### 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

FWDS60815

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



### 3 2 

## A-A 4

1 SUPPORT PAD RIB SYSTEM SLIDE PACK OFF-WING ESCAPE

CARRIER MAINTENANCE ACCESS DOOR SLIDE COMPARTMENT DOOR

LOWER PLATE FWD A AS60818

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 plate details before riveting. Rivet BACR15FR5E3R 2

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 2 1
2 1 A SEE

CONTAINER SHROUD
ACCESS DOORS64513

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
-- Verifybumperforcescarrierintofullystowedposition. 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

A SEE MAINTENANCE ACCESS DOOR SLIDE COMPARTMENT DOOR

FWDS60820

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 FWD YELLOW BAND ACTUATOR CRANK HANDLES60824The 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



### 2 1 PLACARD OFF-WING ESCAPE SYSTEM SLIDE PACK

MAINTENANCE ACCESS DOOR SLIDE COMPARTMENT DOOR

FWD 1.00

1.55S60825

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