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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-28A0073 Original Issue: November 20, 2003 Revision 2: June 04, 2009 ATA System: 2822 SUBJECT: FUEL - Fuel Shutoff Valve Wire Inspection and Reroute in Nacelles/Pylons, Engine to Wing Aft Fairings - Rolls Royce Powered Airplanes 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 1 of 69
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 2 of 69 BOEING SERVICE BULLETIN 757-28A0073
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 6 E. Compliance .............................................. 1 7 F . Approval ............................................... 1 7 G. Manpower .............................................. 1 7 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 1 8 J. References .............................................. 1 8
1. Existing Data: .......................................... 1 8
2. Data supplied with this Service Bulletin: ........................... 1 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 9 K. Publications Affected ......................................... 1 9 L. Interchangeability and Intermixability of Parts ........................... 1 9
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 1 C. Parts Necessary For Each Airplane ................................. 2 1
1. Kits/Parts: ............................................ 2 1
2. Parts and Materials Supplied by the Operator: ........................ 2 4
3. Parts Modified and Reidentified: ................................ 2 5
4. Parts Removed and Not Replaced: .............................. 2 5 D. Parts Necessary to Change Spares ................................. 2 5 E. Special Tooling - Price and Availability ............................... 2 5 F . Special Tooling Necessary to do this Service Bulletin ....................... 2 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 7 FIGURE 1: PREPARE FOR INSPECTION OF WIRE BUNDLE - GROUP 1 CONFIGURATION 1 AIRPLANES [Group 1, Configuration 1] ................................... 3 9 FIGURE 2: INSPECT WIRE BUNDLE AND ADD SUPPORT BRACKET - GROUP 1 CONFIGURATION 1 AIRPLANES [Group 1, Configuration 1] ............................ 4 1 FIGURE 3: LEFT HAND STRUT - REROUTE WIRE BUNDLE - GROUP 1 CONFIGURATION 1 AIRPLANES [Group 1, Configuration 1] ................................... 4 5 FIGURE 4: RIGHT HAND STRUT - REROUTE WIRE BUNDLE - GROUP 1 CONFIGURATION 1 AIRPLANES [Group 1, Configuration 1] ................................... 5 2 FIGURE 5: INSPECT WIRE BUNDLE AND ADD SUPPORT BRACKET - FOR GROUP 1 CONFIGURATION 1 AIRPLANES [Group 1, Configuration 1] ........................... 6 0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 3 of 69 BOEING SERVICE BULLETIN 757-28A0073
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FIGURE 6: RIGHT HAND STRUT - INSTALL BACK-TO-BACK CLAMPS AT THE AFT END OF THE STRUT - GROUP 1 CONFIGURATION 2, AND GROUP 2 AIRPLANES [Group 1, Configuration 2; Group 2 ] ................................................ 6 4 FIGURE 7: LEFT HAND STRUT - INSTALL THE TFE SPIRAL CABLE WRAP ON WIRE BUNDLE W5100 AT THE AFT END OF THE STRUT - GROUP 1 CONFIGURATION 2 AND 3, AND GROUP 2 AIRPLANES [Group 1, Configuration 2-3; Group 2] ..................... 6 6 FIGURE 8: RIGHT HAND STRUT - INSTALL SPIRAL CABLE WRAP ON WIRE BUNDLE W5200 AT THE AFT END OF THE STRUT - GROUP 1 CONFIGURATION 2 AND 3, AND GROUP 2 AIRPLANES [Group 1, Configuration 2-3; Group 2] ............................. 6 8
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 4 of 69 BOEING SERVICE BULLETIN 757-28A0073
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Commercial Airplanes 757 Service Bulletin ALERT Revision Transmittal SheetNumber: 757-28A0073Original Issue: November 20, 2003 Revision 2: June 04, 2009 ATA System: 2822 SUBJECT: FUEL - Fuel Shutoff Valve Wire Inspection and Reroute in Nacelles/Pylons, Engine to Wing Aft Fairings - Rolls Royce Powered Airplanes This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive 2005-18-18 dated October 14, 2005, is related to this service bulletin.
More work is necessary on airplanes changed as shown in the original issue of this service bulletin dated November 20, 2003 or Revision 1 of this service bulletin dated February 24, 2005.
REASON FOR REVISION This revision is sent to tell the operators that Boeing received messages from some operators regarding the interference between the Fuel Shutoff Valve wires and the adjacent fairing at the aft end of the right engine strut.
To prevent possible damage of the Fuel Shutoff Valve wires, Boeing decided to add additional protection to the Fuel Shutoff Valve wires that do not have a Teflon sleeve already installed during production. A new TFE (Tetrafluoroethylene) Spiral Cable Wrap is added to the Fuel Shutoff Valve wires at the aft end of the strut, for both, the left and right engine strut. The Spiral Cable Wrap will improve the Fuel Shutoff Valve wires protection.
NOTE: Some airplanes have a Teflon Sleeve installed on the Fuel Shutoff Valve wires during production. The Teflon Sleeve installed during production starts at the lower part of Nacelle STA 278 and ends in the wing area. It is not necessary to install the Spiral Cable Wrap at the locations given in the bulletin, if the Fuel Shutoff Valve wires already have a Teflon sleeve installed at those locations.
These sections were changed:
1. In Summary, Paragraph Action - Added new action requirement to protect the aft end of the Fuel Shutoff valve wires with a Spiral Cable Wrap, on both Left and Right Engine. Added clarification note.
2. In Summary - Added additional data to Summary, Paragraph Action, and to the Summary illustration.
3. In Planning Information, paragraph 1.A. Effectivity - Added Configuration 3 to Group 1 airplanes in the Group Configuration Table.
4. In Planning Information, paragraph 1.C. Reason - Added the list of all changes included in Revision 2 of this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 5 of 69
5. In Planning Information, paragraph 1.D. Description - Added new action requirement to protect the aft end of the Fuel Shutoff Valve wires with a Spiral Cable Wrap, on both, Left and Right Engine. Added a clarification note.
6. In Planning Information, paragraph 1.E., Compliance - Added data related to the Airworthiness Directive (AD).
7. In Planning Information, paragraph 1.F ., Approval - Changed the existing approval statement with the new approval statement and added data related to the Airworthiness Directive (AD).
8. In Planning Information, paragraph 1.G., Manpower - Added the manpower for the new figures and changed the manpower for some existing figures.
9. In Material Section, paragraph 2.C.2., Parts and Materials Supplied by Operators - Added the Spiral Cable Wrap.
10. In Material Section, paragraph 2.C4., Parts Removed and Not Replaced - Added to the table two screws and two washers that are removed and not replaced.
11. In Accomplishment Instructions, paragraph 3.B. Work Instructions, Part I - Changed format and added instructions to install the Spiral Cable Wrap on Fuel Shutoff Valve wires, at the aft end of the strut, for both, Left and Right Engine.
12. In Accomplishment Instructions, paragraph 3.B. Work Instructions - Added a new Part III that provides instructions to install the Spiral Cable Wrap on Fuel Shutoff Valve wires, at the aft end of the strut, for both, Left and Right Engine, for airplanes that already incorporated Revision 1 of the service bulletin.
13. In Accomplishment Instructions, paragraph 3.B. Work Instructions, Part V - Changed the word "Left" with "Right" in step instruction 1.i.
14. In Accomplishment Instructions, paragraph 3.B. Work Instructions, Figure 1- Added two notes.
15. In Accomplishment Instructions, paragraph 3.B. Work Instructions, Figure 3, Figure 4 - Added the Spiral Cable Wrap and did some minor graphical changes to figures.
16. In Accomplishment Instructions, paragraph 3.B. Work Instructions - Added Figure 7 and Figure 8, for airplanes that incorporated Revision 1 of the service bulletin that have to add the Spiral Cable Wrap on Fuel Shutoff Valve wires, at the aft end of the strut, for both, Left and Right Engine.
The data given in Information Notice 757-28A0073 IN 01 is included in 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 November 20, 2003Original Issue:
February 24, 2005Revision 1:
June 04, 2009Revision 2:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 6 of 69 BOEING SERVICE BULLETIN 757-28A0073
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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-28A0073Original Issue: November 20, 2003 Revision 2: June 04, 2009 ATA System: 2822 SUBJECT: FUEL - Fuel Shutoff Valve Wire Inspection and Reroute in Nacelles/Pylons, Engine to Wing Aft Fairings - Rolls Royce Powered Airplanes
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 The related 757-300 bulletin is 757-28A0074.
This service bulletin provides instructions to do an inspection of wires in the left and right engine to wing aft fairings, repair as necessary and reroute.
One operator reported tripping of the spar fuel shutoff valve circuit breaker due to a chafed wire shorted against structure in the aft fairing flammable leakage zone.The airplane had 10900 hours and 6225 cycles.The operator examined other airplanes in their fleet and found chafed wires in some of the airplanes. The cause of the chafe condition was missing or incorrectly installed wire sleeving, incorrect chafe grommet installation and incorrect wire bundle clamp installation.
Shorting and the creation of arcs and sparks in a flammable leakage zone could cause a fire in flight or on the ground.
Boeing Service Related Problem (SRP) 757-SRP-28-0090 is related to this service bulletin.
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Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 7 of 69
ACTION Inspect the Fuel Shutoff Valve wires from Power Plant Station (PP STA) 278, aft, to the rear spar of the wing in the left and right engine to wing aft fairings. Inspect the Fuel Shutoff Valve wires for chafe sleeves and wire damage at PP STA's 278, 290 and 301. Repair the Fuel Shutoff Valve wires found with damage as required. If no chafe sleeve is installed on the Fuel Shutoff Valve wires, add wrap-on sleeve. Inspect the PP STA 278 and PP STA 301 bulkheads to make sure the installation of the caterpillar grommet is correct. Add a new wire bundle support bracket at PP STA 301 bulkheads. Add also a TFE Spiral Cable Wrap on the Fuel Shutoff Valve wires at the aft end of the right and left strut, if no chafe sleeve was installed during production. Add back-to-back P-clamps between wire and hydraulic supply tube at the aft end of the right hand strut only. Re-route the wire bundles.
NOTE: Some airplanes have a Teflon Sleeve installed on the Fuel Shutoff Valve wires during production. The Teflon Sleeve installed during production starts at the lower part of Nacelle STA 278 and ends in the wing area. It is not necessary to install the Spiral Cable Wrap at the locations given in the bulletin, if the Fuel Shutoff Valve wires already have a Teflon sleeve installed at those locations.
EFFECTIVITY 757-200, 757-200CB and 757-200PF airplanes powered by Rolls Royce engines. Refer to service bulletin Paragraph 1.A.1 for effectivity.
COMPLIANCE Boeing recommends that operators inspect and make the change given in this service bulletin within 5 years from the date of this service bulletin revision.
Federal Aviation Administration (FAA) Airworthiness Directive 2005-18-18 dated October 14, 2005, is related to this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of November 8, 2002. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER The total Task Hours time and Elapsed Hours time depend of the airplane configuration and necessary rework figures. Please refer to Paragraph 1.G, Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 8 of 69 BOEING SERVICE BULLETIN 757-28A0073
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 9 of 69 BOEING SERVICE BULLETIN 757-28A0073
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 10 of 69 BOEING SERVICE BULLETIN 757-28A0073
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BLANK PAGE
Commercial Airplanes 757 Service Bulletin ALERT Number: 757-28A0073 Original Issue: November 20, 2003 Revision 2: June 04, 2009 ATA System: 2822 SUBJECT: FUEL - Fuel Shutoff Valve Wire Inspection and Reroute in Nacelles/Pylons, Engine to Wing Aft Fairings - Rolls Royce Powered Airplanes
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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP Airplanes with wire bundles which are not correctly installed and are in a location where damage to wires can occur.
-1 Airplanes that did not incorporate the intent of the initial release of this service bulletin.
1 Airplanes that have incorporated the intent of the initial release of this bulletin.
2 Airplanes that have incorporated the intent of revision 1 of this service bulletin.
3 Airplanes that incorporated the intent of the initial release of this service bulletin during production.
-2 Airplane Models:
757-200, 757-200CB, 757-200PF
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Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 11 of 69
GroupVariable Number 1NA001 - NA028 1NA191 - NA199 1NA201 - NA239 1NA301 - NA305 1NA341 - NA352 1NA391 - NA399 1NA401 - NA408 1NA441 - NA447 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 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
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Original Issue: November 20, 2003 757-28A0073Revision 2: June 04, 2009 12 of 69 BOEING SERVICE BULLETIN 757-28A0073