 28, 2022 ATA System: 5360 SUBJECT: FUSELAGE - Structural Inspections - STA 1640 Frame Web common to the Lower Hinge Intercostal Tee Clip - 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) 1-49, 51, 53, 55-57, 59-62, 64-76, 79-80, 82-88, 91-92, 94-97, 99-122, 124-138, 140, 142, 144, 146, 148, 150-159, 161-165, 167, 169-174, 177-178, 180, 182-183, 185, 187-188, 190, 192, 194, 196, 198, 200-209, 212-213, 215-236, 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 4 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 the -200CB airplanes with production line numbers 45 and on that have a long inner chord strap at the Body Station (STA) 1640 fuselage frame.
-1 757-300 airplanes.-2 757-200 airplanes within production line numbers 1-44 that have a short inner chord strap at the STA 1640 fuselage frame.
-3 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 5 of 56
DESCRIPTIONCONFIGURATIONGROUP 757-200 Boeing special freighter airplanes (STC ST00916WI-D) within production line numbers 1-44 that have a short inner chord strap at the STA 1640 fuselage frame.
-4 Airplane Models:
757-200, 757-200CB, 757-300 GroupVariable Number 3NA001 - NA021 1NA022 - NA028 3NA191 1NA192 - NA199 4NA201 - NA204 3NA205 4NA206 - NA213 3NA214 1NA237 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 3NA401 - NA403 1NA404 - NA408 1NA441 - NA447 3NA501 - NA504 1NA505 - NA586 3NB001 1NB002 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 GroupVariable Number 1NB161 - NB162 1NB166 - NB168 1NB201 - NB204 1NB221 - NB228 1NB230 1NB236 1NB239 1NB261 - NB267 1NB291 - NB299 1NB301 - NB302 1NB311 - NB312 1NB321 - NB331 1NB421 - NB438 1NB446 1NB451 - NB454 1NB501 - NB523 1NB561 1NB571 1NB581 - NB583 1NC001 - NC033 1NC041 - NC042 1NC051 - NC052 1NC056 - NC062 1NC066 - NC084 1NC091 - NC094 GroupVariable Number 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 1NE141 - NE150 1NE161 - NE177 1NE201 - NE204 1NE301 - NE302 1NE311 - NE325 1NJ001 - NJ004 1NJ031 - NJ032 1NJ551 - NJ555 2NL001 - NL002 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 6 of 56 REQUIREMENTS BULLETIN 757-53A0121
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GroupVariable Number 2NL006 - NL017 2NL101 - NL109 2NL141 2NL601 - NL616 1NN001 - NN002 1NN051 - NN052 1NP901 - NP904 1NT201 - NT202 1NT231 - NT234 1NT237 - NT240 1NT242 1NT245 - NT248 GroupVariable Number 1NT281 - NT289 1NT341 - NT347 1NT351 - NT360 1NT371 - NT373 1NT375 - NT379 1NT381 - NT386 1NT401 - NT409 1NT411 - NT412 1NT426 - NT427 1NT431 - NT432 1NT436 - NT438 1NT441 - NT442 GroupVariable Number 1NT446 1NT701 - NT769 1NT791 - NT796 1NT861 - NT862 1NT881 - NT885 1NT901 - NT916 1NT971 - NT985 1NU031 - NU038 2NU701 - NU705 2NU721 - NU728 2NU731 - NU732 -- 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 757-53A0121 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 757-53A0121 RB mandatory.
Accomplish the required action(s), based on the applicable condition(s) in Tables 1 through 8, 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: September 28, 2022 757-53A0121 RB 7 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
Group 1:
Table 1: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip 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- 53A0121 RB.
Before 20,000 total flight cycles.
Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair.
All Airplanes.
-Within 2,000 flight cycles after the original issue date of Requirements Bulletin 757- 53A0121 RB.
Within 15,000 flight cycles after the frame segment replacement.
Do the Ultrasonic (UT) inspection of the frame web for any crack.
CONDITION 1:
THE EXISTING REPAIR
FOUND IS A FRAME
SEGMENT REPLACE-
MENT THAT IS BOEING
ODA APPROVED WITH AN FAA FORM 8100-9.
-Before further flight.CONDITION 1.1 (AC- TION 1):
CONDITION 1.1:
ANY CRACK FOUND.
Contact The Boeing Company for repair instructions and do the repair.
6,000 flight cycles.-CONDITION 1.1 (AC- TION 2):
Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) CONDITION 1.2:
NO CRACK FOUND.
-Within 2,000 flight cycles after the original issue date of Requirements Bulletin 757- 53A0121 RB.
Before 20,000 total flight cycles.
Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspections and applicable corrective actions.
CONDITION 2:
THE EXISTING REPAIR
FOUND IS NOT A FRAME
SEGMENT REPLACE-
MENT OR IS A FRAME
SEGMENT REPLACE-
MENT THAT IS NOT
BOEING ODA APPROVED
WITH AN FAA FORM 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 8 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
Group 1:
Table 1: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip 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- 53A0121 RB.
Before 20,000 total flight cycles.
Do the Ultrasonic (UT) inspection of the frame web for any crack.
CONDITION 3:
NO EXISTING REPAIR IS FOUND.
-Before further flight.CONDITION 3.1 (AC- TION 1):
CONDITION 3.1:
ANY CRACK FOUND.
Contact The Boeing Company for repair instructions and do the repair.
6,000 flight cycles-CONDITION 3.1 (AC- TION 2):
Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) CONDITION 3.2:
NO CRACK FOUND.
(a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 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 757-53A0121 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 757-53A0121 RB.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 9 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
Group 1:
Table 2: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip 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- 53A0121 RB.
Before 20,000 total flight cycles.
Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair.
All Airplanes.
-Within 2,000 flight cycles after the original issue date of Requirements Bulletin 757- 53A0121 RB.
Within 15,000 flight cycles after the frame segment replacement.
Do the Ultrasonic (UT) inspection of the frame web for any crack.
CONDITION 4:
THE EXISTING REPAIR
FOUND IS A FRAME
SEGMENT REPLACE-
MENT THAT IS BOEING
ODA APPROVED WITH AN FAA FORM 8100-9.
-Before further flight.CONDITION 4.1 (AC- TION 1):
CONDITION 4.1:
ANY CRACK FOUND.
Contact The Boeing Company for repair instructions and do the repair.
6,000 flight cycles.-CONDITION 4.1 (AC- TION 2):
Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) CONDITION 4.2:
NO CRACK FOUND.
-Within 2,000 flight cycles after the original issue date of Requirements Bulletin 757- 53A0121 RB.
Before 20,000 total flight cycles.
Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspections and applicable corrective actions.
CONDITION 5:
THE EXISTING REPAIR
FOUND IS NOT A FRAME
SEGMENT REPLACE-
MENT OR IS A FRAME
SEGMENT REPLACE-
MENT THAT IS NOT
BOEING ODA APPROVED
WITH AN FAA FORM 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 10 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
Group 1:
Table 2: Inspection of Right Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip 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- 53A0121 RB.
Before 20,000 total flight cycles.
Do the Ultrasonic (UT) inspection of the frame web for any crack.
CONDITION 6:
NO EXISTING REPAIR FOUND.
-Before further flight.CONDITION 6.1 (AC- TION 1):
CONDITION 6.1:
ANY CRACK FOUND.
Contact The Boeing Company for repair instructions and do the repair.
6,000 flight cycles.-CONDITION 6.1 (AC- TION 2):
Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) 6,000 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) CONDITION 6.2:
NO CRACK FOUND.
(a) It is not required to do the Ultrasonic (UT) inspection in accordance with Requirements Bulletin 757- 53A0121 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 757-53A0121 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 757-53A0121 RB.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 11 of 56 REQUIREMENTS BULLETIN 757-53A0121
ALERTALERT
Group 2:
Table 3: Inspection of Left Side STA 1640 Frame Web at the Lower Hinge Intercostal Tee Clip 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 757-53A0121 RB.
Do a Maintenance Records check of the STA 1640 frame between S-9 and S-20 for any existing repair.
All Airplanes.
-Within 2,000 flight cycles after the original issue date of Requirements Bulletin 757- 53A0121 RB.
Within 5,600 flight cycles after the frame segment replacement.
Do the Ultrasonic (UT) inspection of the frame web for any crack.
CONDITION 7:
THE EXISTING REPAIR
FOUND IS A FRAME
SEGMENT REPLACE-
MENT THAT IS BOEING
ODA APPROVED WITH AN FAA FORM 8100-9.
-Before further flight.CONDITION 7.1 (AC- TION 1):
CONDITION 7.1:
ANY CRACK FOUND.
Contact The Boeing Company for repair instructions and do the repair.
3,200 flight cycles.-CONDITION 7.1 (AC- TION 2):
Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) 3,200 flight cycles.-Repeat the Ultrasonic (UT) inspection of the frame web for any crack.
(a) CONDITION 7.2:
NO CRACK FOUND.
-Within 2,000 flight cycles after the original issue date of Requirements Bulletin 757-53A0121 RB.
Contact The Boeing Company for alternative inspection and corrective action instructions and do the alternative inspections and applicable corrective actions.
CONDITION 8:
THE EXISTING REPAIR
FOUND IS NOT A FRAME
SEGMENT REPLACE-
MENT OR IS A FRAME
SEGMENT REPLACE-
MENT THAT IS NOT
BOEING ODA APPROVED
WITH AN FAA FORM 8100-9.
-Within 2,000 flight cycles after the original issue date of Requirements Bulletin 757-53A0121 RB.
Do the Ultrasonic (UT) inspection of the frame web for any crack.
CONDITION 9:
NO EXISTING REPAIR FOUND.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 28, 2022 757-53A0121 RB 12 of 56 REQUIREMENTS BULLETIN 757-53A0121