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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-27A0152 Original Issue: April 29, 2009 Revision 1: June 30, 2010 ATA System: 2760 SUBJECT: FLIGHT CONTROLS - Spoiler, Drag Devices and Variable Aerodynamic Fairings - New Spoiler Control Module Relay Installation 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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Original Issue: April 29, 2009 757-27A0152Revision 1: June 30, 2010 2 of 156 BOEING SERVICE BULLETIN 757-27A0152
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Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 8 B. Concurrent Requirements ...................................... 1 8 C. Reason ................................................ 1 8 D. Description .............................................. 1 9 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 3 I. Electrical Load Data ......................................... 2 3 J. References .............................................. 2 4
1. Existing Data: ......................................... 2 4
2. Data supplied with this Service Bulletin: ........................... 2 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 4 K. Publications Affected ........................................ 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 5
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 8 C. Parts Necessary For Each Airplane ................................. 2 8
1. Kits/Parts: ........................................... 2 8
2. Parts and Materials Supplied by the Operator: ........................ 3 6
3. Parts Modified and Reidentified: ............................... 3 6
4. Parts Removed and Not Replaced: .............................. 3 7 D. Parts Necessary to Change Spares ................................. 3 7 E. Special Tooling - Price and Availability ............................... 3 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 0 FIGURE 1: E3-1 ELECTRONICS SHELF - REMOVAL [Group 1-5, Configuration 1] .......... 5 7 FIGURE 2: E3-1 ELECTRONICS SHELF - RELAY BRACKET INSTALLATION [Group 1-5, Configuration 1 ] ................................................ 6 0 FIGURE 3: SPOILER CONTROL MODULE - WIRE PIN STRAPPING REMOVAL [Group 1-5, Configuration 1 ] ................................................ 6 7 FIGURE 4: W1265 WIRE BUNDLE ROUTING [Group 1-2, 5, Configuration 1] ............. 6 9 FIGURE 5: W1265 WIRE BUNDLE CHANGES [Group 1, Configuration 1] ............... 7 0 FIGURE 6: W1265 WIRE BUNDLE CHANGES [Group 2, Configuration 1] ............... 7 7 FIGURE 7: W1265 WIRE BUNDLE CHANGES [Group 5, Configuration 1] ............... 8 4 FIGURE 8: W1265 WIRE BUNDLE ROUTING [Group 3, Configuration 1] ................ 9 1 FIGURE 9: W1265 WIRE BUNDLE CHANGES [Group 3, Configuration 1] ............... 9 2
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FIGURE 10: W1265 WIRE BUNDLE ROUTING [Group 4, Configuration 1] ................ 9 9 FIGURE 11: W1265 WIRE BUNDLE CHANGES [Group 4, Configuration 1] .............. 1 0 0 FIGURE 12: E3-1 ELECTRONICS SHELF - RELAY BRACKET EQUIPPING [Group 1-5, Configuration 1] ................................................. 1 0 7 FIGURE 13: E3-1 ELECTRONICS SHELF - INSTALLATION [Group 1-5, Configuration 1] ....... 1 1 1 FIGURE 14: W4471 WIRE BUNDLE ROUTING [Group 1-2, 5, Configuration 1] ............ 1 1 5 FIGURE 15: W4471 WIRE BUNDLE CHANGES [Group 1, Configuration 1] .............. 1 2 1 FIGURE 16: W4471 WIRE BUNDLE CHANGES [Group 2, Configuration 1] .............. 1 2 3 FIGURE 17: W4471 WIRE BUNDLE CHANGES [Group 5, Configuration 1] .............. 1 2 5 FIGURE 18: W4471 WIRE BUNDLE ROUTING [Group 3, Configuration 1] ............... 1 2 7 FIGURE 19: W4471 WIRE BUNDLE CHANGES [Group 3, Configuration 1] .............. 1 3 3 FIGURE 20: W4471 WIRE BUNDLE ROUTING [Group 4, Configuration 1] ............... 1 3 5 FIGURE 21: W4471 WIRE BUNDLE CHANGES [Group 4, Configuration 1] .............. 1 4 1 FIGURE 22: E3-1 ELECTRONICS SHELF - REMOVAL [Group 1-5, Configuration 2] ......... 1 4 3 FIGURE 23: E3-1 ELECTRONICS SHELF - RELAY BRACKET ASSEMBLY - TORQUE NUTS [Group 1-5, Configuration 2] ........................................ 1 4 6 FIGURE 24: E3-1 ELECTRONICS SHELF - RELAY BRACKET GROUND STUD - TORQUE NUTS AND BOND RESISTANCE TESTS [Group 1-5, Configuration 2] ................. 1 4 9 FIGURE 25: E3-1 ELECTRONICS SHELF - INSTALLATION [Group 1-5, Configuration 2] ....... 1 5 3
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Original Issue: April 29, 2009 757-27A0152Revision 1: June 30, 2010 4 of 156 BOEING SERVICE BULLETIN 757-27A0152
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Commercial Airplanes 757 Service Bulletin ALERT Revision Transmittal SheetNumber: 757-27A0152Original Issue: April 29, 2009 Revision 1: June 30, 2010 ATA System: 2760 SUBJECT: FLIGHT CONTROLS - Spoiler, Drag Devices and Variable Aerodynamic Fairings - New Spoiler Control Module Relay Installation This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue of this service bulletin. The Work Instructions to do bond resistance tests between the bracket assemblies and the terminal lugs on the ground studs were not included in the original issue of this service bulletin. Also, the Work Instructions to torque the bracket assembly installation nuts, and the bracket assembly ground stud nuts were not included in the original issue of this service bulletin.
REASON FOR REVISION As a part of a service bulletin validation program, this change was completed on airplane ND310 by Service Bulletin 757-27A0152 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane ND310 by Service Bulletin 757-27A0152 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane ND310 has the configuration of a Group 2 airplane.
This revision is sent to correct discrepancies found during the validation of the original issue of this service bulletin.
These sections were changed:
1. In Summary, Background and Paragraph 1.C., Reason, added service bulletin validation data.
2. In Summary, Action and Paragraph 1.D., Description, added a paragraph that specifies the more work necessary.
3. In Paragraph 1.G., Manpower:
a. Changed manpower data for Group 1 thru 5, Configuration 1 airplanes.
b. Added manpower table for Group 1 thru 5, Configuration 2 airplanes.
4. In Paragraph 1.H., Weight and Balance Changes, changed weight data.
5. In Paragraph 1.J.1., Existing Data:
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Original Issue: April 29, 2009 757-27A0152Revision 1: June 30, 2010 5 of 156
a. Added Standard Wiring Practices Manual (SWPM) 20-20-10.
b. Added 757 Aircraft Maintenance Manual (AMM) 20-11-00.
6. In Paragraph 2.A., Material - Price and Availability, changed top kit pricing data.
7. In Paragraph 2.C.1., Kits/Parts:
a. Added wire kit 280N3368-109 and wire list 280N3368-109W data.
b. Added note (b).
8. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator:
a. Added Teflon sleeve.
b. Added note (c).
9. In Paragraph 3.B., Work Instructions:
a. Added step to do a continuity check.
b. Operational test of the Spoiler/Speedbrake Control System, step 1.b., changed circuit breaker data.
c. Operational test of the Spoiler/Speedbrake Control System, steps 2.g., changed text to "15-unit detent".
d. Operational test of the Spoiler/Speedbrake Control System, steps 2.o.(1).(a)., changed text to "respond to control wheel commands".
e. Added new Work Instructions for airplanes changed in accordance with the original issue of this service bulletin.
10. In Figures 1 and 13, changed sheet 1.
11. In Figure 2, changed sheets 1 thru 5 and step table.
12. In Figures 5 thru 7, 9 and 11:
a. Sheets 1 and 2, added flag note 19.
b. Sheet 6, wire cut and code table, added note (a).
c. Sheet 7, added wire kit 280N3368-109W cut and code table.
d. Flag note table, flag note 1, added wire list 280N3368-109W.
e. Flag note table, flag note 7, changed terminal lug part number.
f. Flag note table, added flag note 19.
13. In Figure 12:
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a. Changed sheets 1 thru 3.
b. Step table, step 3, added note to torque the nuts.
c. Step table, added step 4.
14. In Figure 13, step table:
a. Step 8, changed the 'more data' note.
b. Removed note (d).
15. Added new Figures 22 thru 25 to torque the nuts and do bond resistance tests in the E3-1 electronics shelf.
The terminology used to refer to procedures in other Boeing documents is changed to agree with the revised Paragraph 3.A., General Information note 8, where necessary. These changes are identified with revision bars, but are not listed in the summary of changes for this revision.
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 April 29, 2009Original Issue:
June 30, 2010Revision 1:
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Original Issue: April 29, 2009 757-27A0152Revision 1: June 30, 2010 8 of 156 BOEING SERVICE BULLETIN 757-27A0152
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-27A0152Original Issue: April 29, 2009 Revision 1: June 30, 2010 ATA System: 2760 SUBJECT: FLIGHT CONTROLS - Spoiler, Drag Devices and Variable Aerodynamic Fairings - New Spoiler Control Module Relay Installation
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 instructions to install new relays adjacent to two of the Spoiler Control Modules (SCM's). The new relays will ground a pin at each of the SCM's, M530 spoiler control module 1L and M531 spoiler control module 2L, when landing flaps are selected and prevent deployment of spoiler pairs 1 and 12, and, 5 and 8, during landing operations. If this service bulletin is not done, under certain gusty and windy conditions during landing, the airplane could potentially be put in an unsafe condition because of excessive lateral control.
Boeing has received twelve reports of 757 in-service events where the flight crew reported unwanted lateral oscillations during the final approach just before landing. The oscillations are characterized by large wheel inputs at high rates that are out of phase with airplane response. Pilot inputs being out of phase with airplane response is known as pilot induced oscillation (PIO). PIO's are often related to tasks where the pilot is trying to precisely and quickly accomplish a flight maneuver, such as the final phase of a landing in gusty and turbulent wind conditions. To help reduce PIO's Boeing issued Service Bulletin 757-27A0146 (757-200's) and Service Bulletin 757-27A0147 (757-300's) which install a wheel damper to the first officer's lateral control quadrant, and Service Bulletin 757-57A0058 (757-200's) which installs vortex generators on the leading edge of each outboard main flap. This service bulletin adds another level of protection to further reduce the chance of PIO's on the 757 airplanes.
The two spoiler pairs 1 and 12, and, 5 and 8, will be disabled from responding to control wheel commands when the flaps are in the landing configuration by the use of relays to ground pins at each affected SCM. The speedbrake operation will be unaffected in-air and during on-ground operation. The airplane will be protected for the most important hydraulic system failures by re-engaging the spoiler pairs 1 and 12 if the right hydraulic system fails.
Accomplishment of the service bulletin will reduce the lateral control capability at landing flap (detent 25 and detent 30) by disabling spoiler pairs 1 and 12, and, 5 and 8, during landing operations. Disablement of these spoiler pairs will reduce the chance of a PIO occurrence.
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Original Issue: April 29, 2009 757-27A0152Revision 1: June 30, 2010 9 of 156
Boeing Service Related Problem (SRP) 757-SRP-27-0182 is related to this service bulletin.
As a part of a service bulletin validation program, this change was completed on airplane ND310 by Service Bulletin 757-27A0152 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane ND310 by Service Bulletin 757-27A0152 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane ND310 has the configuration of a Group 2 airplane.
ACTION (PRR 54530-278RS) Group 1-5, Configuration 1:
Get access to the Electronic Equipment Bay (E/E Bay) and remove the E3-1 electronics shelf from the airplane.
Make changes to the E3-1 electronics shelf to install three new bracket assemblies, three new relays, and to make changes to wire bundle W1265. Install the E3-1 electronics shelf to the airplane and make changes to wire bundle W4471 between the E3-1 electronics shelf and the E5-1 electronics shelf. Do a test of the Spoiler/Speedbrake Control System.
Group 1-5, Configuration 2:
More work is necessary. Get access to the Electronic Equipment Bay (E/E Bay) and remove the E3-1 electronics shelf from the airplane. Torque the bracket assembly installation nuts, and the bracket assembly ground stud nuts. Do bond resistance tests between the bracket assemblies and the terminal lugs on the ground studs. Install the E3-1 electronics shelf to the airplane.
EFFECTIVITY All 757-200, -200CB, -200PF, -300 Airplanes. Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Boeing recommends that the change given in this service bulletin be done within 60 months after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Service Bulletin Manpower Paragraph 1.G., Manpower.
MATERIAL INFORMATION Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: April 29, 2009 757-27A0152Revision 1: June 30, 2010 10 of 156 BOEING SERVICE BULLETIN 757-27A0152
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BOEING SERVICE BULLETIN 757-27A0152
ALERT ALERT E5-1 ELECTRONICS SHELF:
- CHANGE WIRE BUNDLE W4471 E3-1 ELECTRONICS SHELF:
-REMOVE ELECTRONICS SHELF -CHANGE WIRE BUNDLES W1265 AND W4471 K10877 -INSTALL CHANGED
ELECTRONICS SHELF K10878 K10876 M522 M530 W1265
INSTALL NEW BRACKETS AND
RELAYS, AND MAKE CHANGES E3-1 ELECTRONICS SHELF TO WIRE BUNDLE W1265 1441661 (TYPICAL) Original Issue: April 29, 2009 Revision 1: June 30, 2010 757-27A0152
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 156
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