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Commercial Airplanes 757 Service Bulletin
SPECIAL ATTENTION Number: 757-24-0105 Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 SUBJECT: ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Slat Auxiliary Track.
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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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: September 30, 2004 757-24-0105Revision 5: July 30, 2009 1 of 41
5.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 2 of 41 BOEING SERVICE BULLETIN 757-24-0105
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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 5 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F. Approval ............................................... 1 8 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 1 9 I. Electrical Load Data ......................................... 1 9 J. References .............................................. 1 9
1. Existing Data: ......................................... 1 9
2. Data supplied with this Service Bulletin: ........................... 2 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 0 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 0
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 1
3. Parts Modified and Reidentified: ............................... 2 2
4. Parts Removed and Not Replaced: .............................. 2 2 D. Parts Necessary to Change Spares ................................. 2 2 E. Special Tooling - Price and Availability ............................... 2 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: GROUP 1, CONFIGURATION 1, AIRPLANES, LEFT WING INBOARD AUXILIARY TRACK POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. .... 3 0 FIGURE 2: GROUP 1, CONFIGURATION 1, AIRPLANES, RIGHT WING INBOARD AUXILIARY TRACK POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. .... 3 3 FIGURE 3: GROUP 1, CONFIGURATION 2, AIRPLANES, LEFT WING INBOARD AUXILIARY TRACK POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. .... 3 6 FIGURE 4: GROUP 1, CONFIGURATION 2, AIRPLANES, RIGHT WING INBOARD AUXILIARY TRACK POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. .... 3 9 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 4 of 41 BOEING SERVICE BULLETIN 757-24-0105
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Commercial Airplanes 757 Service Bulletin
SPECIAL ATTENTION Revision Transmittal SheetNumber: 757-24-0105Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 SUBJECT: ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Slat Auxiliary Track.
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed as shown in the original issue or Revisions 1,2,3 or 4 of this service bulletin. Airplanes moved from Group 2 to Group 1, Configuration 2 should make sure that the clamp is installed on the lower bracket on the left wing as shown in Figure 3.
REASON FOR REVISION Revision 5 is sent to change the Group and Configuration data, to add maintenance zones, and to add another optional fastener to plug the hole in the bracket.
These sections were changed:
1. Summary, Action: Added Configuration 1 and Configuration 2 to Group 1 airplanes.
2. Paragraph 1.A.1. Airplanes: Changed from Group 1 and Group 2 to Group 1, Configuration 1 and Group 1, Configuration 2.
3. Paragraph 1.C., Reason: Added Configuration 1 to airplane Group 1.
4. Paragraph 1.D. Description: Added Configuration 1 and Configuration 2 to Group 1 airplanes.
5. Paragraph 1.D. Description: Added Affected Maintenance Zones.
6. Paragraph 1.F. Approval: Changed paragraph letter for Alternate Method Of Compliance.
7. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added optional blind rivet, part number NAS1398B8AB2. Also corrected the part number of the collar to read BACC30M8U.
8. Figure 1, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table.
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Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 5 of 41
9. Figure 2, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table.
10. Figure 3, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table.
11. Figure 4, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table.
The data given in Information Notice 757-24-0105 IN 02 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 September 30, 2004Original Issue:
June 23, 2005Revision 1:
April 20, 2006Revision 2:
October 03, 2006Revision 3:
January 04, 2008Revision 4:
July 30, 2009Revision 5:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 6 of 41 BOEING SERVICE BULLETIN 757-24-0105
Commercial Airplanes 757 Service Bulletin
SPECIAL ATTENTION SummaryNumber: 757-24-0105Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 SUBJECT: ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Slat Auxiliary Track.
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND The changes in this service bulletin will prevent possible chafe damage between the number 5 and 6 inboard slat auxiliary slat tracks and the power feeder wire bundles W3312 and W3412. The attach points for the support clamps for the power feeder wires in each wing are changed to get the necessary clearance for the power feeder wires.
One operator told Boeing they found that the power feeder wire bundle had chafed against the number 6 auxiliary slat track at Front Spar Station (FSS) 148.90. On one airplane two of the three phases of the power feeder wire bundle were worn through to the conductor. The electrical cables had arced against the auxiliary slat track and caused damage to the auxiliary slat track and power feeder wire. This condition can result in a possible ignition source for leaked flammable fluids or a generator trip with loss of power from that generator.
The attach bracket for the power feeder wire bundle clamp at FSS 148.90 has two holes where the power feeder wire bundle can be installed. The support clamp for the damaged power feeder wires was attached to the upper hole of the attach bracket. It was found that the lower hole of the attach bracket can be used to give sufficient clearance between the power feeder wire bundle and the auxiliary slat track.
This service bulletin gives instructions to do a general visual inspection of the power feeder wire bundles W3312 and W3412 for chafe damage and to make sure that the support clamps are correctly installed. Support clamps for the power feeder wire bundles are found in the left and right wings at FSS 148.90 near the number 5 and 6 inboard auxiliary slat tracks. Airplane group 1, line numbers 1 - 88 should use the upper hole of the 271N6178-5 bracket to attach the left power feeder wire bundle. Rivets are installed in the open holes that are not used in the brackets to prevent use of the holes. If Service Letter 757-SL-24-072 has been done, install rivets in the open holes that are not used in the attach brackets. A similar change was made on line number 1024 and subsequent airplanes before they were delivered.
The related 757-300 bulletin is 757-24-0106.
Service Letter 757-SL-24-072 is also related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 7 of 41
Boeing Service Related Problem (SRP) 757-SRP-24-0109 is related to this service bulletin.
ACTION For Group 1, Configuration 1 airplanes: get access to the support clamps for the power feeder wire bundles W3312 and W3412 at FSS 148.90 in the left and right wings. Do a general visual inspection of each power feeder wire bundle. Repair damaged wires as necessary. Make sure that the support clamp on the left wing power feeder wire bundle (W3312) is installed in the upper hole of the 271N6178-5 bracket. Make sure that the lobe of the clamp is installed in the up position. Make sure that the cable support on the right wing power feeder wire bundle (W3412) is installed in the lower hole of the 287N1401-306 support bracket. Rivet plug the holes in the brackets that are not used to prevent use, this includes airplanes that have done Service Letter 757-SL-24-072.
For Group 1, Configuration 2 airplanes: get access to the support clamps for the power feeder wire bundles W3312 and W3412 at FSS 148.90 in the left and right wings. Do a general visual inspection of each power feeder wire bundle. Repair damaged wires as necessary. Make sure that the support clamps for the left and right power feeder wire bundles are installed in the lower hole of the 287N1401-306 support bracket. Rivet plug the holes in the brackets that are not used to prevent use, this includes airplanes that have done Service Letter 757-SL-24-072.
EFFECTIVITY 757-200, 757-200CB and 757- 200PF airplanes. Refer to Service Bulletin Paragraph 1.A. 1 for effectivity.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2007-03-01 Boeing recommends that operators do the changes in this service bulletin in 24 months or less from the initial release date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of September 5, 2003. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
4.758.0Group 1, Configuration 1
4.257.5Group 1, Configuration 2
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 8 of 41 BOEING SERVICE BULLETIN 757-24-0105
BOEING SERVICE BULLETIN 757-24-0105
INSPECT THE WIRE BUNDLE AT
THIS LOCATION FOR DAMAGE AND REPAIR IF NECESSARY. CHANGE THE POSITION OF THE CLAMP.
ISS
150.74
RIGHT WING SHOWN (LEFT WING EQUIVALENT) ISS 423837
119.21 Original Issue: September 30, 2004 Revision 5: July 30, 2009 757-24-0105 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 41
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 10 of 41 BOEING SERVICE BULLETIN 757-24-0105
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Commercial Airplanes 757 Service Bulletin
SPECIAL ATTENTION Number: 757-24-0105 Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 SUBJECT: ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Slat Auxiliary Track.
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
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 757-200s from line numbers 0001 through 1016.-1 Airplanes that have two attach brackets on the left wing and one attach bracket on the right wing.
1 Airplanes that have one attach bracket on the left wing and one attach bracket of the right wing.
2 Airplane Models:
757-200, 757-200CB, 757-200PF GroupVariable Number 1NA001 - NA028 1NA191 - NA199 1NA201 - NA239 1NA301 - NA305 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 11 of 41
GroupVariable Number 1NA341 - NA352 1NA391 - NA399 1NA401 - NA408 1NA441 - NA447 1NA501 - NA586 1NB001 - NB004 1NB021 - NB023 1NB036 - NB041 1NB051 - NB053 1NB061 - NB073 1NB079 1NB131 - NB148 1NB161 - NB162 1NB166 - NB168 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 1NC001 - NC033 1NC041 - NC042 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 30, 2004 757-24-0105Revision 5: July 30, 2009 12 of 41 BOEING SERVICE BULLETIN 757-24-0105