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Commercial Airplanes 757 Service Bulletin Number: 757-57-0061 Original Issue: February 06, 2003 Revision 3: December 07, 2012 ATA System: 5710 2810 SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series) 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:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2003 Boeing.
Unpublished Work. All Rights Reserved.
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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management Company.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 1 of 56
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 2 of 56 BOEING SERVICE BULLETIN 757-57-0061
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 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 2 E. Compliance .............................................. 1 3 F. Approval ............................................... 1 3 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 5 J. References .............................................. 1 5
1. Existing Data: ......................................... 1 5
2. Data Supplied with this Service Bulletin: ........................... 1 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 6 M. Software Accomplishment Summary ................................ 1 6
2. MATERIAL INFORMATION ........................................ 1 7 A. Material - Price and Availability ................................... 1 7 B. Industry Support Information .................................... 1 7 C. Parts Necessary for Each Airplane ................................. 1 7
1. Kits/Parts: ........................................... 1 7
2. Parts and Materials Supplied by the Operator: ........................ 1 7
3. Parts Modified and Reidentified: ............................... 1 7
4. Parts Removed and Not Replaced: .............................. 1 7 D. Parts Necessary to Change Spares ................................. 1 8 E. Special Tooling - Price and Availability ............................... 1 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 9 A. GENERAL INFORMATION ..................................... 1 9 B. WORK INSTRUCTIONS ....................................... 2 0 FIGURE 1: OPEN ACCESS - AIR CONDITIONING DUCT REMOVAL - GROUP 1, GROUP 2 AND GROUP 3 ................................................. 3 0 FIGURE 2: INSPECTION - SECONDARY FUEL BARRIER - FRONT SPAR - GROUP 1 AND GROUP 3, CONFIGURATION 1 ...................................... 3 1 FIGURE 3: INSPECTION - SECONDARY FUEL BARRIER - UPPER PANEL - GROUP 1 AND GROUP 3, CONFIGURATION 1 ...................................... 3 6 FIGURE 4: INSPECTION - THICKNESS MEASUREMENTS - FRONT SPAR - GROUP 1 AND GROUP 3 .................................................. 4 3 FIGURE 5: INSPECTION - THICKNESS MEASUREMENTS - UPPER PANEL - GROUP 1 AND GROUP 3 ................................................. 4 6 FIGURE 6: INSPECTION AND APPLICATION OF THE SECONDARY FUEL BARRIER - GROUP 2 . 51 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 7: CLOSE ACCESS - AIR CONDITIONING DUCT INSTALLATION - GROUP 1, GROUP 2 AND GROUP 3 ............................................ 5 3 Appendix A: RECORD OF THICKNESS MEASUREMENTS ........................ 5 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 4 of 56 BOEING SERVICE BULLETIN 757-57-0061
Commercial Airplanes 757 Service Bulletin Revision Transmittal SheetNumber: 757-57-0061Original Issue: February 06, 2003 Revision 3: December 07, 2012 ATA System: 5710 2810 SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series) This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making: NPRM 2011-NM-070-AD, is related to this service bulletin.
No more work is necessary on the airplane(s) changed in accordance with the Revision 1 or 2, of this service bulletin.
REASON FOR REVISION This revision is sent to change the quantity of locations listed in Figure 5, Sheet 5 of 5, Step 2 in order to match the view shown in Figure 5, sheet 1 of 5 and the Upper Panel (TP) Table in Appendix A.
These sections were changed:
1. In Summary Compliance, Added NPRM.
2. In Paragraph 1.C. Reason, Added Revision 3 description.
3. In Paragraph 1.E. Compliance, Added NPRM.
4. In Paragraph 1.J. References, Added NPRM.
5. In Paragraph 3.A. Updated General Notes.
6. In Figure 5, Added new View F-F and changed Step 2. PRT and LTP quantity to match locations shown in the Figure and listed in Appendex A, Inspection Worksheet.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 5 of 56
REVISION HISTORY February 06, 2003Original Issue:
May 24, 2007Revision 1:
May 04, 2012Revision 2:
December 07, 2012Revision 3:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 6 of 56 BOEING SERVICE BULLETIN 757-57-0061
Commercial Airplanes 757 Service Bulletin SummaryNumber: 757-57-0061Original Issue: February 06, 2003 Revision 3: December 07, 2012 ATA System: 5710 2810 SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series)
CONCURRENT REQUIREMENTS None.
BACKGROUND Inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied to the outboard corners of the front spar. More inspections found defective examples of the Secondary Fuel Barrier applied along the front spar and the upper panel.
The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure. When the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from fuel leaks or fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener holes or cracks in the structure and pass into the passenger compartment. There are no reports of fuel leaks or fumes in the passenger compartment.
This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front spar and upper panel. The inspections will identify locations where the secondary fuel barrier is not satisfactory. A new layer of secondary fuel barrier will be applied if it is necessary. A satisfactory secondary fuel barrier will keep fuel leaks or fumes out of the pressurized cabin.
Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
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 AffectedNoPublications Affected Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 7 of 56
ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/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 YesSpecial Tooling Required ACTION Get access to the front spar and the top of the Wing Center Section by removal of the seats, floor covers, floor panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If necessary, remove the bulkhead lining for more access.
Examine the specified locations where the Secondary Fuel Barrier is applied. Look for examples of missing, peeled, non-continuous or non-transparent secondary fuel barrier. Make sure the applied thickness of the secondary fuel barrier is between the specified limits. Remove the corrosion inhibitor compound if it is necessary, then clean the area where the new layer of secondary fuel barrier will be applied. Install all the components that were removed for access. Do system tests as necessary.
EFFECTIVITY Airplane Model 757-300; Line numbers 804 thru 964; divided into three groups.
COMPLIANCE Federal Aviation Administration (FAA) Notice of Proposed Rule Making:NPRM 2011-NM-070-AD, is related to this service bulletin.
Boeing recommends the inspection of the Secondary Fuel Barrier at the next regularly scheduled heavy maintenance check. Apply the secondary fuel barrier, if it is necessary, no later than five years after the release of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for 757 airplanes. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER See Paragraph 1.G Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 757-57-0061 STA 90 STA 1040
EXAMINE THE UPPER PANEL AND FRONT
SPAR FOR DEFECTIVE APPLICATION OF SECONDARY FUEL BARRIER.
IF DEFECTIVE, REMOVE AND APPLY A NEW LAYER OF SECONDARY FUEL BARRIER.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BLANK PAGE
Commercial Airplanes 757 Service Bulletin Number: 757-57-0061 Original Issue: February 06, 2003 Revision 3: December 07, 2012 ATA System: 5710 2810 SUBJECT: WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series)
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-24N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 757-300 Airplanes that must complete the whole bulletin-1 757-300 Airplanes that only require inspection of the front spar center section.
-2 757-300 Airplanes previously in Group 1 that could have fuel vapor barrier material applied that was thinned with lacquer thinner.
-3 Group 3 Airplanes that have not incorporated the previous release of service bulletin 757-57-0061.
1 Group 3 Airplanes that have incorporated the previous release of service bulletin 757-57-0061.
2 Airplane Models:
757-300 GroupVariable Number 2NL001 - NL002 1NU701 - NU705 1NU721 - NU723 3NU724 - NU727 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 11 of 56
GroupVariable Number 1NU728 3NU731 - NU732
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason Inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied to the outboard corners of the front spar. More inspections found defective examples of the Secondary Fuel Barrier applied along the front spar and the upper panel.
The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure.
When the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from fuel leaks or fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener holes or cracks in the structure and pass into the passenger compartment. There are no reports of fuel leaks or fumes in the passenger compartment.
This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front spar and upper panel. The inspections will identify locations where the secondary fuel barrier is not satisfactory. A new layer of secondary fuel barrier will be applied if it is necessary. A satisfactory secondary fuel barrier will keep fuel leaks or fumes out of the pressurized cabin.
NOTE: A satisfactory secondary fuel barrier is described in the Accomplishment Instructions.
Boeing Service Related Problem (SRP): 757-SRP-28-0067 is related to this service bulletin.
Revision 1 is sent to add a group of airplanes that may have been delivered with improperly mixed secondary fuel vapor barrier sealant and to provide new thickness measurement inspection limits. This revision includes the correct special tooling requirements for the accomplishment of the service bulletin, and provides clarifications and corrections to inspection points on the Front Spar and Upper Panel.
Revision 2 is sent to reference possibly release an Airworthiness Directive, to revise the Industry Support information, to add Damage Tolerance Information, to remove the title of Part III, and the Group 2 from the title of Part III, IV, and V, to delete "and upper panel" from step 1 of Part VI of the work Instructions and to correct a typographical error from Part VI and Part V.
Revision 3 is sent to change the quantity of locations listed in Figure 5, Sheet 5 of 5, Step 2 in order to match the view shown in Figure 5, sheet 1 of 5 and the Upper Panel (TP) Table in Appendix A.
D. Description Get access to the front spar and the top of the Wing Center Section by removal of the seats, floor covers, floor panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If necessary, remove the bulkhead lining for more access.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2003 757-57-0061Revision 3: December 07, 2012 12 of 56 BOEING SERVICE BULLETIN 757-57-0061