Boeing Special Attention Service Bulletin 757-22-0096: Revision 1, text

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION Number: 757-22-0096 Original Issue: March 23, 2015 Revision 1: February 08, 2016 ATA System: 2212 2222 3209 SUBJECT: AUTOFLIGHT - Automatic Stabilizer Trim System - On-Ground Stabilizer Autotrim Inhibit System Installation Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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:

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: March 23, 2015 757-22-0096Revision 1: February 08, 2016 1 of 240

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Original Issue: March 23, 2015 757-22-0096Revision 1: February 08, 2016 2 of 240 BOEING SERVICE BULLETIN 757-22-0096

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Table of Contents

Revision Transmittal Sheet7

Summary9

1. PLANNING INFORMATION15

A. Effectivity15

1. Airplanes15

2. Spares Affected20

B. Concurrent Requirements20

C. Reason20

D. Description21

E. Compliance22

F. Approval23

G. Manpower23

H. Weight and Balance Changes25

I. Electrical Load Data26

J. References26

1. Existing Data:26

2. Data Supplied with this Service Bulletin:26

3. Installation Drawings Used in the Preparation of this Service Bulletin:26

K. Publications Affected27

L. Interchangeability and Intermixability of Parts27

M. Software Accomplishment Summary27

2. MATERIAL INFORMATION29

A. Material - Price and Availability29

B. Industry Support Information32

C. Parts Necessary for Each Airplane32

1. Kits/Parts32

2. Parts and Materials Supplied by the Operator46

3. Parts Modified and Reidentified46

4. Parts Removed and Not Replaced46

D. Parts Necessary to Change Spares46

E. Special Tooling - Price and Availability47

F. Special Tooling Necessary to do this Service Bulletin47

3. ACCOMPLISHMENT INSTRUCTIONS49

A. GENERAL INFORMATION49

B. WORK INSTRUCTIONS50

FIGURE 1: MAIN EQUIPMENT CENTER - SERVICE PANEL - AUTO TRIM TEST SWITCH INSTALLATION

[Group 1-2, 4-5]70

FIGURE 2: MAIN EQUIPMENT CENTER - SERVICE PANEL - AUTO TRIM TEST SWITCH INSTALLATION

[Group 3]74

FIGURE 3: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE W1154 - WIRING ROUTING [Group 1]78

FIGURE 4: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE W1154 -WIRING CHANGE [Group 1]80

FIGURE 5: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE W1164 - WIRING ROUTING [Group 1]82

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FIGURE 6: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE W1164 - WIRING CHANGE [Group 1]84

FIGURE 7: MAIN EQUIPMENT CENTER - E3-1, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE 4501 - WIRING ROUTING [Group 1]86

FIGURE 8: MAIN EQUIPMENT CENTER - E3-1, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE 4501 - WIRING CHANGE [Group 1]91

FIGURE 9: MAIN EQUIPMENT CENTER - E3-3, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4505 - WIRING ROUTING [Group 1]94

FIGURE 10: MAIN EQUIPMENT CENTER - E3-3, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4505 - WIRING CHANGE [Group 1]101

FIGURE 11: MAIN EQUIPMENT CENTER - E3-2, E2-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4503 - WIRING ROUTING [Group 1]104

FIGURE 12: MAIN EQUIPMENT CENTER - E3-2, E2-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4503 - WIRING CHANGE [Group 1]111

FIGURE 13: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2060 - WIRING ROUTING [Group 1] . 114 FIGURE 14: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2060 - WIRING CHANGE [Group 1] . 116 FIGURE 15: MAIN EQUIPMENT CENTER - WIRE BUNDLE W4402 - WIRING ROUTING [Group 1] . 118 FIGURE 16: MAIN EQUIPMENT CENTER - WIRE BUNDLE W4402 - WIRING CHANGE [Group 1] . 119 FIGURE 17: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE W1260 - WIRING ROUTING [Group 2-5]121

FIGURE 18: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE W1260 - WIRING CHANGE [Group 2-5]122

FIGURE 19: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE 1270 - WIRING ROUTING [Group 2-5]125

FIGURE 20: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL -

WIRE BUNDLE 1270 - WIRING CHANGE [Group 2-5]126

FIGURE 21: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING ROUTING [Group 2-3]128

FIGURE 22: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING CHANGE [Group 2-3]136

FIGURE 23: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING ROUTING [Group 2-3]139

FIGURE 24: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING CHANGE [Group 2-3]147

FIGURE 25: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING ROUTING [Group 2-3]150

FIGURE 26: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING CHANGE [Group 2-3]157

FIGURE 27: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING ROUTING [Group 4]160

FIGURE 28: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING CHANGE [Group 4]168

FIGURE 29: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING ROUTING [Group 4]170

FIGURE 30: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING CHANGE [Group 4]178

FIGURE 31: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING ROUTING [Group 4]180

Original Issue: March 23, 2015 757-22-0096Revision 1: February 08, 2016 4 of 240 BOEING SERVICE BULLETIN 757-22-0096

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FIGURE 32: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING CHANGE [Group 4]186

FIGURE 33: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING ROUTING [Group 5]188

FIGURE 34: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING CHANGE [Group 5]196

FIGURE 35: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING ROUTING [Group 5]198

FIGURE 36: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING CHANGE [Group 5]206

FIGURE 37: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING ROUTING [Group 5]208

FIGURE 38: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING CHANGE [Group 5]215

FIGURE 39: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING ROUTING [Group 2-3] . 218 FIGURE 40: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING ROUTING [Group 4] . 221 FIGURE 41: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING ROUTING [Group 5] . 226 FIGURE 42: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING CHANGE [Group 2-5] . 230 FIGURE 43: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2072 - WIRING ROUTING [Group 2-5] . 232 FIGURE 44: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2072 - WIRING CHANGE [Group 2-5] . 238

APPENDIX A: PART DEMAND INTENT240

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION Revision Transmittal SheetNumber: 757-22-0096Original Issue: March 23, 2015 Revision 1: February 08, 2016 ATA System: 2212 2222 3209 SUBJECT: AUTOFLIGHT - Automatic Stabilizer Trim System - On-Ground Stabilizer Autotrim Inhibit System Installation This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Effects of this Revision on airplanes on which Original Issue was previously done:

None.

REASON FOR REVISION This revision is sent to to provide wire routing improvements, work instruction updates, and kit/part changes based on service bulletin post-release validation findings.

As a result of the validation findings wire routing figure updates provide more accurate routing details and Auto Trim Test Switch wire terminal lug specifications are changed. Wire kit material specification and information are changed. Also, notes have been added for clarity on Command selection using either buttons or switches.

1. In Paragraph 1.K, Planning Information: Updated sections impacted in Publications Affected table.

2. In Paragraph 2.A, Material Information: Modified tables to show updated kits and parts.

3. In Paragraph 2.C, Material Information: Modified tables to show updated kits and parts.

4. In Paragraph 2.C, Material Information: Added tables to show new kits.

5. In Paragraph 3.B, Work Instructions: Added notes for clarity on Command selection using either buttons or switches.

6. In Paragraph 3.B, Work Instructions: Updated Figures 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, and 44 notes to show updated kits.

7. In Paragraph 3.B, Work Instructions: Modified tables in Figures 4, 6, 8, 10, 12, 22, 24, 26, 28, 30, 32, 34, 36, and 38 to show updated kits and parts.

8. In Paragraph 3.B, Work Instructions: Updated table footnotes for splice ID's in Figures 4, 6, 8, 10, 12, 22, 24, 26, 28, 30, 32, 34, 36, and 38.

Original Issue: March 23, 2015 757-22-0096Revision 1: February 08, 2016 7 of 240

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9. In Paragraph 3.B, Work Instructions: Added footnotes for optional wire in Figures 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, and 44.

10. In Paragraph 3.B, Work Instructions: Added a footnote on Figure 18 for sleeving.

11. In Paragraph 3.B, Work Instructions: Updated Figures 21, 23, 25, 29, 39, and 43 for clarity.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.

Pages with no vertical lines have no changes.

REVISION HISTORY March 23, 2015Original Issue:

February 08, 2016Revision 1:

Original Issue: March 23, 2015 757-22-0096Revision 1: February 08, 2016 8 of 240 BOEING SERVICE BULLETIN 757-22-0096

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 757-22-0096Original Issue: March 23, 2015 Revision 1: February 08, 2016 ATA System: 2212 2222 3209 SUBJECT: AUTOFLIGHT - Automatic Stabilizer Trim System - On-Ground Stabilizer Autotrim Inhibit System Installation BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of this service bulletin will introduce changes to prevent engagement of the automatic stabilizer trim system while on ground. As a result of uncommanded autopilot engagement, the automatic stabilizer trim system can be engaged while on the ground and has potential to cause stabilizer movement outside of the takeoff settings. The root cause of the uncommanded autopilot engagement at airplane takeoffs was not determined at the time of release of this service bulletin. Any one of multiple possible single failures in the Autopilot Flight Director System can cause an uncommanded engagement of the autopilot. If this service bulletin is not accomplished, an on-ground autopilot engagement could cause the stabilizer to be trimmed outside of the greenband limits, which could increase the possibility of high-speed rejected takeoff (RTO) and/or reduced controllability of the airplane.

The relays and wiring are modified to open and close the Flight Control Computer (FCC) analog output that controls the stabilizer trim adjustment. The relays are operated by the air-ground switch and are open when the air-ground switch is in the on-ground position. A momentary action ground test switch is installed to bypass the air/ground contacts to allow testing of the Automatic Trim function when the airplane is on the ground. A repeated interval functional check of the new test switch, given in this service bulletin, will be necessary.

This service bulletin gives instructions to utilize existing relays and install wiring to inhibit the Automatic Stabilizer Trim Arm discrete when the airplane is on ground. In addition, it also provides instruction to install a two position momentary contact test switch in the Main Equipment Center to allow for ground testing of the autotrim function.

Boeing Service Related Problem (SRP) 757-SRP-22-0035 is related to this service bulletin.

Boeing Fleet Team Digest (FTD) 757 FTD 22-12001 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

Original Issue: March 23, 2015 757-22-0096Revision 1: February 08, 2016 9 of 240

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ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Accomplishment of this service bulletin changes the flight deck and/or operations of the airplane. Refer to Paragraph 1.K., Publications Affected, for affected publications.

The changes in this service bulletin will not change the Engine Indication and Crew Alerting System (EICAS).

Group 1:

1. In the Main Equipment Center, do these changes:

a. At the Service Panel located right and outboard of the E2 equipment rack, install the Test Switch S70007 and guard.

b. In the P36 Miscellaneous Electrical Equipment Panel, change Wire Bundle W1154.

c. In the P37 Miscellaneous Electrical Equipment Panel, change Wire Bundle W1164.

d. Between the Test Switch S70007 and E3-1 and E4-1 shelf assemblies, change Wire Bundle W4501.

e. Between the Test Switch S70007 and E3-3 and E4-1 shelf assemblies, change Wire Bundle W4505

f. Between the Test Switch S70007 and E3-2 and E2-1 shelf assemblies, change Wire Bundle W4503.

g. Between the Test Switch S70007 and the P36 Miscellaneous Electrical Equipment Panel, change Wire Bundle W2060.

h. Between the Test Switch S70007 and the P37 Miscellaneous Electrical Equipment Panel, change Wire Bundle W4402.

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2. Do a test to make sure the changed Automatic Stabilizer Trim System operates correctly.

Group 2-5:

1. In the Main Equipment Center, do these changes:

a. At the Service Panel located right and outboard of the E2 equipment rack, install the Test Switch S70007 and guard.

b. In the P36 Miscellaneous Electrical Equipment Panel, change Wire Bundle W1260.

c. In the P37 Miscellaneous Electrical Equipment Panel, change Wire Bundle W1270.

d. Between the Test Switch S70007 and E2-1 and E3-1 shelf assemblies, change Wire Bundle W4471.

e. Between the Test Switch S70007 and E2-3 and E3-1 shelf assemblies, change Wire Bundle W4475.

f. Between the Test Switch S70007 and E2-2 and E4-1 shelf assemblies, change Wire Bundle W4473.

g. Between the Test Switch S70007 and the P36 Miscellaneous Electrical Equipment Panel, change Wire Bundle W2260.

h. Between the Test Switch S70007 and the P37 Miscellaneous Electrical Equipment Panel, change Wire Bundle W2072.

2. Do a test to make sure the changed Automatic Stabilizer Trim System operates correctly.

EFFECTIVITY 757-200/-200CB/-200PF/-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes, 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 24 months after the original issue date of this service bulletin.

Boeing recommends that all airplanes do the Automatic Stabilizer Trim System Operational Test at intervals not to exceed 1,500 flight hours. Refer to Paragraph 3.B., Work Instructions, Step 11, for the test.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

Original Issue: March 23, 2015 757-22-0096Revision 1: February 08, 2016 11 of 240 BOEING SERVICE BULLETIN 757-22-0096

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MANPOWER Elapsed HoursTotal Task HoursAirplanes

34.7069.45Group 1

41.1082.25Group 2

41.1082.25Group 3

40.1580.35Group 4

38.0576.15Group 5

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

Operators are encouraged to complete the survey provided in APPENDIX A of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Original Issue: March 23, 2015 757-22-0096Revision 1: February 08, 2016 12 of 240 BOEING SERVICE BULLETIN 757-22-0096

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