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Commercial DEDEING Airplanes 757 Service Bulletin
- ALERT Number: 757-57A0064 Original Issue: July 16, 2007 Revision 1: October 05, 2009 ATA System: 5710 5720 SUBJECT: WINGS - Center and Outer Wing - Fastener Sealing and Wire Bundle Support Inspection and Modification 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 ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
Original Issue: July 16, 2007 Revision 1: October 05, 2009 BOEING PROPRIETARY - 757-57A0064 Copyright © Unpublished Work - See page 1 for details. 1 of 442
6.0
BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT
BLANK PAGE Original Issue: July 16, 2007 Revision 1: October 05, 2009 BOEING PROPRIETARY - 757-57A0064 Copyright © Unpublished Work - See page 1 for details. 2 of 442
BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT Table of Contents Revision Transmittal Sheet 7 Summary . 11
1. PLANNING INFORMATION 15 A. Effectivity 15
1. Airplanes 15
2. Spares Affected 21 B. Concurrent Requirements 21 C. Reason 21 D. Description 22 Compliance 23 F Approval 24 G. Manpower 25 H. Weight and Balance Changes. 35 Electrical Load Data 35 J. References . 35 Existing Data: 35 2 Data supplied with this Service Bulletin 35
3. Installation Drawings Used in the Preparation of this Service Bulletin: 35 K. Publications Affected 36 L Interchangeability and Intermixability of Parts 36
2. MATERIAL INFORMATION. 37 A. Material - Price and Availability. 37 B. Industry Support Information. 37 C. Parts Necessary For Each Airplane 37 Kits/Parts: 37
2. Parts and Materials Supplied by the Operator: 37
3. Parts Modified and Reidentified: 45
4. Parts Removed and Not Replaced: 46 D. Parts Necessary to Change Spares. 46 E. Special Tooling - Price and Availability 46 F. Special Tooling Necessary to do this Service Bulletin. 46
3. 47 GENERAL INFORMATION 47 WORK INSTRUCTIONS. 49 FIGURE 1: GROUPS 1-2 - LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 1-2] • 76 FIGURE 2: GROUPS 1-2 - RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 1-2] .
FIGURE 3: GROUPS 3-4 - LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 3-4] .
FIGURE 4: GROUPS 3-4 - RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 3-4] .
FIGURE 5: GROUPS 5-7 - LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 5-7] • FIGURE 6: GROUPS 5-7 - RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 5-7] FIGURE 7: GROUPS 8-10 - LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 8-10] .
FIGURE 8: GROUPS 8-10 - RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 8-10].
FIGURE 9: GROUPS 11-12 - LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 11-12] .
FIGURE 10: GROUPS 11-12 - RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 11-12] Original Issue: July 16, 2007 Revision 1: October 05, 2009 BOEING PROPRIETARY 757-57A0064 Copyright © Unpublished Work - See page 1 for details. 3 of 442
BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT FIGURE 11: GROUPS 13-14 - LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 13-14] . 212 FIGURE 12: GROUPS 13-14 - RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS [Group 13-14] FIGURE 13: GROUPS 1-5 - LEFT SIDE - FRONT SPAR - LOCATION OF FASTENERS [Group 1-5] . 240 FIGURE 14: GROUPS 1-5 - RIGHT SIDE - FRONT SPAR - LOCATION OF FASTENERS [Group 1-5] . 248 FIGURE 15: GROUPS 6-7, GROUPS 11-12 - LEFT SIDE - FRONT SPAR - LOCATION OF FASTENERS [Group 6-7, 11-12] FIGURE 16: GROUPS 6-7, GROUPS 11-12 - RIGHT SIDE - FRONT SPAR - LOCATION OF FASTENERS [Group 6-7, 11-12] FIGURE 17: GROUPS 8-10, GROUPS 13-14 - LEFT SIDE - FRONT SPAR - LOCATION OF FASTENERS [Group 8-10, 13-14] .
FIGURE 18: GROUPS 8-10, GROUPS 13-14 - RIGHT SIDE - FRONT SPAR - LOCATION OF FASTENERS [Group 8-10, 13-14] FIGURE 19: GROUP 1, GROUP 3, GROUPS 5-7, GROUPS 11-12 - CENTER TANK - LOCATION OF FASTENERS [Group 1, 3, 5-7, 11-12] 286 FIGURE 20: GROUP 2, GROUP 4 - CENTER TANK - LOCATION OF FASTENERS [Group 2, 4] 293 FIGURE 21: GROUPS 8-10, GROUPS 13-14 - CENTER TANK - LOCATION OF FASTENERS [Group 8-10, 13-14] 300 FIGURE 22: GROUPS 1-7, GROUPS 11-12 - LEFT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY - WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 1-7, 11-12] FIGURE 23: GROUPS 1-7, GROUPS 11-12 - RIGHT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY
- WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 1-7, 11-12] FIGURE 24: GROUPS 8-10, GROUPS 13-14 - LEFT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY
- WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 8-10, 13-14] . 314 FIGURE 25: GROUPS 8-10, GROUPS 13-14 - RIGHT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY
- WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 8-10, 13-14] . 318 FIGURE 26: GROUPS 1-7, GROUPS 11-12 - LEFT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY - WIRE BUNDLES - CLAMP REPLACMENT AND/OR SLEEVE INSTALLATION [Group 1-7, 322 FIGURE 27: GROUPS 1-7, GROUPS 11-12 - RIGHT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY
- WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 1-7, 11-12] FIGURE 28: GROUPS 8-10, GROUPS 13-14 - LEFT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY
- WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 8-10, FIGURE 29: GROUPS 8-10, GROUPS 13-14 - RIGHT SIDE - EQUIPMENT COOLING SYSTEM (ECS) BAY
- WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 8-10, FIGURE 30: ALL GROUPS - LEFT SIDE - REAR SPAR - WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 1-14] 342 FIGURE 31: ALL GROUPS - RIGHT SIDE - REAR SPAR - WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 1-14] FIGURE 32: ALL GROUPS - LEFT SIDE - REAR SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 1-14] FIGURE 33: ALL GROUPS - RIGHT SIDE - REAR SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 1-14] FIGURE 34: GROUPS 7-8, GROUP 12, GROUP 14 - LEFT SIDE - FRONT SPAR - WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 7-8, 12, 14] FIGURE 35: GROUPS 7-8, GROUP 12, GROUP 14 - RIGHT SIDE - FRONT SPAR - WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 7-8, 12, 14] Original Issue: July 16, 2007 Revision 1: October 05, 2009 BOEING PROPRIETARY - 757-57A0064 Copyright © Unpublished Work - See page 1 for details. 4 of 442
BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT FIGURE 36: GROUP 9, GROUP 11, GROUP 13 - LEFT SIDE - FRONT SPAR - WIRE BUNDLES SUPPORT
- GENERAL VISUAL INSPECTION [Group 9, 11, 13] 375 FIGURE 37: GROUP 9, GROUP 11, GROUP 13 - RIGHT SIDE - FRONT SPAR - WIRE BUNDLES SUPPORT
- GENERAL VISUAL INSPECTION [Group 9, 11, 13] 380 FIGURE 38: GROUPS 1-6, GROUP 10 - LEFT SIDE - FRONT SPAR - WIRE BUNDLES SUPPORT GENERAL VISUAL INSPECTION [Group 1-6, 10] 384 FIGURE 39: GROUPS 1-6, GROUP 10 - RIGHT SIDE - FRONT SPAR - WIRE BUNDLES SUPPORT - GENERAL VISUAL INSPECTION [Group 1-6, 10] 389 FIGURE 40: GROUPS 7-8, GROUP 12, GROUP 14 - LEFT SIDE - FRONT SPAR - WIRE BUNDLES CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 7-8, 12, 14] 393 FIGURE 41: GROUPS 7-8, GROUP 12, GROUP 14 - RIGHT SIDE - FRONT SPAR - WIRE BUNDLES CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 7-8, 12, 14] 399 FIGURE 42: GROUP 9, GROUP 11, GROUP 13 - LEFT SIDE - FRONT SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 9, 11, 13] . 403 FIGURE 43: GROUP 9, GROUP 11, GROUP 13 - RIGHT SIDE - FRONT SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 9, 11, 13] . 409 FIGURE 44: GROUPS 1-6, GROUP 10 - LEFT SIDE - FRONT SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 1-6, 10]. . 414 FIGURE 45: GROUPS 1-6, GROUP 10 - RIGHT SIDE - FRONT SPAR - WIRE BUNDLES - CLAMP REPLACEMENT AND/OR SLEEVE INSTALLATION [Group 1-6, 10]. 420 FIGURE 46: ALL GROUPS - REAR SPAR, FRONT SPAR AND CENTER TANK FASTENERS - APPLICATION OF SEALANT [Group 1-14] . 425 FIGURE 47: GROUPS 1-10 LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS. 427 FIGURE 48: GROUPS 1-10 RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS 431 FIGURE 49: GROUPS 11- 14 LEFT SIDE - REAR SPAR - LOCATION OF FASTENERS 435 FIGURE 50: GROUPS 11-14 - RIGHT SIDE - REAR SPAR - LOCATION OF FASTENERS 439 Original Issue: July 16, 2007 Revision 1: October 05, 2009 BOEING PROPRIETARY - 757-57A0064 Copyright © Unpublished Work - See page 1 for details. 5 of 442
BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT
BLANK PAGE Original Issue: July 16, 2007 Revision 1: October 05, 2009 BOEING PROPRIETARY - 757-57A0064 Copyright © Unpublished Work - See page 1 for details. 6 of 442
Commercial OBOEING Airplanes 757 Service Bulletin
- ALERT Number: 757-57A0064 Revision Transmittal Sheet Original Issue: July 16, 2007 Revision 1: October 05, 2009 ATA System: 5710 5720 SUBJECT: WINGS - Center and Outer Wing - Fastener Sealing and Wire Bundle Support Inspection and Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-23-19, is related to this service bulletin.
More work is necessary as shown in the original issue of this service bulletin. Operators that have done the work in accordance with the original issue must do the additional fastener sealing in accordance with Part 11 of this service bulletin.
REASON FOR REVISION This revision is sent to:
Add requirements to seal 20 additional fasteners in the main fuel tanks (left and right sides) for lightning strike protection.
- Allow the installation of TFE-2X Teflon sleeve on the breakout wire separately from main bundle at locations where the wire break out is within 1.5 inches of the clamp.
- Allow the use of Teflon tape to wrap around TFE-2X Teflon sleeve on wire bundle for smooth transition and cover any gaps at locations where the bend radius of the wire bundle is too small to allow the proper installation of Teflon sleeves.
Replace BACC10JU-101 and BACC10JU-102 full cushion clamps with BACC10GU-101 and BACC10GU-102 due to availability.
Clarify required length of Teflon sleeve protruding beyond the clamp at 0.5 inch minimum (both ends).
- Allow the use of alternate size clamps and to note existing wire bundle may differ from those shown in this service bulletin.
- Correct names of fuel tank access doors that were not named correctly.
- Correct the warranty information in Industry Support Information in the Summary to match exiting warranty information in Paragraph 2.B of the service bulletin.
The data given in Information Notice 757-57A0064 IN 01 and 757-57A0064 IN 02 is included in this revision.
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•Copyright © Unpublished Work - See page 1 for details. 7 of 442
BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT These sections were changed:
1. In the Summary section, the background was revised, added reference to the AD and updated the warrant and manpower sections.
2. In Paragraph 1.C., Reason, clarified and formated reason statement to be Airworthiness Directive Friendly.
3. In Paragraph 1.D., Description, added Maintenance Zone tables.
4. In Paragraph 1.E., Compliance, changed as follows:
a. Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-23-19.
b. Revised compliance times to within 5 years after December 30, 2008, was within 5 years after issue date on this Service Bulletin, to match effective date in Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-23-19.
5. In Paragraph 1.F., Approval, added an Alternative Methods of Compliance statement.
6. In Paragraph 1.G., Manpower, changed as follows:
a. Changed task hours for Figures 1 through 10, to increase hours for additional fasteners to be sealed.
b. Added task hour tables for Figures 47 through 50, for groups 1 through 14.
7. In Paragraph 1.K., Publications Affected, added the Damage Tolerance statement.
8. In Paragraph 2.C.2., Parts and Material Supplied by the Operator, for all groups change as follows:
a. Changed Full Cushion Clamp part number in parts tables to BACC10GU-101 and BACC10GU-102 was BACC10JU-101 and BACC10JU-102.
b. Added Teflon tape and associated notes (f) and (g).
9. In Paragraph 3.A., General Information, changed as follows:
a. Added note 10 to note existing fasteners that have been sealed previously are acceptable.
b. Added note 11 to note quantity of fasteners shown are approximate and to seal additional fasteners as required.
c. Added notes 12 and 13 to explain operator applicability of Parts 1 through 11.
d. Added note 14 to allow approved wire bundle support installation deviations
10. In Paragraph 3.B., Work Instructions, Part 1, for all groups corrected access door names as follows:
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BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT
a. In steps (2) and (14) changed name of 531AB, 531BB, and 531CB to center fuel tank access door, was left main fuel tank access door.
b. In steps (4) and (16) changed name of 631AB, 631BB, and 631CB to center fuel tank access door, was right main fuel tank access door.
c. In steps (6) and (12) changed name of 134BZ, 134CZ and 134DZ to fuel bay baffle door, was center fuel fuel tank access door.
11. In Paragraph 3.B., Work Instructions, Part 2 through Part 10, for all groups, changed instructions; from replace Teflon tape to install TFE-2X sleeve.
12. In Paragraph 3.B., Work Instructions, added Part 11 work instructions for operators that has done the work of the original issue of this service bulletin
13. In Figures 1 through 12, changed as follows:
a. Changed view B to show 21 fasteners was 22.
b. Changed work step 1 to locate 21 fasteners was 22.
c. Added requirements to seal additional fasteners in areas between rib numbers 14 and 15, and between rib numbers 18 and 19.
14. In Figures 3 and 4, work step 7, changed quantity to 7 was 9.
15. IN Figures 5 and 6, work step 8, changed quantity to 7 was 9.
16. In Figures 23 and 27, revised wire harness (W2506) routing to better match actual aircraft configuration.
17. In Figures 22 through 45, added notes to:
a. Allow the installation of TFE-2X Teflon sleeve on the breakout wire separately from main bundle at locations where the wire break out is within 1.5 inches of the clamp D. Allow the use of Teflon tape to wrap around TFE-2X Teflon sleeve on wire bundle for smooth transition and cover any gaps at locations where the bend radius of the wire bundle is too small to allow the proper installation of Teflon sleeves
18. In Figures 26 through 29, 32, 33 and 40 through 45, added view to show 0.5 inch minimum sleeve protruding beyond ends of clamp added note to show the same.
19. In Figures 27, 28, 29, 32, 33, 40, 41, 42, 43, 44, and 45 changed quantity of Teflon Sleeve in illustration to match quantity in step table.
20. In Figures 40, 42 and 44, added note to advice operators that to remove clamps between IFSS 119.21 and IFSS 132.98 surrounding pneumatic ducts may have to be removed.
21. Added Figures 47, 48, 49 and 50 to seal an additional 20 fasteners in the main fuel tank (left and right side) for operators that have done the work of the original issues of this service bulletin.
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BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
REVISION HISTORY Original Issue: July 16, 2007 Revision 1: October 05, 2009 Original Issue: July 16, 2007 Revision 1: October 05, 2009 BOEING PROPRIETARY - 757-57A0064 Copyright © Unpublished Work - See page 1 for details. 10 of 442
Commercial CADEING Airplanes 757 Service Bulletin
- ALERT Number: 757-57A0064 Summary Original Issue: July 16, 2007 Revision 1: October 05, 2009 ATA System: 57 10 5720 SUBJECT: WINGS - Center and Outer Wing - Fastener Sealing and Wire Bundle Support Inspection and Modification
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 A review by Boeing has found it possible for some fuel tank fasteners, in the event of a fault current, to become an ignition source. Sealing fuel tank fasteners, general inspection of wire support bundles, replacing clamps and installing a Teflon sleeve where required may reduce the risk of fuel tank fasteners becoming an ignition source. Replacing clamps and installing Teflon sleeve provides for additional layers of protection against hot shorts. Accomplishment of the this service bulletin will help prevent certain ignition sources within the fuel tanks.
If not corrected, in the event of a fault current, ignition sources within the fuel tanks may possibly result in fire or explosion.
This service bulletin is the result of the safety assessments conducted by Boeing under SFAR 88,iFuel Tank System Fault Tolerance Evaluation Requirementsi ACTION Purge the left and right main fuel tanks. Get access to the left and right main fuel tanks. Seal fasteners on the front and rear spars, left and right side. Purge the center fuel tanks. Get access to the center fuel tank. Seal fasteners on the center tank lower panel. In the left and right Equipment Cooling System (ECS) bay, do a general visual inspection of the wire bundle clamps. Along the left and right side front and rear spars, do a general visual inspection of the wire bundle clamps. If the wire bundle support installation is not as shown in this service bulletin, get access to and change the wire bundle support hardware. The airplanes are divided into 14 groups because of variations in the fasteners to be sealed and the wire bundle clamps to be inspected.
EFFECTIVITY All 757-200, 757-200CB, 757-200PF., and 757-300 series airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity.
Original Issue: July 16, 2007 Revision 1: October 05, 2009 757-57A0064
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 442
BOEING SERVICE BULLETIN 757-57A0064
ALERT ALERT
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-23-19 is related to this service bulletin.
See Service Bulletin Paragraph 1.E. for compliance information.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for 757 airplanes in warranty as of May 17, 2005. Please refer to Paragraph 2.B Industry Support Information.
MANPOWER Total hours for Parts 1 through 10:
Group Total Total Group Total Total Group Total Total Task Elapsed Task Elapsed Task Elapsed Hours Hours Hours Hours Hours Hours 1 642.94 128.43 6 652.94 131.67 11 659.17 133.03
643.68 130.42 7 654.53 132.21 12 658.53 132.71
646.18 127.41 8 645.39 126.93 13 653.27 127.49 4 648.44 131.68 9 646.03 127.25 14 652.63 127.17 5 646.94 128.93 10 | 643.80 126.39 Part 11:
Group Task Elapsed Hours Hours 1-14 48.00 14.25
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
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