Commercial

Airplane

Group

757

Service Bulletin

SPECIAL ATTENTION

Number: 757-25-0219 Summary Date: August 3, 2000

ATA System: 2565

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Bumper Assembly

And Placard Installation

THE BOEING COMMERCIAL AIRPLANE GROUP

RECOMMENDS THAT EACH OPERATOR

EXAMINE THIS SERVICE BULLETIN

IMMEDIATELY.

CONCURRENT REQUIREMENTS

None

BACKGROUND

The Federal Aviation Administration (FAA) has

issued an Airworthiness Directive (AD) which

requires incorporation of Service Bulletin

757-25-0200, Revision 0. This service bulletin is

equivalent to Service Bulletin 757-25-0200, Revision

0. This service bulletin applies to 757-300 airplanes.

Service Bulletin 757-25-0200, Revision 1, applies to

757-200 airplanes.

This change will prevent off-wing slide loss while in

flight due to the slide compartment door opening.

Five operators have reported loss of an off-wing

slide while in flight. In each of these incidents, the

slide compartment door opened, the slide carrier

rotated out and the slide departed from the aircraft.

This may result in tears and punctures in the wing

flaps and airplane skin.

This service bulletin gives instructions to add a

bumper to the bottom of the off-wing escape slide

carrier. The bumper forces the carrier to stay in the

fully stowed position when the off-wing slide

compartment door is faired. In the fully stowed

position the locking pin for the slide carrier will line

up with the hole in the carrier lock fitting. This

allows the carrier to be locked without the

opportunity for the locking pin to jam.

As part of a service bulletin validation program, this

change was completed on airplane NT795 by

Service Bulletin 757-25-0200 (Rapid Revision

RR92025-22V) before the initial release of Service

Bulletin 757-25-0200.

Boeing Service Related Problem (SRP)

757-SRP-25-0140 is related to this service bulletin.

ACTION (PRR 54530-209)

On the left and right off-wing escape systems.

Install a bumper assembly on the off-wing slide

carrier. Install a witness mark placard on the lip of

the maintenance access door opening. Install a new

instruction placard on the back of the maintenance

access door.

EFFECTIVITY

Operator Airplanes

CDF NU701, NU721 - NU723

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness

Directive 99-17-20, Amendment 39-11266 is related

to this service bulletin.

Boeing recommends that the instructions in this

service bulletin be done as soon as manpower and

materials are available.

Airplanes changed as shown in Service Bulletin

757-25-0200, Revision 0, do not require additional

work.

757-25-0219

Summary Page 1 of 2
BOEING SERVICE BULLETIN 757-25-0219

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the

configuration changes given in this service bulletin.

MANPOWER

Total Man-Hours for

Each Airplane

Elapsed Time

(Hours)

3.25 1.75

MATERIAL INFORMATION

Boeing Supplied Kits

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

Availability.

INSTALL BUMPER ASSEMBLY

MAINTENANCE

ACCESS DOOR

INSTALL A WITNESS

MARK PLACARD

REPLACE INSTRUCTION

PLACARD

OFF-WING ESCAPE

SYSTEM SLIDE PACK

SLIDE COMPARTMENT DOOR

FWD

S60815

August 3, 2000 757-25-0219

Summary Page 2 of 2
Commercial

Airplane

Group

757

Service Bulletin

SPECIAL ATTENTION

Number: 757-25-0219

Date: August 3, 2000

ATA System: 2565

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Bumper Assembly

And Placard Installation

THE BOEING COMMERCIAL AIRPLANE GROUP 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. An equivalent change is on subsequent

production airplanes. Refer to PRR54530-209 for data about this change.

Airplane Models:

757-300

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, AND VARIABLE NUMBER

CONDOR (CDF)

NU701 NU721-NU723

IDENTIFICATION BY VARIABLE NUMBER

NU701 NU721-NU723

2. Spares

None

August 3, 2000 757-25-0219

Page 1 of 19
BOEING SERVICE BULLETIN 757-25-0219

B. Concurrent Requirements

None

C. Reason

The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires

incorporation of Service Bulletin 757-25-0200, Revision 0. This service bulletin is equivalent to

Service Bulletin 757-25-0200, Revision 0. This service bulletin applies to 757-300 airplanes. Service

Bulletin 757-25-0200, Revision 1, applies to 757-200 airplanes.

This change will prevent off-wing slide loss while in flight due to the slide compartment door opening.

Five operators have reported loss of an off-wing slide while in flight. In each of these incidents, the

slide compartment door opened, the slide carrier rotated out and the slide departed from the aircraft.

This may result in tears and punctures in the wing flaps and airplane skin.

This service bulletin gives instructions to add a bumper to the bottom of the off-wing escape slide

carrier. The bumper forces the carrier to stay in the fully stowed position when the off-wing slide

compartment door is faired. In the fully stowed position the locking pin for the slide carrier will line up

with the hole in the carrier lock fitting. This allows the carrier to be locked without the opportunity for

the locking pin to jam.

As part of a service bulletin validation program, this change was completed on airplane NT795 by

Service Bulletin 757-25-0200 (Rapid Revision RR92025-22V) before the initial release of Service

Bulletin 757-25-0200.

Boeing Service Related Problem (SRP) 757-SRP-25-0140 is related to this service bulletin.

D. Description

On the left and right off-wing escape systems: A bumper assembly is installed on the off-wing slide

carrier. A witness mark placard is installed on the lip of the maintenance access door opening. A

new instruction placard is installed on the back of the maintenance access door.

An evaluation form is attached to this service bulletin. Please use this form to tell us what you think

of the quality of this service bulletin.

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive 99-17-20, Amendment 39-11266, is

related to this service bulletin.

Boeing recommends that the instructions in this service bulletin be done as soon as manpower and

materials are available.

Airplanes changed as shown in Service Bulletin 757-25-0200, Revision 0, do not require additional

work.

August 3, 2000 757-25-0219

2
BOEING SERVICE BULLETIN 757-25-0219

F. Approval

NOTE: Joint Airworthiness Requirements (JAR) compliance status may be found in the Service

Bulletin Index, Section 1.

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes

specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and

are FAA approved. The changes specified in this service bulletin also comply with the applicable

Joint Airworthiness Requirements (JAR) and are FAA approved as delegated by the Joint Aviation

Authorities (JAA). This service bulletin and the FAA approval were based on the airplane in its

original Boeing delivery configuration or as modified by other FAA approved Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also

affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory

agency approval before incorporating this service bulletin.

This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle

Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service

bulletin as an alternative method of compliance to the requirements of paragraph a.2. of AD 99-17-20

All provisions of AD 99-17-20 that are not specifically referenced in the above sentence remain fully

applicable and must be complied with.

August 3, 2000 757-25-0219

3
BOEING SERVICE BULLETIN 757-25-0219

G. Manpower

The table below shows an estimate of the man-hours necessary to do this change for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

man-hour data if necessary. The estimate does not include lost time. These are some examples of

lost time:

- Time to adjust to the workplace

- Time to schedule the work

- Time to examine the work

- Time to find the tools.

Task Number of Persons Man-Hours Elapsed Time (Hours)

Prepare 1 0.25 0.25

Open Access 2 0.50 0.25

Change 2 1.50 0.75

Close Access 2 0.50 0.25

Test 2 0.50 0.25

TOTAL FOR EACH AIRPLANE 3.25 1.75

H. Weight and Balance Changes

None

I. Electrical Load Data

Not applicable

August 3, 2000 757-25-0219

4
BOEING SERVICE BULLETIN 757-25-0219

J. References

1. Existing Data:

a. Engineering Change Memo PRR 54530-209

b. Service Related Problem (SRP) 757-SRP-25-0140

c. 757 Maintenance Manual (AMM) Subjects 25-65-00, 25-65-09, 52-71-00

d. Boeing Standard Overhaul Practices Manual 20-50-05

e. Boeing Service Bulletin 757-25-0200

f. FAA Airworthiness Directive 99-17-20, Amendment 39-11266

2. Data supplied with this service bulletin:

None

3. Installation Drawings:

None

K. Publications Changed

Publication Chapter-Section

757 Maintenance Manual........................ 11-21, 25-65

Component Maintenance Manual.................. 25-65

Overhaul Manual............................... 25-65

L. Interchangeability and Intermixability

Refer to Paragraph 2.E., Existing Parts Accountability, for interchangeability and intermixability

information.

August 3, 2000 757-25-0219

5
BOEING SERVICE BULLETIN 757-25-0219

BLANK PAGE

August 3, 2000 757-25-0219

6
BOEING SERVICE BULLETIN 757-25-0219

2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown

below. Kit availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date

Boeing gets the purchase order.

Kit Number Name

ROLT

(weeks)

Unit Price thru

Apr 30/99

012N8980-1 Top Kit 36 $ 457.00

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service

bulletin.

C. Parts Necessary For Each Airplane

1. Kits:

To get the parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: One top kit is necessary for each airplane.

012N8980 TOP KIT - BUMPER ASSEMBLY AND PLACARD INSTALLATION

-1

QTY Part Number Name

- 012N8980-1 Top Kit

2 416N2826-87 Bumper Assembly (Left and Right Side)

1 BAC27NPA1556 Instruction Placard (Left Side)

1 BAC27NPA1557 Instruction Placard (Right Side)

1 BAC29PPS37740 Witness Mark Placard (Left Side)

1 BAC29PPS37741 Witness Mark Placard (Right Side)

8 BACR15FR5E3R (a) Rivet

(a) Quantity shown in excess of installation requirement.

2. Parts and Materials Supplied by the Operator:

QTY Part Number {Specification} Name

1 Ounce BMS 10-11, Type I Primer

D. Parts Necessary to Change Spares

None

August 3, 2000 757-25-0219

7
BOEING SERVICE BULLETIN 757-25-0219

E. Existing Parts Accountability

None

F. Special Tooling - Price and Availability

None

G. Special Tooling Necessary to do This Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But,

maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be

necessary. Examine operator tool supply to make sure all necessary tools are available.

August 3, 2000 757-25-0219

8
BOEING SERVICE BULLETIN 757-25-0219

3. ACCOMPLISHMENT INSTRUCTIONS

GENERAL NOTES

1. The paragraphs identified with a letter give the general work instructions and the necessary tests.

The instructions identified with numbers on the figures give the recommended sequence of steps.

2. The accomplishment instructions and the steps in the figures are given for one side of the

airplane; i.e., the left off-wing escape system. The accomplishment instructions and the steps in

the figures must be repeated for the other side to complete the airplane change.

3. Unless shown differently, these dimensions and tolerances are used:

- Linear dimensions are in inches

- Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03

inch

- Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

- Angular tolerance is plus or minus 2 degrees

- Hole dimensions for standard solid rivets are given in 757 Structural Repair Manual, Chapter 51

- Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, Chapter 51.

4. Alternative fasteners are given in 757 Structural Repair Manual, Chapter 51.

5. Obey all of the warnings and cautions given in the specified manual sections.

WORK INSTRUCTIONS

A. Disarm the off-wing escape system. Refer to 757 Maintenance Manual (AMM) Subject 25-65-00.

B. Open these circuit breakers, and attach DO-NOT-CLOSE identifiers:

Location

(Panel/Position) Name Circuit Breaker

P6 / C005 EMER ESCAPE - L C4343

P6 / C006 EMER ESCAPE - R C4344

P 11- 1 / C001 EMER ESCAPE TEST C4320

P 11- 4 / R033 DOOR IND C4144

C. Open the off-wing escape slide compartment door. Refer to 757 Maintenance Manual (AMM)

Subject 25-65-09.

D. Install bumper assembly. Refer to Figure 1.

E. Verify bumper assembly functionality. Refer to Figure 2.

F. Close the off-wing escape slide compartment door. Refer to 757 Maintenance Manual (AMM)

Subject 25-65-09.

G. Install witness mark placard. Refer to Figure 3.

H. Install instruction placard. Refer to Figure 4.

I. Remove the DO-NOT-CLOSE identifiers, and close the circuit breakers that were opened in

instruction B.

August 3, 2000 757-25-0219

9
BOEING SERVICE BULLETIN 757-25-0219

J. Do a system test on the off-wing escape slide compartment doors. Refer to 757 Maintenance

Manual (AMM) Subject 52-71-00-735-053.

K. Arm the off-wing escape system. Refer to 757 Maintenance Manual (AMM) Subject 25-65-00.

L. Put the airplane back in a serviceable condition.

August 3, 2000 757-25-0219

10
BOEING SERVICE BULLETIN 757-25-0219

FIGURE TABLE OF CONTENTS

Title Page

FIGURE 1. BUMPER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FIGURE 2. VERIFY BUMPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

FIGURE 3. WITNESS MARK PLACARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . 16

FIGURE 4. INSTRUCTION PLACARD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 18

August 3, 2000 757-25-0219

11
BOEING SERVICE BULLETIN 757-25-0219

2 3

A-A

4

1

SUPPORT PAD

RIB

SYSTEM SLIDE PACK

OFF-WING ESCAPE

CARRIER

MAINTENANCE

ACCESS DOOR

SLIDE COMPARTMENT DOOR

LOWER PLATE

FWD

A A

S60818

FIGURE 1. BUMPER ASSEMBLY INSTALLATION

August 3, 2000 SHEET 1 OF 2 757-25-0219

12
BOEING SERVICE BULLETIN 757-25-0219

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the left side off-wing escape

slide system. The right side off-wing escape slide system is opposite and has an equal number of parts.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove /

Discard

Rivet -- 2 On the carrier assembly.

2 Apply Primer (BMS

10-11) Type I

-- -- Exposed countersink on the

carrier assembly. Refer to

Boeing Standard Overhaul

Practices Manual 20-41-02.

NOTE: Primer need not be cured prior to completion of the remaining steps.

3 Mark / Drill Bumper Assembly 416N2826-87 2 0.156 diameter. To match the

holes drilled out on carrier

assembly 416N2821-31.

4 Install Bumper Assembly 416N2826-87 1 Position bumper assembly

against pad, rib, and lower Rivet BACR15FR5E3R 2 plate details before riveting.

FIGURE 1. BUMPER ASSEMBLY INSTALLATION

August 3, 2000 SHEET 2 OF 2 757-25-0219

13
BOEING SERVICE BULLETIN 757-25-0219

INBD

FWD

A

1 2

1 2

SEE A

CONTAINER SHROUD

ACCESS DOOR

S64513

FIGURE 2. VERIFY BUMPER ASSEMBLY

August 3, 2000 SHEET 1 OF 2 757-25-0219

14
BOEING SERVICE BULLETIN 757-25-0219

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the left side off-wing escape

slide system. The right side off-wing escape slide system is opposite and has an equal number of parts.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove /

Keep

Bolt BACB30NN3K7 18 --

Access Door 140N0811-3 (Left

Side)

1 140N0811-4 (Right Side).

NOTE: Rig Bumper Assembly 140N2826-87. See Verify bumper functionality.

2 Install /

Kept

Access Door 140N0811-3 (Left

Side)

1 140N0811-4 (Right Side).

Bolt BACB30NN3K7 18 --

Verify bumper forces carrier into fully stowed position.

I. This is a two person operation and must be done for both the left and right side escape slide systems.

This procedure must be completed with the 140N0811 Access Door removed from the 140N0810

Container Assembly. A container assembly is located in the upper aft outboard corner of the main

gear wheel well on both the left and right sides.

(a) Person 1 - Locate person 1 on trailing edge by the off-wing escape slide system to get access to

the slide compartment door and the escape slide system maintenance access door.

(b) Person 2 - Locate person 2 in the wheel well at the 140N0810 Container Assembly.

II. Person 1 - Can slide compartment door be closed and faired with yellow crank handle in unlocked (full

up) position?

(a) If yes - Hold slide compartment door in faired position for Steps III. and IV.

(b) If no - Remove one NAS1149E0363 washer from each screw on bumper assembly. Return to

Step II.

III. Person 2 - Push carrier outboard until contact is made with slide compartment door and bumper.

Hold this position while performing Step IV.

IV. Person 1 - Attempt to lock system by releasing trigger and moving yellow crank handle to locked

position. Does yellow crank handle move normally to the locked position?

(a) If no and yellow crank handle jams before it reaches the locked position - Add one NAS1149E0363

washer to each screw on bumper assembly. Return to Step III.

(b) If no and moving the yellow crank handle to the locked position requires higher than normal forces

on the crank handle and the bottom of the slide compartment door deflects outward, 0.01 inches to

0.18 inches further than the previously faired condition - Remove one NAS1149E0363 washer from

each screw on bumper assembly. Return to Step IV.

(c) If yes - Step IV. Complete. Rigging of bumper complete.

FIGURE 2. VERIFY BUMPER ASSEMBLY

August 3, 2000 SHEET 2 OF 2 757-25-0219

15
BOEING SERVICE BULLETIN 757-25-0219

SYSTEM SLIDE PACK

OFF-WING ESCAPE

SEE A

MAINTENANCE

ACCESS DOOR

SLIDE COMPARTMENT DOOR

FWD

S60820

FIGURE 3. WITNESS MARK PLACARD INSTALLATION

August 3, 2000 SHEET 1 OF 2 757-25-0219

16
BOEING SERVICE BULLETIN 757-25-0219

1

A

YELLOW BAND FWD

ACTUATOR CRANK HANDLE

S60824

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the left side off-wing escape

slide system. The right side off-wing escape slide system is opposite and has an equal number of parts.

STEP TASK NAME PART NUMBER QTY NOTE

1 Install Witness Mark Placard BAC29PPS37740 1 Align placard with inner

edge of access door cutout.

Align yellow band on

placard with actuator crank

handle in the locked

position. Refer to Boeing

Standard Overhaul

Practices Manual 20-50-05.

FIGURE 3. WITNESS MARK PLACARD INSTALLATION

August 3, 2000 SHEET 2 OF 2 757-25-0219

17
BOEING SERVICE BULLETIN 757-25-0219

1 2 PLACARD

OFF-WING ESCAPE

SYSTEM SLIDE PACK

MAINTENANCE

ACCESS DOOR

SLIDE COMPARTMENT DOOR

FWD

1.00

1.55

S60825

FIGURE 4. INSTRUCTION PLACARD REPLACEMENT

August 3, 2000 SHEET 1 OF 2 757-25-0219

18
BOEING SERVICE BULLETIN 757-25-0219

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the left side off-wing escape

slide system. The right side off-wing escape slide system is opposite and has an equal number of parts.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove /

Discard

Instruction Placard BAC27NPA1358 1 --

2 Install Instruction Placard BAC27NPA1556 1 Refer to Boeing Standard

Overhaul Practices

Manual 20-50-05.

FIGURE 4. INSTRUCTION PLACARD REPLACEMENT

August 3, 2000 SHEET 2 OF 2 757-25-0219

19

Commercial

Airplane

Group

757

Service Bulletin

Number: 757-25-0219 Evaluation Form

Date: August 3, 2000

ATA System: 2565

Prepared By: Katherine Hunter

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Bumper Assembly

And Placard Installation

Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data

that you give us to improve the quality of our service bulletins.

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these

changes, please use a Publication Change Request (PCR) form.

Please give us this data:

(If necessary, please use the other side. Thank you for the time you used to give us your comments.)

OPERATOR: TODAY'S DATE:

PREPARED BY: TITLE:

ORGANIZATION: TELEX CODE:

TELEPHONE NUMBER: BASE:

Please rate the quality of this service bulletin: (good) 4321 (poor)

Please rate the quality of the illustrations: (good) 4321 (poor)

Will you do the change given by this service bulletin? Yes No If not, please explain:

Is this service bulletin easy to understand? Yes No If not, please explain:

Is this service bulletin easy to use? Yes No If not, please explain:

Are the Planning Information, Material Information, and

Accomplishment Instructions accurate? Yes No If not, please explain:

Is the Manpower estimate accurate? Yes No If not, please explain:

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form

directly to this address:

Manager

Service Bulletin Engineering

Boeing Commercial Airplane Group

P.O. Box 3707, Mail Stop 2H-37

Seattle, WA 98124-2207