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 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 757-22-0096 1 of 224

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Table of Contents

Summary7

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 8 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 3 I. Electrical Load Data ......................................... 2 4 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 5 L. Interchangeability and Intermixability of Parts ........................... 2 5 M. Software Accomplishment Summary ................................ 2 5

2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 9 C. Parts Necessary for Each Airplane ................................. 2 9

1. Kits/Parts ............................................ 2 9

2. Parts and Materials Supplied by the Operator ........................ 4 0

3. Parts Modified and Reidentified ................................ 4 0

4. Parts Removed and Not Replaced .............................. 4 0 D. Parts Necessary to Change Spares ................................. 4 0 E. Special Tooling - Price and Availability ............................... 4 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 0

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 1 A. GENERAL INFORMATION ..................................... 4 1 B. WORK INSTRUCTIONS ....................................... 4 2 FIGURE 1: MAIN EQUIPMENT CENTER - SERVICE PANEL - AUTO TRIM TEST SWITCH INSTALLATION [Group 1-2, 4-5] ......................................... 6 2 FIGURE 2: MAIN EQUIPMENT CENTER - SERVICE PANEL - AUTO TRIM TEST SWITCH INSTALLATION [Group 3] ............................................ 6 6 FIGURE 3: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE W1154 - WIRING ROUTING [Group 1] ................... 7 0 FIGURE 4: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE W1154 -WIRING CHANGE [Group 1] .................... 7 2 FIGURE 5: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE W1164 - WIRING ROUTING [Group 1] ................... 7 4 FIGURE 6: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE W1164 - WIRING CHANGE [Group 1] ................... 7 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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

- WIRE BUNDLE 4501 - WIRING ROUTING [Group 1] ................... 7 8 FIGURE 8: MAIN EQUIPMENT CENTER - E3-1, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE 4501 - WIRING CHANGE [Group 1] .................... 8 3 FIGURE 9: MAIN EQUIPMENT CENTER - E3-3, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4505 - WIRING ROUTING [Group 1] .................. 8 5 FIGURE 10: MAIN EQUIPMENT CENTER - E3-3, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4505 - WIRING CHANGE [Group 1] ................... 9 2 FIGURE 11: MAIN EQUIPMENT CENTER - E3-2, E2-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4503 - WIRING ROUTING [Group 1] .................. 9 4 FIGURE 12: MAIN EQUIPMENT CENTER - E3-2, E2-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4503 - WIRING CHANGE [Group 1] .................. 1 0 1 FIGURE 13: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2060 - WIRING ROUTING [Group 1] . 103 FIGURE 14: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2060 - WIRING CHANGE [Group 1] . 105 FIGURE 15: MAIN EQUIPMENT CENTER - WIRE BUNDLE W4402 - WIRING ROUTING [Group 1] . 107 FIGURE 16: MAIN EQUIPMENT CENTER - WIRE BUNDLE W4402 - WIRING CHANGE [Group 1] . 108 FIGURE 17: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE W1260 - WIRING ROUTING [Group 2-5] ................. 1 1 0 FIGURE 18: MAIN EQUIPMENT CENTER - P36 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE W1260 - WIRING CHANGE [Group 2-5] .................. 1 1 1 FIGURE 19: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE 1270 - WIRING ROUTING [Group 2-5] .................. 1 1 3 FIGURE 20: MAIN EQUIPMENT CENTER - P37 MISCELLANEOUS ELECTRICAL EQUIPMENT PANEL - WIRE BUNDLE 1270 - WIRING CHANGE [Group 2-5] ................... 1 1 4 FIGURE 21: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING ROUTING [Group 2-3] ................ 1 1 6 FIGURE 22: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING CHANGE [Group 2-3] ................. 1 2 4 FIGURE 23: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING ROUTING [Group 2-3] ................ 1 2 7 FIGURE 24: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING CHANGE [Group 2-3] ................. 1 3 5 FIGURE 25: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING ROUTING [Group 2-3] ................ 1 3 8 FIGURE 26: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING CHANGE [Group 2-3] ................. 1 4 5 FIGURE 27: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING ROUTING [Group 4] .................. 1 4 8 FIGURE 28: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING CHANGE [Group 4] .................. 1 5 6 FIGURE 29: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING ROUTING [Group 4] .................. 1 5 8 FIGURE 30: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING CHANGE [Group 4] .................. 1 6 6 FIGURE 31: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING ROUTING [Group 4] .................. 1 6 8 FIGURE 32: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

Original Issue: March 23, 2015 757-22-0096 4 of 224 BOEING SERVICE BULLETIN 757-22-0096

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

- WIRE BUNDLE W4471 - WIRING ROUTING [Group 5] .................. 1 7 6 FIGURE 34: MAIN EQUIPMENT CENTER - E2-1, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4471 - WIRING CHANGE [Group 5] .................. 1 8 4 FIGURE 35: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING ROUTING [Group 5] .................. 1 8 6 FIGURE 36: MAIN EQUIPMENT CENTER - E2-3, E3-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4475 - WIRING CHANGE [Group 5] .................. 1 9 4 FIGURE 37: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING ROUTING [Group 5] .................. 1 9 6 FIGURE 38: MAIN EQUIPMENT CENTER - E2-2, E4-1 ELECTRONICS SHELVES AND SERVICE PANEL

- WIRE BUNDLE W4473 - WIRING CHANGE [Group 5] .................. 2 0 3 FIGURE 39: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING ROUTING [Group 2-3] . 206 FIGURE 40: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING ROUTING [Group 4] . 209 FIGURE 41: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING ROUTING [Group 5] . 214 FIGURE 42: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2260 - WIRING CHANGE [Group 2-5] . 218 FIGURE 43: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2072 - WIRING ROUTING [Group 2-5] . 220 FIGURE 44: MAIN EQUIPMENT CENTER - WIRE BUNDLE W2072 - WIRING CHANGE [Group 2-5] . 222 APPENDIX A: PART DEMAND INTENT ................................... 2 2 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 757-22-0096Original Issue: March 23, 2015 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.

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ReferenceAffectedPlanning Data 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.

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

Original Issue: March 23, 2015 757-22-0096 8 of 224 BOEING SERVICE BULLETIN 757-22-0096

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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 each 1,500 flight hour interval. 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.

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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.

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BOEING SERVICE BULLETIN 757-22-0096

INSTALL SWITCH AND CHANGE

WIRING FOR AUTO TRIM INHIBIT

SYSTEM INSTALLATION

MAIN EQUIPMENT CENTER GROUP 2-5

INSTALL SWITCH AND CHANGE

WIRING FOR AUTO TRIM INHIBIT

SYSTEM INSTALLATION MAIN EQUIPMENT CENTER 2380460 Original Issue: March 23, 2015 Export Controlled ECCN: 9E991 - BOEING 757-22-0096 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 224

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