Commercial

Airplane

Group

757

Service Bulletin

Number: 757-25-0182 Revision Transmittal Sheet Date: October 10, 1996

Revision 2: January 11, 2001

ATA System: 2565

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Modification Of The

Door Latch System And The Sensor Installation

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work may be necessary on airplanes retrofitted per the initial release or Revision 1 of this service

bulletin.

REASON FOR REVISION

This revision:

- changes the identification of Line Number 727 to 726 on Summary page, removes NE325 from Effectivity,

and adds NE323 to Effectivity.

- divides the Accomplishment Instructions into two parts, Part I and II. Part l modifies airplanes that have

never been retrofitted by this service bulletin. Part ll modifies airplanes that have been retrofitted by earlier

releases of this bulletin.

- Part I of the Accomplishment Instructions modifies the compartment door latch assembly and relocates the

door lock sensing mechanism from the aft end of the door to the forward end of door.

- Part II of the Accomplishment Instructions modifies airplanes that have previously incorporated earlier

versions of this bulletin.

- identifies the subset of airplanes that must open circuit breaker C4435.

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

related to this service bulletin

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the

Effectivity paragraph for changes.

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

Initial Release: October 10, 1996

Revision 1: June 12, 1997

Revision 2: January 11, 2001

757-25-0182

Revision Transmittal Page 1 of 1

Commercial

Airplane

Group

757

Service Bulletin

Number: 757-25-0182 Summary Date: October 10, 1996

Revision 2: January 11, 2001

ATA System: 2565

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Modification Of The

Door Latch System And The Sensor Installation

CONCURRENT REQUIREMENTS

None

BACKGROUND

This service bulletin provides instructions to improve

the door sensing system that identifies whether the

off-wing escape slide compartment door is positively

locked, or still open after the crank handle has been

moved to the locked position.

Since June 1993, four operators and Boeing have

reported a total of six losses of the off-wing escape

slides while airplanes were in flight. These slides

are known to have caused damage to the fuselage

aft of the slide compartment and to the inboard

flaps. The escape slide in each incident, was

damaged beyond repair and had to be replaced.

Boeing analysis of the off-wing slide losses indicates

that sometimes the forward edge of the slide

compartment door does not latch positively

because: (1) it is difficult to visually ensure that the

slide compartment door is positively locked; (2) the

aft location of the door sensor proximity switch on

the compartment door does not ensure that the

forward end of the door is locked; (3) incorrect

installation of the lockbase retainer on the door latch

tube may prevent positive locking of the

compartment door.

This service bulletin provides instructions to: (1)

replace the lockbase retainer and the bearing in the

door locking mechanism with more reliable parts; (2)

move the door sensor proximity switch to the

forward location on the compartment door, and

install a new target, for sensing more positive

indication that the compartment door is securely

locked.

As part of a service bulletin validation program, this

change was completed on airplane NE325 before

the initial release of the service bulletin.

Several operators have reported clearance and

alignment problems with the target and door sensor

proximity switch installations with airplanes

retrofitted per prior releases of this service bulletin.

Investigation of these earlier modification

installations has determined that installation of the

door sensor proximity switch, could interfere with the

door latch tube. This interference can damage the

door sensor proximity switch.

Boeing Service Related Problem (SRP) 25-0079 is

related to this service bulletin.

ACTION (PRR 54530-146)

On airplanes that have never been retrofitted, a new

bearing and new lockbase retainer are installed on

the compartment door latching mechanism. The

door sensor proximity switch and the door sensor

target are relocated from the aft end of the

compartment door to the forward end of the door.

The off-wing escape slide pneumatic deployment

system test, and system test of the slide

compartment door will complete this modification.

On airplanes that have been retrofitted by the initial

release of this service bulletin, or Revision 1,

additional work may be required. A simple test that

verifies that the compartment door sensor, as

retrofitted, provides an accurate indication of the

door lock condition , will preclude any further work.

If the test indicates that the compartment door is not

locking positively, then a new target must replace

the installed target and the switch remounted on the

new bracket, per this revision R2.

EFFECTIVITY

All 757 airplanes with off-wing escape slide systems

through Line Number 726, except 715 and 716.

757-25-0182

Summary Page 1 of 2
BOEING SERVICE BULLETIN 757-25-0182

COMPLIANCE

Boeing recommends that the change in this service

bulletin be accomplished during the next scheduled

maintenance check.

Federal Aviation Administration (FAA) Airworthiness

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

to this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the

configuration changes given in this service bulletin.

MANPOWER

See Paragraph I.G

MATERIAL INFORMATION

Operator Supplied Parts

OVERWING EMERGENCY

EXIT HATCH

SWITCH FROM AFT DOOR LOCATION

TO FORWARD DOOR LOCATION

RELOCATE DOOR SENSOR PROXIMITY

FROM AFT DOOR LOCATION TO

FORWARD DOOR LOCATION

RELOCATE DOOR SENSOR TARGET

NEW IMPROVED PARTS

RETAINER AND BEARING WITH

REPLACE EXISTING LOCKBASE

CARRIER

DOOR LATCH TUBE

OFF-WING ESCAPE

SLIDE PACK

COMPARTMENT DOOR

OFF-WING ESCAPE SLIDE

FWD

R80931

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 Summary Page 2 of 2
Commercial

Airplane

Group

757

Service Bulletin

Number: 757-25-0182

Date: October 10, 1996

Revision 2: January 11, 2001

ATA System: 2565

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Modification Of The

Door Latch System And The Sensor Installation

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.

Airplane Models:

757-200 757-200CB

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AEROMEXICO (AMX)

NE301

AMERICAN AIRLINES (AAL)

ND011-ND059 ND111-ND113 ND161-ND166 ND168-ND199

CONDOR (CDF)

NE162-NE177

CONTINENTAL AIRLINES (CAL)

ND301-ND317

DELTA AIR LINES (DAL)

NA501-NA586 NB001-NB004

EL AL ISRAEL AIRLINES (ELA)

ND001-ND007

ETHIOPIAN AIRLINES (ETH)

NE201-NE204

FAR EASTERN AIR TRANSPORT (FAT)

NE3020

IBERIA AIRLINES (IBE)

ND241-ND245 ND248

ICELANDAIR (ICE)

ND201-ND203

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 Page 1 of 51
BOEING SERVICE BULLETIN 757-25-0182

MEXICANA AIRLINES (CMA)

NE161

NATIONAL AIRLINES (NAB)

ND246-ND247

NORTHWEST AIRLINES (NWA)

NE311-NE323

ROYAL NEPAL AIRLINES (RNA)

ND891 ND895

SHANGHAI AIRLINES (SHA)

NE001-NE007

UNITED AIRLINES (UAL)

NE011-NE088 NE091-NE093 NE141-NE150

XIAMEN AIRLINES (XIA)

ND221-ND225

IDENTIFICATION BY VARIABLE NUMBER

NA501-NA586 NB001-NB004 ND001-ND007 ND011-ND059 ND111-ND113 ND161-ND199

ND201-ND203 ND221-ND225 ND241-ND248 ND301-ND317 ND891 ND895

NE001-NE007 NE011-NE088 NE091-NE093 NE141-NE150 NE161-NE177 NE201-NE204

NE301-NE302 NE311-NE323

2. Spares

Examine your spares supply for the parts identified in Paragraph 2.E., Existing Parts

Accountability. If any parts are found, refer to Paragraph 2.E., Existing Parts Accountability, for

the recommended use.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 2
BOEING SERVICE BULLETIN 757-25-0182

B. Concurrent Requirements

None

C. Reason

This service bulletin provides instructions to improve the door sensing system that identifies whether

the off-wing escape slide compartment door is positively locked, or still open after the crank handle

has been moved to the locked position.

Since June 1993, four operators and Boeing have reported a total of six losses of the off-wing escape

slides while airplanes were in flight. These slides are known to have caused damage to the fuselage

aft of the slide compartment and to the inboard flaps. The escape slide in each incident, was

damaged beyond repair and had to be replaced.

Boeing analysis of the off-wing slide losses indicates that sometimes the forward edge of the slide

compartment door does not latch positively because: (1) it is difficult to visually ensure that the slide

compartment door is positively locked; (2) the aft location of the door sensor proximity switch on the

compartment door does not ensure that the forward end of the door is locked; (3) incorrect installation

of the lockbase retainer on the door latch tube may prevent positive locking of the compartment door.

This service bulletin provides instructions to: (1) replace the lockbase retainer and the bearing in the

door locking mechanism with more reliable parts; (2) move the door sensor proximity switch to the

forward location on the compartment door, and install a new target for sensing more positive

indication that the compartment door is securely locked.

Several operators have reported clearance and alignment problems with the target and door sensor

proximity switch installations with airplanes retrofitted per prior releases of this service bulletin.

Investigation of these earlier modification installations has determined that installation of the door

sensor proximity switch, could interfere with the door latch tube. This interference can damage the

door sensor proximity switch.

Before release of Revision 2 of this service bulletin, the Top Kit 012N8928-1 identified in previous

releases of this service bulletin, was inadvertently superseded by Top Kit 012N8928-51. This service

bulletin provides instructions and parts that replace the target, bracket and parts provided in Top Kits

012N8928-1 and -51, with new parts. When these new parts are installed per this Revision 2, the

retrofitted configuration will be the same or equivalent to the production configuration.

Revision 1 added airplane ND895 to the service bulletin effectivity.

This revision:

- changes the identification of Line Number 727 to 726 on Summary page, removes NE325 from

Effectivity, and adds NE323 to Effectivity.

- divides the Accomplishment Instructions into two parts, Part I and II. Part l modifies airplanes that

have never been retrofitted by this service bulletin. Part ll modifies airplanes that have been

retrofitted by earlier releases of this bulletin.

- Part I of the Accomplishment Instructions modifies the compartment door latch assembly and

relocates the door lock sensing mechanism from the aft end of the door to the forward end of door.

- Part II of the Accomplishment Instructions modifies airplanes that have previously incorporated

earlier versions of this bulletin.

- identifies the subset of airplanes that must open circuit breaker C4435.

- identifies Federal Aviation Administration (FAA) Airworthiness Directive 99-17-20, Amendment

39-11266 is related to this service bulletin

As part of a service bulletin validation program, this change was completed on airplane NE325 before

the initial release of this service bulletin.

Boeing Service Related Problem (SRP) 25-0079 is related to this service bulletin.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 3
BOEING SERVICE BULLETIN 757-25-0182

D. Description

The off-wing escape slide compartment doors on each side of the airplane are modified.

On airplanes that have never been retrofitted, a new bearing and new lockbase retainer are installed

on the compartment door latching mechanism. The door sensor proximity switch and the door sensor

target are relocated from the aft end of the compartment door to the forward end of the door. The

off-wing escape slide pneumatic deployment system test, and system test of the slide compartment

door will complete this modification.

On airplanes that have been retrofitted by the initial release of this service bulletin, or Revision 1,

additional work may be required. A simple test that verifies that the compartment door sensor, as

retrofitted, provides an accurate indication of the door lock condition, will preclude any further work. If

the test indicates that the compartment door is not locking positively, then a new target must replace

the installed target and the switch remounted on the new bracket, per this revision R2.

This service bulletin contains actions that are also in service bulletin 757-25-0200,

"EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Bumper Assembly and

Placard Installation". To reduce overall airplane down time, operators may desire to schedule

modifications to both service bulletins at the same time.

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

Boeing recommends that the change given in this service bulletin be done during the next scheduled

maintenance time.

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

related to this service bulletin.

F. Approval

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. 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 approved the modification defined in this service bulletin as an alternative

method of compliance to the requirements of paragraph (a) 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.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 4
BOEING SERVICE BULLETIN 757-25-0182

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 cure the materials

- Time to make the parts

- Time to find the tools.

TABLE I - PART I

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

Modify Door Latch Tube

Mechanism, Relocate

Door Sensor Proximity

Switch and Door

SensorTarget

2 16 8

Functional Test 2 4 2

TOTAL FOR EACH SIDE OF THE AIRPLANE

TO ACCOMPLISH PART I.

20 10

TOTAL FOR EACH AIRPLANE TO

ACCOMPLISH PART I.

40 20

TABLE II - PART II

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

Install Door Sensor

Proximity Switch on new

Bracket, and Install new

Door Sensor Target

2 4 2

Door Open Test 2 1 0.5

TOTAL FOR EACH SIDE OF THE AIRPLANE

TO ACCOMPLISH PART II

5 2.5

TOTAL FOR EACH AIRPLANE TO

ACCOMPLISH PART II

10 5

H. Weight and Balance Changes

None

I. Electrical Load Data

Not changed

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 5
BOEING SERVICE BULLETIN 757-25-0182

J. References

1. Existing Data:

a. Engineering Change Memo PRR 54530-146

b. Service Related Problem (SRP) 25-0079

c. 757 Maintenance Manual (AMM) Subject 20-30-03, 25-65-00, 25-65-07, 25-65-09, 52-71-00

d. 757 Structural Repair Manual (SRM) Subject 51-20-01, 51-30-01, 51-30-03, 51-40-01

e. Boeing Standard Overhaul Practices Manual (BSOPM) 20-30-03, 20-41-02, 20-42-05,

20-42-10, 20-43-03, 20-50-03, 20-50-05, 20-50-10, 20-50-12

f. Boeing Service Bulletin 757-25-0200, "EQUIPMENT/FURNISHINGS - Emergency - Off-Wing

Escape System - Bumper Assembly and Placard Installation"

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

2. Data supplied with this service bulletin:

None

3. Installation Drawings:

Drawing Number Title

284N1893 Kit - Sensor Installation - Off-Wing Escape Slide Door

Unlatched

284N4148 Sensor Installation - Escape Slide Door Unlatched, Off-Wing

416N2720 Door Latch Installation - Off-Wing Escape Slide System

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Changed

Publication Chapter-Section

757 Maintenance Manual 52-71

757 Wiring Diagram Manual 52-71-11, 52-71-21

757 Illustrated Parts Catalog 25-65, 52-71

L. Interchangeability and Intermixability of Parts

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

information.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 6
BOEING SERVICE BULLETIN 757-25-0182

2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in the kits in Paragraph 2.C., Parts Necessary

For Each Airplane. As an alternative, operators can purchase the kit from Boeing Spares. The

Boeing price data shown below is given for planning purposes. Supply data can be given if

requested.

Kit Number Name

Unit Price thru

April 30,2001

012N8928-1 Top Kit No Longer Active

012N8928-2 Subkit No Longer Active

012N8928-3 Subkit No Longer Active

012N8928-4 Subkit No Longer Active

012N8928-51 * Top Kit No Longer Active

012N8928-53 Subkit No Longer Active

012N8928-54 Subkit No Longer Active

012N8928-55 * Supplemental Top Kit No Longer Active

012N8928-97 Top Kit $ 2,786.00

012N8928-2 Subkit $ 1,289.00

012N8928-98 Subkit $ 767.00

012N8928-99 Subkit $ 730.00

012N8928-100 Supplemental Top Kit $ 1,036.00

* Top Kit 012N8928-51 and Supplemental Kit 012N8928-55 were

released prior to release of Revision 2 of this service bulletin. Operators

who have procured these kits should combine the parts in these kits with

parts in Supplemental Kit 012N8928-100 to create a kit equivalent to

Top Kit 012N8928-97.

The kits are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States

dollars. Terms: Net 30 days.

Send purchase orders and letters about the supply data to the Director of Spares and refer to this

service bulletin number.

B. Industry Support Information

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

bulletin. However, the 012N8928-100 Supplemental Top Kit will be supplied at no-charge to

operators who have previously purchased the 012N8928-1 or -51 Top Kits.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 7
BOEING SERVICE BULLETIN 757-25-0182

C. Parts Necessary For Each Airplane

1. Kits:

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the

Operator, are necessary for each airplane.

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

012N8928 TOP KIT - MODIFICATION OF DOOR LATCH SYSTEM AND SENSOR

INSTALLATION

-100 -99 -98 -97

Quantity Part Number Name

. . . - 012N8928-97 Top Kit - Modification of Door Latch System and

Sensor Installation

. . . 1 012N8928-2 Subkit - Modification of Door Latch System

. . - 1 012N8928-98 (a) Subkit - Movement of Sensor Proximity Switch

. - . 1 012N8928-99 (a) Subkit - Movement of Sensor Target

- . . . 012N8928-100 (a) Supplemental Top Kit

1 . 1 . 284N1085-19 Bracket Assembly, Left Side

1 . 1 . 284N1085-20 Bracket Assembly, Right Side

1 1 . . 284N1085-27 Target, Left Side

1 1 . . 284N1085-28 Target, Right Side

4 . 4 . 284N1641-4 Shim

. . 8 . BACB30MY5K3X Bolt, Hi-Lok, 1/64 OS

5 - 5 . BACB30NX6K3X

(Optional:

BACB30MY6K3X)

Bolt, Hi-Lok, 1/64 OS

. 5 . . BACB30NY6K4 Bolt, Hi-Lok

. 5 . . BACB30NY6K5 Bolt, Hi-Lok

. 5 . . BACB30NY6K6 Bolt, Hi-Lok

. . 8 . BACC30M5 Collar

5 15 5 . BACC30X6S Collar

(Optional BACC30M6) Collar (These collars are only used when optional

Bolt BACB30MY6K3X is used)

. 3 . . BACF3F003J017NN Filler

. 3 . . BACF3H07GK013HG Radius Filler

. . 2 . BACG20AF2C1J Grommet

. . 3 . BACR15BA5D8 Rivet

. . 10 . BACR15BB6D6 Rivet

. . 6 . BACR15BA6D8 Rivet

- - 4 BACR15ET6D8 Rivet

. . 1 . BAC27NEX1832 Aluminum Foil Marker, Left Side

. . 1 . BAC27NEX1833 Aluminum Foil Marker, Right Side

. . 5 . NAS1801-3-7 Screw

(a) The kit has more parts than are necessary for installation. Discard parts that are not used or keep

the parts for spares.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 8
BOEING SERVICE BULLETIN 757-25-0182

The kits below were released prior to release of Revision 2 of this service bulletin. Operators that

have these kits should replace Targets 284N1085-25 and -26 with Targets 284N1085-27 and -28

from Supplemental Kit 012N8928-100. Operators should then install the parts per Part II of the

Accomplishment Instructions.

012N8928 TOP KIT - MODIFICATION OF DOOR LATCH SYSTEM AND SENSOR INSTALLATION

-55 -54 -53 -51

Quantity Part Number Name

. . . - 012N8928-51 Top Kit - Modification of Door Latch System and

Sensor Installation

. . - 1 012N8928-53 (a) Subkit - Movement of Proximity Switch

. - . 1 012N8928-54 (a) Subkit - Movement of Target

- . . . 012N8928-55 (a) Supplemental Kit

1 . 1 . 284N1085-19 Bracket Assembly, Left Side

1 . 1 . 284N1085-20 Bracket Assembly, Right Side

1 . 1 284N1085-25 Target, Left Side

1 . 1 284N1085-26 Target, Right Side

4 . 4 . 284N1641-4 Shim

5 . 5 . BACB30MY6K3X Bolt, Hi-Lok, 1/64 oversize

. 5 . . BACB30NY6K4 Bolt, Hi-Lok

5 5 . . BACB30NY6K5 Bolt, Hi-Lok

5 5 . . BACB30NY6K6 Bolt, Hi-Lok

5 . 5 . BACC30M6 Collar

5 . . . BACC30X3S Collar, 1/64th oversize

5 15 . . BACC30X6S Collar, 1/64th oversize

3 3 . . BACF3F003J017NN Filler

3 3 . . BACF3H07GK013HG Radius Filler

. . 2 . BACG20AF2C1J Grommet

. . 3 . BACR15BA5D8 Rivet

. . 8 . BACR15BB5AD5 Rivet

. . 10 . BACR15BB6AD6 Rivet

. . 3 . BACR15FT6D8 Rivet

. . 1 . BAC27NEX1832 Aluminum Foil Marker, Left Side

. . 1 . BAC27NEX1833 Aluminum Foil Marker, Right Side

5 . 5 . NAS1801-3-7 Screw

(a) The kit has more parts than are necessary for installation. Discard parts that are not used or keep

the parts for spares.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 9
BOEING SERVICE BULLETIN 757-25-0182

The kits shown below were issued to support of the initial release and Revision 1 of this service

bulletin. Operators that already have Subkit 012N8928-2 should install this Subkit as described in

this service bulletin. Operators that already have subkit 012N8928-3 should replace Bracket

Assembly 284N1085-11 and -12 with the latest Bracket Assembly 284N1085-19 and -20, and

install target 284N1085-27 and -28, from new Supplemental Kit 012N8928-100, per Part ll

instructions.

012N8928 TOP KIT - MODIFICATION OF DOOR LATCH SYSTEM AND SENSOR INSTALLATION

-4 -3 -2 -1

Quantity Part Number Name

. . . - 012N8928-1 Top Kit - Modification of Door Latch System and

Sensor Installation

. . - 1 012N8928-2 Subkit - Modification of Door Latch System

. - . 1 012N8928-3 (a) Subkit - Movement of Sensor Proximity Switch

- . . 1 012N8928-4 (a) Subkit - Movement of Sensor Target

. 1 . . 284N1085-11 Bracket Assembly, Left Side

. 1 . . 284N1085-12 Bracket Assembly, Right Side

. 4 . . 284N1641-4 Shim

. . 2 . 416N2721-7 Drip Washer

. . 2 . 416N2723-21 Lockbase Retainer

. . 2 . BACB10GD12GC Bearing

. 5 . . BACB30MY6K3X Bolt, Hi-Lok, 1/64 oversize

5 . . . BACB30NY6K4 Bolt, Hi-Lok

5 . . . BACB30NY6K5 Bolt, Hi-Lok

5 . . . BACB30NY6K6 Bolt, Hi-Lok

. 5 . . BACC30M6 Collar

15 . . . BACC30X6S Collar, 1/64th oversize

3 . . . BACF3F003J022NN Filler

3 . . . BACF3H07GK013HG Radius Filler

. 2 . . BACG20AF2C1J Grommet

. 3 . . BACR15BA5D8 Rivet

. 8 . . BACR15BB5AD5 Rivet

. 10 . . BACR15BB6AD6 Rivet

. 3 . . BACR15FT6D8 Rivet

. 1 . . BAC27NEX1832 Aluminum Foil Marker, Left Side

. 1 . . BAC27NEX1833 Aluminum Foil Marker, Right Side

. . 2 . MS16625-1156 Retaining Ring

. . 2 . MS24665-151 Cotter Pin

. . 2 . MS39086-142 Rolled Spring Pin

. 5 . . NAS1801-3-7 Screw

(a) The kit has more parts than are necessary for installation. Discard parts that are not used or keep

the parts for spares.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 10
BOEING SERVICE BULLETIN 757-25-0182

2. Parts and Materials Supplied by the Operator:

Quantity Part Number (Specification) Name

2 ounces MIL-G-23827 Grease

1 pint BMS 10-11, Type 1 Primer

3 feet MS20995C32 Lock Wire

3 ounces BMS 5-126, Type 2, Class 1 Adhesive

3 ounces BMS 5-92 Adhesive

3 ounces BMS 5-95 Pressure and Environmental Sealant

See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier

data.

3. Materials Supplied by the Operator Necessary to Make the Replacement Target.

NOTE: If operator has Top Kit 012N8928-97 or Supplemental Kit 012N8928-100, the correct

target is included in the kit and there is NO necessity to fabricate the target per Figure 11.

Quantity Part Number (Specification) Name

2.0 x 2.9 x

0.063

4130, Annealed Per

MIL-S-18729

(a) Alloy Steel Sheet

As

Necessary

BMS 10-11, Type 1 (b) Primer, Color - Green (Optional Yellow)

As

Necessary

BMS 10-11, Type 2 (c) Enamel, Color - BAC702, White Gloss

As

Necessary

QQ-P-416, Type 2, Class 2 (d) Cadmium Plating

(a) See SRM 51-30-03 for more data.

(b) See AMM 20-30-03, BSOPM 20-41-02 or SRM 51-30-03 for material sources.

(c) See AMM 20-30-03, BSOPM 20-41-02 for material sources.

(d) See BSOPM 20-41-02 or SRM 51-30-03 for material sources

D. Parts Necessary to Change Spares

None

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 11
BOEING SERVICE BULLETIN 757-25-0182

E. Existing Parts Accountability

The parts shown below are changed as shown in this service bulletin. Quantity is the number of parts

changed on each airplane.

Existing Part Number RUC Name Quantity New Part Number PNC RC

284N1085-11 DIS Bracket Assembly 1 284N1085-19 S A

284N1085-12 DIS Bracket Assembly 1 284N1085-20 S A

284N1085-5 DIS Target 1 284N1085-27 S A

284N1085-6 DIS Target 1 284N1085-28 S A

284N1085-7 DIS Bracket Assembly 1 284N1085-19 S A

284N1085-8 DIS Bracket Assembly 1 284N1085-20 S A

287N4410-214 DIS Bracket 2 - - B

416N2723-10 DIS Bearing 2 BACB10GD12GC S C

416N2723-18 DIS Lockbase Retainer 2 416N2723-21 S C

BACF003J022NN DIS Radius Filler 2 BACF003J017NN S A

RUC Recommended Use Code

DIS - Discard the part.

- Keep the part if there are other uses for it.

PNC Part Number Code

S - This is the part number for the new equivalent or replacement part.

- To get a new part, use this part number in your order.

- This part is used in production.

RC Replacement Code

A - Do not use the existing part to replace the new or changed part.

B - This part is removed from the airplane. This part has no replacement.

C - You can use the existing part to replace the new or changed part. If you use the

existing part, you cancel the effect of the change given in this service bulletin.

F. Special Tooling - Price and Availability

None

G. Special Tooling Necessary to do this Service 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 I.K., References, can be

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

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 12
BOEING SERVICE BULLETIN 757-25-0182

3. ACCOMPLISHMENT INSTRUCTIONS

GENERAL NOTES

1. Use these accomplishment instructions to change the off-wing escape slide systems on both the

left and right sides of the airplane. The left side of the airplane is shown in all figures; the right

side is to be considered equivalent but opposite to the figures except as noted.

2. Do NOT extend or retract flaps when working on the off-wing escape slide compartment doors.

3. To all bare aluminum surfaces, unless otherwise noted, apply Chemical Conversion Coating,

Class A, followed by BMS 10-11, Type 1 primer and BMS10-11, Type 2 enamel. Refer to Boeing

Standard Overhaul Practices Manual ( BSOPM) 20-41-02 and 20-43-03.

4. 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.

5. At operator's option, Door Open/Door Closed indications can be taken from the PSEU (Proximity

Switch Electronic Unit) that is located in the Main E/E Equipment Center instead of the EICAS

Display in the Flight Deck.

6. The following steps are optional for measuring distances between the door sensor target and the

door sensor proximity switch:

a. attach modeling clay to the surface of the proximity switch

b. close and latch escape slide compartment door

c. open escape slide compartment door

d. measure distance of gap as created by the indentation of the door sensor target in the clay to

the surface of the door sensor proximity switch.

e. remove modeling clay

7. To check door open and door closed indications on the EICAS computer, rotate the EICAS

computer to the "AUTO" position. The message "L WING SLIDE' or "R WING SLIDE" should

appear as appropriate. If EICAS message "EMER DOORS" is displayed, more than one

emergency door is open. Close any open emergency door.

8. 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.

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

10. Install 1/32 oversize rivets, as necessary. Refer to 757 Structural Repair Manual Subject

51-40-01.

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

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 13
BOEING SERVICE BULLETIN 757-25-0182

WORK INSTRUCTIONS

Part I. Modification of airplanes that have not been previously retrofitted by

the initial release or by Revision 1 of this service bulletin.

Replace the Bearing and Lockbase Retainer in the Off-Wing Escape Slide Door Latch

Assembly - Figure 1 - Use subkit 012N8928-2.

Relocate the Compartment Door Sensor Switch and Door Target to new forward location on

compartment door, and replace target with new improved target. Test the Door Indication

System to ensure door closure - Figures 2, 3, 4, 5, 6, 7, 9, 10 and 11 - Use parts in Topkit

012N8928-97.

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

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

PANEL P6 CIRCUIT BREAKER LOCATION

EVAC SIGNAL * C4435 C004

EMER ESCAPE - L C4343 C005

EMER ESCAPE - R C4344 C006

PANEL P11 CIRCUIT BREAKER LOCATION

EMER ESCAPE TEST C4320 C001

DOOR IND C4144 R033

* Applicable only to airplanes ND011 - ND059, ND111 - ND113,

ND161 - ND199, NE011 - NE088, NE091 - NE093, and NE141 - NE150

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

25-65-09.

D. Remove the door latch tube from the escape slide compartment door assembly. Refer to 757

Maintenance Manual Subject 25-65-07.

E. Replace the bearing and the lockbase retainer in the compartment door latch assembly as shown

in Figure 1.

F. Install the door latch tube on the escape slide compartment door assembly. Refer to 757

Maintenance Manual Subject 25-65-07.

G. Test the compartment door latch tube to make sure it stays in the locked position as follows:

1. With the round crank handle in the locked position, hold the compartment door latch tube and

try to move the lockbase retainer and the spring assembly aft.

2. If the compartment door latch tube remains in the locked position, go to Step H.

3. If the compartment door latch tube does not remain in the locked position, remove the

compartment latch tube. Refer to 757 Maintenance Manual Subject 25-65-07.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 14
BOEING SERVICE BULLETIN 757-25-0182

4. Make sure all components are in the correct position and reinstall the door latch tube. Refer to

757 Maintenance Manual Subject 25-65-07.

5. Go to Step G.1. and repeat the test again.

H. Remove the existing door sensor target from the aft location on the compartment door, as shown

in Figure 2.

I. Remove the existing door sensor proximity switch, switch mounting bracket as shown in Figure 3.

J. Install the door sensor proximity switch on the new bracket 284N1085-19 (-20 opposite) and then

temporarily install this new switch/bracket assembly on the structure, as shown in Figure 4.

K. Install the new door sensor target 284N1085-27 (-28 opposite) at the new forward location on the

compartment door, as shown in Figure 5.

NOTE: As an option to the operator, the door sensor target may be fabricated as shown in

Figure 11.

L. Ensure that the door sensor target, door sensor switch, and door latch tube clearances meet the

dimensions shown in Figure 6.

M. Conduct the Left off-wing escape slide compartment, Door OPEN test as follows:

NOTE: Close all emergency doors before starting escape slide compartment door test.

1. Verify, that the "EMER DOORS" light is extinguished.

2. Rotate, the EICAS COMPUTER Select switch to the "L" position.

3. Verify, there is no message "L WING SLIDE" on the EICAS display.

4. Rotate, the EICAS COMPUTER Select switch to the "R" Position.

5. Verify, there is no message "L WING SLIDE" on the EICAS display.

6. OPEN, maintenance access door located aft of SLIDE DOOR L.

7. RAISE, the yellow handle to open SLIDE DOOR L.

8. Open, the SLIDE DOOR L 0.24 inches, see Figure 10.

NOTE: Measure the gap from the outside of the door to the fuselage. EICAS message

should be displayed when the SLIDE DOOR is opened 0.240 inches.

9. Verify, that the "EMER DOORS" light is illuminated on P5.

10. If "EMER DOORS" light on P5 does not illuminate, then follow the adjustment instructions in

Figure 9 until the "EMER DOORS" light on P5 does illuminate.

11. Rotate, the EICAS COMPUTER Select switch to the "L" position.

12. Verify, message "L WING SLIDE" on the EICAS display.

13. Rotate, the EICAS COMPUTER Select switch to the "R" position.

14. Verify, message "L WING SLIDE" on the EICAS display.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 15
BOEING SERVICE BULLETIN 757-25-0182

15. Close, maintenance access door located aft of Slide Door L.

16. Verify, that the "EMER DOORS" light is extinguished.

17. This ends the Left off-wing escape slide compartment Door OPEN test.

18. Mark final bracket location footprint. Refer to step O. for permanent installation of

switch/bracket assembly.

N. Conduct the Right off-wing escape slide compartment Door OPEN test. The test is identical to the

test for the LEFT door above in step M, the only difference is that the EICAS display messages

will display "R WING SLIDE" in lieu of "L WING SLIDE".

O. When all the adjustments have been made, permanently install the door sensor switch/bracket

assembly to structure, as shown in Figure 7.

P. Reinstall the forward door assembly with the 13 fasteners, in the main gear wheel well, that was

removed to gain access to the bracket fasteners. See Figure 3.

Q. Close the off-wing escape slide compartment door. Refer to 757 Maintenance Manual Subject

25-65-09.

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

Instruction B.

S. Conduct operational test of the off-wing escape slide pneumatic deployment system. Refer to 757

Maintenance Manual Subject 25-65-00, task 25-65-00-715-033.

T. Conduct a system test on the off-wing escape slide compartment doors. Refer to 757

Maintenance Manual Subject 52-71-00, task 52-71-00-735-053.

U. Arm the off-wing escape slide system. Refer to 757 Maintenance Manual Subject 25-65-00.

V. Put the airplane back in a serviceable condition.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 16
BOEING SERVICE BULLETIN 757-25-0182

Part II. Door Open/Door Closed Test of Compartment Door, and/or

Replacement of parts on airplanes that have been retrofitted by the initial

release or by Revision 1 of this service bulletin,

Replace the Compartment Door Target with new improved target, install Door Sensor Switch

on new bracket, and Conduct Door Indication System Test to ensure door closure - Figures

3, 4, 5, 6, 7, 8, 9 and 10 - Use parts in Topkit 012N8928-97, as required.

A. Check that clearance between the door latch tube and the door sensor proximity switch is 0.05

inch minimum. See Figure 6 section A-A.

B. Conduct door open/door closed test, Left off-wing escape slide compartment door, as follows:

NOTE: Close all emergency doors before starting escape slide compartment door test.

1. Verify, that the "EMER DOORS" light is extinguished.

2. Rotate, the EICAS COMPUTER Select switch to the "L" position.

3. Verify, there is no message "L WING SLIDE" on the EICAS display.

4. Rotate, the EICAS COMPUTER Select switch to the "R" Position.

5. Verify, there is no message "L WING SLIDE" on the EICAS display.

6. OPEN, maintenance access door located aft of SLIDE DOOR L.

7. RAISE, yellow handle to open SLIDE DOOR L.

8. Open, the SLIDE DOOR L 0.24 inches, see Figure 10.

NOTE: Measure the gap from the outside of the door to the fuselage. EICAS message

should be displayed when the SLIDE DOOR is opened 0.240 inches.

9. Verify, that the "EMER DOORS" light is illuminated on P5.

10. If "EMER DOORS" light on P5 does not illuminate, then follow the shim removal adjustment

instructions in Figure 9 (Reference only), until the "EMER DOORS" light on P5 does illuminate.

11. Rotate, the EICAS COMPUTER Select switch to the "L" position.

12. Verify, message "L WING SLIDE" on the EICAS display.

13. Rotate, the EICAS COMPUTER Select switch to the "R" position.

14. Verify, message "L WING SLIDE" on the EICAS display.

15. Close, access door located aft of Slide Door L.

16. Verify, that the "EMER DOORS" light is extinguished.

17. This ends the Left off-wing escape slide compartment Door OPEN test.

C. Conduct door open/door closed test, Right off-wing escape slide compartment door. The test is

identical to the test for the LEFT door above in step B, the only difference is that the EICAS

display messages will display "R WING SLIDE" in lieu of "L WING SLIDE".

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 17
BOEING SERVICE BULLETIN 757-25-0182

D. If the Left and Right Compartment Doors pass the door open/door closed tests, then no further

action is required at this time.

E. If the Left or Right Compartment Doors fail either test, then the airplane should be retrofitted

starting with Step F. below through the last step in this section.

F. Disarm the off-wing escape system. Refer to 757 Maintenance Manual Subject 25-65-00.

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

PANEL P6 CIRCUIT BREAKER LOCATION

EVAC SIGNAL * C4435 C004

EMER ESCAPE - L C4343 C005

EMER ESCAPE - R C4344 C006

PANEL P11 CIRCUIT BREAKER LOCATION

EMER ESCAPE TEST C4320 C001

DOOR IND C4144 R033

* Applicable only to airplanes ND011 - ND059, ND111 - ND113,

ND161 - ND199, NE011 - NE088, NE091 - NE093, and NE141 - NE150

H. Open the off-wing escape slide compartment door. Refer to 757 Maintenance Manual

Subject25-65-09.

I. Remove the existing door sensor target 284N1085-5 (-6 opposite), from it's present (forward)

location on the compartment door. For reference location only, see Figure 5.

J. Remove the door sensor proximity switch and bracket on which switch is mounted to airplane

structure, as shown in Figure 8.

K. Install the existing door sensor proximity switch on the new bracket 284N1085-19 (-20 opposite) at

the forward location, and then temporarily install this new assembly on the airplane as shown in

Figure 4.

L. Install the new door sensor target 284N1085-27 (-28 opposite) at the same location on the

compartment door where the target 284N1085-5 (-6 opposite) was removed (Step I. above), as

shown in Figure 5.

NOTE: As an option to the operator, the door sensor target may be fabricated as shown in

Figure 11.

M. Ensure that the door sensor target to door sensor switch, and the door sensor switch to door latch

tube, clearances meet the dimensions shown in Figure 6.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 18
BOEING SERVICE BULLETIN 757-25-0182

N. Conduct the Left off-wing escape slide compartment, Door OPEN test as follows:

NOTE: Close all emergency doors before starting escape slide compartment door test.

1. Verify, that the "EMER DOORS" light is extinguished.

2. Rotate, the EICAS COMPUTER Select switch to the "L" position.

3. Verify, there is no message "L WING SLIDE" on the EICAS display.

4. Rotate, the EICAS COMPUTER Select switch to the "R" Position.

5. Verify, there is no message "L WING SLIDE" on the EICAS display.

6. OPEN, maintenance access door located aft of SLIDE DOOR L.

7. RAISE, yellow handle to open SLIDE DOOR L.

8. Open, the SLIDE DOOR L 0.24 inches, see Figure 10.

NOTE: Measure the gap from the outside of the door to the fuselage. EICAS message

should be displayed when the SLIDE DOOR is opened 0.240 inches.

9. Verify, that the "EMER DOORS" light is illuminated on P5.

10. If "EMER DOORS" light on P5 does not illuminate, then follow the adjustment instructions in

Figure 9 until the "EMER DOORS" light on P5 does illuminate.

11. Rotate, the EICAS COMPUTER Select switch to the "L" position.

12. Verify, message "L WING SLIDE" on the EICAS display.

13. Rotate, the EICAS COMPUTER Select switch to the "R" position.

14. Verify, message "L WING SLIDE" on the EICAS display.

15. Close, access door located aft of Slide Door L.

16. Verify, that the "EMER DOORS" light is extinguished.

17. This ends the Left off-wing escape slide compartment Door OPEN test.

18. Mark final bracket location footprint. Reference step P. to permanently install switch/bracket

assembly.

O. Conduct the Right off-wing escape slide compartment Door OPEN test. The test is identical to the

test for the LEFT door above in step K, the only difference is that the EICAS display messages will

display "R WING SLIDE" in lieu of "L WING SLIDE".

P. When all the adjustments have been made, permanently install the door sensor switch/bracket

assembly to structure, as shown in Figure 7.

Q. Reinstall the forward door assembly with the 13 fasteners, in the main gear wheel well that was

removed to gain access to the bracket fasteners. See Figure 3.

R. Close the off-wing escape slide compartment door. Refer to 757 Maintenance Manual Subject

25-65-09.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 19
BOEING SERVICE BULLETIN 757-25-0182

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

Instruction B.

T. Conduct a system test on the off-wing escape slide compartment doors. Refer to 757

Maintenance Manual Subject 52-71-00, task 52-71-00-735-053.

U. Arm the off-wing escape slide system. Refer to 757 Maintenance Manual Subject 25-65-00.

V. Put the airplane back in a serviceable condition.

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 20
BOEING SERVICE BULLETIN 757-25-0182

FIGURE TABLE OF CONTENTS

Title Page

FIGURE 1. REPLACEMENT OF THE BEARING AND THE LOCKBASE

RETAINER IN THE OFF-WING ESCAPE SLIDE COMPARTMENT

DOOR LATCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

FIGURE 2. REMOVAL OF DOOR SENSOR TARGET FROM AFT LOCATION ON

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR . . . . . . . . . . . . . . . . . 25

FIGURE 3. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH FROM

AFT LOCATION ON THE OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

FIGURE 4. TEMPORARY INSTALLATION OF DOOR SENSOR PROXIMITY

SWITCH AT FORWARD LOCATION ON COMPARTMENT DOOR -

ADJUSTMENT OF SWITCH IN RELATION TO

TARGET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FIGURE 5. INSTALLATION OF DOOR SENSOR TARGET AT NEW FORWARD

LOCATION ON THE OFF-WING ESCAPE SLIDE COMPARTMENT

DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 6. CLEARANCE MEASUREMENTS OF THE DOOR SENSOR

PROXIMITY SWITCH FROM DOOR LATCH TUBE AND FROM THE

DOOR SENSOR TARGET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

FIGURE 7. PERMANENT INSTALLATION OF DOOR SENSOR PROXIMITY

SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

FIGURE 8. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH -

RETROFITTED AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FIGURE 9. ADJUSTMENT OF DOOR SENSOR PROXIMITY SWITCH

LOCATION IN RELATION TO DOOR SENSOR TARGET . . . . . . . . . . . . . . 46

FIGURE 10. OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

MEASUREMENT FOR DOOR OPEN/DOOR CLOSED INDICATIONS

ON EICAS COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIGURE 11. FABRICATION INSTRUCTIONS FOR DOOR SENSOR TARGET . . . . . . . 51

October 10, 1996 757-25-0182

Revision 2: January 11, 2001 21
BOEING SERVICE BULLETIN 757-25-0182

9 SPRING PIN

6

OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR

OVERWING EMERGENCY

EXIT HATCH

SEE A

COTTER PIN

10 LOCK WIRE

A

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

DOOR

LATCH TUBE

CARRIER

SEE B

OFF-WING ESCAPE

SLIDE PACK

DOOR LATCH

FITTING

DOOR LATCH

FITTING

FWD

R80905

FIGURE 1. REPLACEMENT OF THE BEARING AND THE LOCKBASE RETAINER IN THE OFF-WING

ESCAPE SLIDE COMPARTMENT DOOR LATCH ASSEMBLY

October 10, 1996 SHEET 1 OF 3 757-25-0182

Revision 2: January 11, 2001 22
BOEING SERVICE BULLETIN 757-25-0182

FWD INBD

3 PRIMER

2

8 DRIP WASHER

BEARING

4

LOCKBASE

RETAINER

B

SHAFT

ASSEMBLY

5

SPRING

RETAINER

1 7

SPRING

RETAINING

RING

FITTING

ASSEMBLY

AFT SHAFT

STA

1179.90

R80863

FIGURE 1. REPLACEMENT OF THE BEARING AND THE LOCKBASE RETAINER IN THE OFF-WING

ESCAPE SLIDE COMPARTMENT DOOR LATCH ASSEMBLY

October 10, 1996 SHEET 2 OF 3 757-25-0182

Revision 2: January 11, 2001 23
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

NOTES:

1. The following circle notes identify the parts that must be replaced to define the new configuration of

the door latch assembly. Operators should refer to 757 Maintenance Manual Subject 25-65-07 for

actual access, removal, installation and test instructions.

2. Parts are from Subkit 012N8928-2.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/

Discard

Lockbase Retainer 416N2723-18 1 Replace with new part,

see note 7 below.

2 Remove /

Discard

Bearing 416N2723-10 1 Refer to BSOPM

20-50-03.

3 Apply Primer BMS 10-11, Type I 1 One layer to fitting

assembly bore , allow to

dry before installing

bearing.

4 Install Bearing BACB10GD12GC 1 Refer to BSOPM

20-50-03.

5 Replace Retaining Ring MS16625-1156 1 Retaining Ring

replacement is necessary

during bearing

replacement.

6 Replace Cotter Pin MS24665151 1 As necessary.

7 Install Lockbase Retainer 416N2723-21 1 Refer to BSOPM

20-50-03.

8 Replace Drip Washer 416N2721-7 1 Drip washer replacement

is necessary during

lockbase retainer

replacement.

9 Replace Spring Pin MS39086-142 1 Replace rolled spring pin

as necessary

NOTE: Reinstall lockwire during door latch tube installation, per AMM 25-67-07.

10 Install Lock Wire MS20995C32 1 Through rolled spring pin

per NASM33540. Twist

on inboard aft corner of

crank.

FIGURE 1. REPLACEMENT OF THE BEARING AND THE LOCKBASE RETAINER IN THE OFF-WING

ESCAPE SLIDE COMPARTMENT DOOR LATCH ASSEMBLY

October 10, 1996 SHEET 3 OF 3 757-25-0182

Revision 2: January 11, 2001 24
BOEING SERVICE BULLETIN 757-25-0182

1 5 2

4

3

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

OVERWING EMERGENCY

EXIT HATCH

FWD

FASTENERS DOOR SENSOR

TARGET

FITTING (FORWARD)

DOOR LATCH

FITTING (AFT)

DOOR LATCH

OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR

OFF-WING ESCAPE

SLIDE PACK

DOOR LATCH TUBE

V35143

FIGURE 2. REMOVAL OF DOOR SENSOR TARGET FROM AFT LOCATION ON OFF-WING ESCAPE

SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 1 OF 2 757-25-0182

Revision 2: January 11, 2001 25
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

NOTE: Parts are from Subkit 012N8928-99. Parts may also be salvaged from Subkits -4 or -54 that

were released to support the initial release or Revision 1 of this service bulletin.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/

Discard

Bolt BACB30NY6K( ) or

140T1301D6-5

2

Collar BACC30X6S 2

2 Remove/

Discard

Door Sensor

Target

284N1085-5

(-6 opposite)

1

3 Remove/

Discard

Filler BACF3F003J022NN 1

Radius Filler BACF3H07GK013HG 1

4 Clean Compartment door

where door sensor

target was

removed.

416N2620-21

(-22 opposite)

1 Refer to BSOPM 20-30-03

5 Install Bolt, Hi-Lok BACB30NY6K4 2 Plug holes with bolt on the

outboard side of the door.

Fastener head should be flush

to plus 0.01, minus 0.00. Collar BACC30X6S 2

FIGURE 2. REMOVAL OF DOOR SENSOR TARGET FROM AFT LOCATION ON OFF-WING ESCAPE

SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 2 OF 2 757-25-0182

Revision 2: January 11, 2001 26
BOEING SERVICE BULLETIN 757-25-0182

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1

1

SEE A

STA

1140

STA

1180

INBD FWD

MAIN WHEEL WELL FAIRING

WL

170

ACCESS TO BRACKET FASTENERS

FORWARD DOOR ASSEMBLY FOR

(13 PLACES)

BOLT

V35177

FIGURE 3. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH FROM AFT LOCATION ON THE

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 1 OF 3 757-25-0182

Revision 2: January 11, 2001 27
BOEING SERVICE BULLETIN 757-25-0182

6

7 9

7 8

7

7

5

3

3

3 4

2

A

10

FWD

INBD

FASTENERS

FASTENERS

BRACKET

BRACKET

RIVET

CLAMP,

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT

RIVET

DOOR SENSOR

PROXIMITY SWITCH

RIVET

SHIM

BRACKET

ASSEMBLY

SCREW

STA

1147

STA

1170

STA

1160

R85280

FIGURE 3. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH FROM AFT LOCATION ON THE

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 2 OF 3 757-25-0182

Revision 2: January 11, 2001 28
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

NOTE: Parts are from Subkit 012N8928-98. Parts may also be salvaged from subkits -3 or -53 that were

released to support of the initial release or Revision 1 of this service bulletin.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove /

Keep

Forward Door

Assembly for

access to the door

sensor proximity

switch mounting

fasteners

149N7562-23

(-24 opposite)

1 Save for installation later.

Bolt BACB30LR3-6 13

2 Remove /

Discard

Clamp BACC10DK( ) 1 Two locations.

Screw NAS1801-3-( ) 1

Washer AN960PD10L 1

Nut BACN10JC3 1

3 Remove /

Discard

Bracket 287N4410-214 1 Two locations.

Rivet BACR15FT6D( ) 2

4 Install Rivet BACR15BB6D6 4 Plug two holes in each stiffener.

5 Remove /

Discard

Screw NAS1801-3-7 2

6 Remove /

Keep

Door Sensor

Proximity Switch

S283T006-10 1 Save for re-installation at new

forward location on escape

slide compartment door, See

Figure 4.

7 Remove /

Discard

Bracket Assembly

on which the

Proximity Switch is

mounted

284N1085-7 1

(-8 opposite)

(284N1085-1 & -2

optional)

Shim 284N1641-4 1

Rivet BACR15FT6D( ) 1

Bolt, Hi-Lok BACB30MY5K( ) 3

Collar BACC30M5 3

8 Install Bolt

Collar

BACB30MY5K3X

BACC30M5

3

3

Plug holes with 1/64th oversize

bolt.

9 Install Rivet BACR15BA6D8 1 Plug hole in chord and curved

intercostal with rivet head on

the bottom.

10 Remove /

Discard

Rivet BACR15FT6D( ) 2 From Stiffener 149N7523-147

(-148 opposite)

FIGURE 3. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH FROM AFT LOCATION ON THE

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 3 OF 3 757-25-0182

Revision 2: January 11, 2001 29
BOEING SERVICE BULLETIN 757-25-0182

SEE A

OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR

OFF-WING ESCAPE

SLIDE PACK

OVERWING EMERGENCY

EXIT HATCH

FWD

FITTING (AFT)

FITTING (FORWARD)

DOOR LATCH

DOOR LATCH

LEFT SIDE SHOWN

V35193

RIGHT SIDE OPPOSITE

FIGURE 4. TEMPORARY INSTALLATION OF DOOR SENSOR PROXIMITY SWITCH AT FORWARD

LOCATION ON COMPARTMENT DOOR - ADJUSTMENT OF SWITCH IN RELATION TO TARGET

October 10, 1996 SHEET 1 OF 3 757-25-0182

Revision 2: January 11, 2001 30
BOEING SERVICE BULLETIN 757-25-0182

A

1

0.66

1

2

0.76

A-A

2

2 BRACKET

STIFFENER

2

STIFFENERS

INBD

A

A

BRACKET

DOOR LATCH TUBE NOT SHOWN

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT

SHIM,

DOOR SENSOR

PROXIMITY SWITCH,

FASTENERS

ASSEMBLY

BRACKET

PROXIMITY SWITCH

DOOR SENSOR

STIFFENER

INBD

FWD

STA

1160

1147

STA

V35200

FIGURE 4. TEMPORARY INSTALLATION OF DOOR SENSOR PROXIMITY SWITCH AT FORWARD

LOCATION ON COMPARTMENT DOOR - ADJUSTMENT OF SWITCH IN RELATION TO TARGET

October 10, 1996 SHEET 2 OF 3 757-25-0182

Revision 2: January 11, 2001 31
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

NOTE: Parts are from Subkit 012N8928-98. Parts may also be salvaged from Subkits -3 or -53 that

were released to support of the initial release or Revision 1 of this service bulletin.

STEP TASK NAME PART NUMBER QTY NOTES

1 Install Door Sensor

Proximity Switch

S283T006-10 1 Door sensor proximity switch

(same switch that was removed

per Figure 3 instructions) and

new shim on new bracket, with

screws. Do not bond shim to

bracket at this time, it will be

bonded later in Figure 7.

Shim 284N1641-4 1

Door Sensor

Proximity Switch

mounted on bracket

assembly

284N1085-19

(-20 opposite)

1

Screw NAS1801-3-7 2

2 Align / Adjust

Temporarily

Clamp and

Tape

Door Sensor

Proximity Switch

mounted on bracket

assembly

284N1085-19

(-20 opposite)

1 The bottom edge of the bracket

should initially be 0.76 from the

top edge of the stiffener. See

A-A.

The centerline of the inboard

hole of the stiffener should be

0.66 from the inboard edge of

the bracket. See A-A.

Tape forward end of bracket to

structure and clamp aft end of

bracket to stiffener to keep

bracket from moving.

This is a temporary installation

to conduct tests and to

establish the final installation

location of the proximity switch

in relation to the target.

Permanent installation of the

target is accomplished in Figure

5. Permanent installation of the

switch is accomplished in

Figure 7.

FIGURE 4. TEMPORARY INSTALLATION OF DOOR SENSOR PROXIMITY SWITCH AT FORWARD

LOCATION ON COMPARTMENT DOOR - ADJUSTMENT OF SWITCH IN RELATION TO TARGET

October 10, 1996 SHEET 3 OF 3 757-25-0182

Revision 2: January 11, 2001 32
BOEING SERVICE BULLETIN 757-25-0182

OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR

OFF-WING ESCAPE

DOOR

SLIDE COMPARTMENT

DOOR LATCH TUBE

OFF-WING ESCAPE

SLIDE PACK

BOLT

3 6 4 6 BOLT

3 5

2

1

OVERWING EMERGENCY

EXIT HATCH

FWD

FWD

(FORWARD)

FITTING

DOOR LATCH

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

FILLER

RADIUS

TARGET, FILLERS

DOOR SENSOR

BOLT

FITTING (AFT)

DOOR LATCH

V35155

FIGURE 5. INSTALLATION OF DOOR SENSOR TARGET AT NEW FORWARD LOCATION ON THE

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 1 OF 4 757-25-0182

Revision 2: January 11, 2001 33
BOEING SERVICE BULLETIN 757-25-0182

DOOR SENSOR

TARGET, FILLER,

RADIUS FILLER

3 7 4 5 6

OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR

1147

STA

6 FASTENERS

SEALANT

7

STA

1160

DOOR LATCH TUBE NOT SHOWN

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT

A

INBD

FWD

V40099

FIGURE 5. INSTALLATION OF DOOR SENSOR TARGET AT NEW FORWARD LOCATION ON THE

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 2 OF 4 757-25-0182

Revision 2: January 11, 2001 34
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

NOTE: Parts are from Subkit 012N8928-99. Parts may also be salvaged from Subkits -4 or -54 that were

released to support the initial release or Revision 1 of this service bulletin.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Bolt BACB30NY6K( ) 1 This is the first plugged

fastener located aft of the

forward door latch fitting.

2 Backdrill Radius Filler BACF3H07GK013HG 1 Backdrill two 0.190 - 0.198

diameter holes in the

radius filler using the

target as a template.

3 Align Door Sensor Target 284N1085-27

(-28 opposite)

1 Align forward fastener hole

in the target with existing

fastener hole in the door.

The lower surface of the

door sensor target should

be parallel to the upper

surface of the door sensor

proximity switch.

Filler BACF3F003J017NN 1

Radius Filler BACF3H07GK013HG 1

4 Backdrill Compartment Door 416N2620-21

(-22 opposite)

1 Backdrill one 0.190 - 0.198

diameter hole in the

compartment door using

the aft hole in the door

sensor target as template.

Countersink hole 100

degrees outboard side of

door.

Door SensorTarget 284N1085-27

(-28 opposite)

1

Radius Filler BACF3H07GK013HG 1

5 Bond Filler BACF3F00J017NN 1 Bond filler and radius filler

in place with adhesive.

Reference BSOPM

20-50-12.

Radius Filler BACF3H07GK013HG 1

Escape Slide

Compartment Door

416N2620-21 (-22

opposite)

1

Adhesive BMS 5-92 -

6 Install Door Sensor Target 284N1085-27 (-28

opposite)

1 Bolt head installed on far

side. Fastener should be

flush to plus 0.01, minus

0.00.

Filler BACF3F003J017NN 1

Radius Filler BACF3H07GK013HG 1

Bolt, Hi-Lok BACB30NY6K5 2 If BACB30NY6K5 are not

long enough, then use

BACB30NY6K6

Collar BACC30X6S 2

FIGURE 5. INSTALLATION OF DOOR SENSOR TARGET AT NEW FORWARD LOCATION ON THE

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 3 OF 4 757-25-0182

Revision 2: January 11, 2001 35
BOEING SERVICE BULLETIN 757-25-0182

(Continued)

STEP TASK NAME PART NUMBER QTY NOTES

7 Apply Pressure and

environmental

Sealant

BMS 5-95 Sealant should be applied

around the entire outside

edges of the target and

the fillers.

FIGURE 5. INSTALLATION OF DOOR SENSOR TARGET AT NEW FORWARD LOCATION ON THE

OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

October 10, 1996 SHEET 4 OF 4 757-25-0182

Revision 2: January 11, 2001 36
BOEING SERVICE BULLETIN 757-25-0182

SEE A

OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR

OFF-WING ESCAPE

SLIDE PACK

OVERWING EMERGENCY

EXIT HATCH

FWD

FITTING (AFT)

FITTING (FORWARD)

DOOR LATCH

DOOR LATCH

LEFT SIDE SHOWN

V35202

RIGHT SIDE OPPOSITE

FIGURE 6. CLEARANCE MEASUREMENTS OF THE DOOR SENSOR PROXIMITY SWITCH FROM DOOR

LATCH TUBE AND FROM THE DOOR SENSOR TARGET

October 10, 1996 SHEET 1 OF 3 757-25-0182

Revision 2: January 11, 2001 37
BOEING SERVICE BULLETIN 757-25-0182

MINIMUM

0.05

DOOR SENSOR

TARGET

TUBE

DOOR LATCH

DOOR

SLIDE COMPARTMENT

OFF-WING ESCAPE

A-A

2 0.10

1 A

INBD

A

A

SHIM

PROXIMITY

SWITCH

DOOR SENSOR

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT

DOOR LATCH TUBE NOT SHOWN

STIFFENER

INBD

FWD

1160

STA

STA

1147

V35201

FIGURE 6. CLEARANCE MEASUREMENTS OF THE DOOR SENSOR PROXIMITY SWITCH FROM DOOR

LATCH TUBE AND FROM THE DOOR SENSOR TARGET

October 10, 1996 SHEET 2 OF 3 757-25-0182

Revision 2: January 11, 2001 38
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

STEP TASK NAME PROCEDURE NOTES

1 Measure Distance Operator's Standard Procedure Measure distance, check

clearance between door latch

tube and door sensor proximity

switch. The minimum dimension

should be 0.05. See A-A.

2 Measure Distance Operator's Standard Procedure or

with the use of modeling clay as

described in General Note 5 of the

Accomplishment Instructions

Measure distance between door

sensor proximity switch and door

sensor target. The minimum

dimension should be 0.10. See

A-A.

FIGURE 6. CLEARANCE MEASUREMENTS OF THE DOOR SENSOR PROXIMITY SWITCH FROM DOOR

LATCH TUBE AND FROM THE DOOR SENSOR TARGET

October 10, 1996 SHEET 3 OF 3 757-25-0182

Revision 2: January 11, 2001 39
BOEING SERVICE BULLETIN 757-25-0182

EXIT HATCH

OVERWING EMERGENCY

SLIDE PACK

OFF-WING ESCAPE

COMPARTMENT DOOR

OFF-WING ESCAPE SLIDE

SEE A

FWD

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

DOOR LATCH

DOOR LATCH

FITTING (FORWARD)

FITTING (AFT)

V35203

FIGURE 7. PERMANENT INSTALLATION OF DOOR SENSOR PROXIMITY SWITCH

October 10, 1996 SHEET 1 OF 3 757-25-0182

Revision 2: January 11, 2001 40
BOEING SERVICE BULLETIN 757-25-0182

5

DOOR SENSOR

PROXIMITY SWITCH

1

1 2 3 4 5

BRACKET

3 RIVET

3

INBD

A-A

INTERCOSTAL

CURVED

FILLER

3 BRACKET

ASSEMBLY

3 CHORD

3

7

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT

DOOR LATCH TUBE NOT SHOWN

FWD

A

INBD

ADHESIVE, SHIM

GROMMET

WIRE,

RIVET

0.30

0.40

3

1 5 SCREW

1 4

MARKER

COLLARS

BOLTS, 2

STA

1160

1147

STA

6

A

A

V40101

FIGURE 7. PERMANENT INSTALLATION OF DOOR SENSOR PROXIMITY SWITCH

October 10, 1996 SHEET 2 OF 3 757-25-0182

Revision 2: January 11, 2001 41
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

NOTE: Parts are from Subkit 012N8928-98. Parts may also be salvaged from Subkits -3 or -53 that

were released to support of the initial release or Revision 1 of this service bulletin.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove/

Keep

Door Sensor

Proximity Switch

S283T006-10 1 From bracket on

which the switch is

mounted. Bracket 284N1085-19 (-20

opposite)

1

Shim 284N1641-4 2

Screw NAS1801-3-7 2

2 Install Bracket 284N1085-19 (-20

opposite)

1 On stiffener, using

hole in stiffener as a

template, backdrill

0.203 - 0.207 dia hole

in the stackup parts. Bolt BACB30NX6K3X 2

Collar BACC30X6S 2

3 Drill/Install Bracket 284N1085-19 (-20

opposite)

1 From the top,

measure dimensions

to locate a hole for

the rivet as shown in

figure. Drill a 0.159 -

0.171 diameter hole in

the bracket assembly.

Drill 100 degree

countersink in filler

that is installed below

the curved intercostal.

Install rivet, attaching

bracket to airplane

structure.

Chord 149N7523-137

(-138 opposite)

1

Curved intercostal 149N7523-141

(-142 opposite)

1

Filler 149N7564-1

(-2 opposite)

1

Rivet BACR15BA5D8 1

4 Bond Shim 284N1641-4 1 To bracket assembly

using adhesive.

Reference BSOPM

20-50-12.

Adhesive BMS 5-126, Type

2, Class 1

5 Install Door Sensor

Proximity Switch

S283T006-10 1 To bracket using

screws.

Screw NAS1801-3-7 2

6 Pull Proximity Switch

Wire

- Excess wire through

hole, coil and clamp

as necessary.

Replace grommet, if

necessary.

Grommet BACG20AF2C1J 1

7 Install Aluminum foil

marker

BAC27NEX1832,

BAC27NEX1833

(opposite)

1 Reference BSOPM

20-50-05.

FIGURE 7. PERMANENT INSTALLATION OF DOOR SENSOR PROXIMITY SWITCH

October 10, 1996 SHEET 3 OF 3 757-25-0182

Revision 2: January 11, 2001 42
BOEING SERVICE BULLETIN 757-25-0182

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

1

1

SEE A

STA

1140

STA

1180

INBD FWD

MAIN WHEEL WELL FAIRING

WL

170

ACCESS TO BRACKET FASTENERS

FORWARD DOOR ASSEMBLY FOR

(13 PLACES)

BOLT

R84862

FIGURE 8. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH - RETROFITTED AIRPLANES

October 10, 1996 SHEET 1 OF 3 757-25-0182

Revision 2: January 11, 2001 43
BOEING SERVICE BULLETIN 757-25-0182

5 RIVET

4

3

2

A

DOOR SENSOR

PROXIMITY SWITCH

SHIM, FASTENERS

BRACKET ASSEMBLY,

SCREW

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT

1147

STA

FWD

INBD

1170

STA

STA

1160

V35171

FIGURE 8. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH - RETROFITTED AIRPLANES

October 10, 1996 SHEET 2 OF 3 757-25-0182

Revision 2: January 11, 2001 44
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove /

Keep

Forward Door

Assembly for

access to the door

sensor proximity

switch mounting

bracket fasteners

149N7562-23

(-24 opposite)

1

Bolt BACB30LR3-6 13

2 Remove /

Discard

Screw NAS1801-3-7 2

3 Remove /

Keep

Door Sensor

Proximity Switch

S283T006-10 1

4 Remove /

Discard

Bracket Assembly 284N1085-7 1

(-8 opposite)

(284N1085-1 & -2

optional)

Shim 284N1641-4 1

Rivet BACR15FT5D( ) 1

Bolt, Hi-Lok BACB30MY5K( ) 2

Collar BACC30M5 2

5 Install Rivet BACR15BA5D8 1 To plug existing hole, rivet head

on bottom.

FIGURE 8. REMOVAL OF THE DOOR SENSOR PROXIMITY SWITCH - RETROFITTED AIRPLANES

October 10, 1996 SHEET 3 OF 3 757-25-0182

Revision 2: January 11, 2001 45
BOEING SERVICE BULLETIN 757-25-0182

SEE A

OFF-WING ESCAPE SLIDE

COMPARTMENT DOOR

OFF-WING ESCAPE

SLIDE PACK

OVERWING EMERGENCY

EXIT HATCH

FWD

FITTING (FORWARD)

FITTING (AFT)

DOOR LATCH

DOOR LATCH

LEFT SIDE SHOWN

V40102

RIGHT SIDE OPPOSITE

FIGURE 9. ADJUSTMENT OF DOOR SENSOR PROXIMITY SWITCH LOCATION IN RELATION TO DOOR

SENSOR TARGET

October 10, 1996 SHEET 1 OF 3 757-25-0182

Revision 2: January 11, 2001 46
BOEING SERVICE BULLETIN 757-25-0182

2

OFF-WING ESCAPE

BRACKET

SWITCH

PROXIMITY

0.10

1

A-A

SLIDE COMPARTMENT

DOOR

DOOR LATCH

TUBE

TARGET

DOOR SENSOR

INBD

SHIM

DOOR SENSOR

SWITCH

PROXIMITY

STIFFENER

A

FWD

A

DOOR SENSOR

DOOR SENSOR

TARGET

A

DOOR LATCH TUBE NOT SHOWN

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT

SWITCH

PROXIMITY

STA

1160

INBD

1147

STA

BRACKET

1

2 SHIM

0.05 MIN

V35204

FIGURE 9. ADJUSTMENT OF DOOR SENSOR PROXIMITY SWITCH LOCATION IN RELATION TO DOOR

SENSOR TARGET

October 10, 1996 SHEET 2 OF 3 757-25-0182

Revision 2: January 11, 2001 47
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

STEP TASK NAME

PART

NUMBER PROCEDURE

1 Remove Shim 284N1641-4 Remove Shim laminations between door

sensor switch and switch mounting bracket

284N1085-19 (-20 Opp) in 0.02 inch

increments until the "EMER DOORS" light

on P5 illuminates. Also see Part I. Step

M.8. or (Part II. Step B.8. or N.8.) of

Accomplishment Instructions for reference.

Repeat process until all shims are gone.

If light on P5 does not illuminate when all

the shims have been removed, then

proceed with Step 2 below.

2 Move/Relocate Bracket (on

which the door

proximity

switch is

mounted)

284N1085-19

(-20 Opposite)

Relocate Bracket inboard by releasing

clamps and tape to new location in 0.02

inch increments until the light on the P5

illuminates. To keep track of bracket

relocations, mark the bracket footprint

each time bracket is relocated.

Mark the final footprint.

Secure the bracket at this location with

clamps and masking tape.

Install the switch/bracket assembly to

airplane structure per instructions in

Figure 7.

FIGURE 9. ADJUSTMENT OF DOOR SENSOR PROXIMITY SWITCH LOCATION IN RELATION TO DOOR

SENSOR TARGET

October 10, 1996 SHEET 3 OF 3 757-25-0182

Revision 2: January 11, 2001 48
BOEING SERVICE BULLETIN 757-25-0182

3 1.00

3

0.24

1 EICAS DISPLAY

PSEU

GAP

2

V39617

FIGURE 10. OFF-WING ESCAPE SLIDE COMPARTMENT DOOR MEASUREMENT FOR DOOR

OPEN/DOOR CLOSED INDICATIONS ON EICAS COMPUTER

October 10, 1996 SHEET 1 OF 2 757-25-0182

Revision 2: January 11, 2001 49
BOEING SERVICE BULLETIN 757-25-0182

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

STEP TASK NAME NOTES

1 Monitor Door Open/

Door Closed

Indication

Monitor Door Open/Door Closed

indications on the EICAS Computer

in the Flight Deck.

2 Slowly

Open

Escape Slide

Compartment

Door

Slowly open door until Door Open is

indicated on the EICAS Computer.

3 Measure Gap It will be necessary for someone to

monitor the EICAS Computer in the

Flight Deck.

Measure gap created by the open

door at the moment at which Door

Open/Door Closed is identified.

Measure gap at the lower edge of the

door at 1.0 from the forward end of

the door.

FIGURE 10. OFF-WING ESCAPE SLIDE COMPARTMENT DOOR MEASUREMENT FOR DOOR

OPEN/DOOR CLOSED INDICATIONS ON EICAS COMPUTER

October 10, 1996 SHEET 2 OF 2 757-25-0182

Revision 2: January 11, 2001 50
BOEING SERVICE BULLETIN 757-25-0182

2

3 1 4 5

FORWARD HOLE

1.17

1.50

0.46

0.35

OML

1.72

1.30

0.50

0.40

0.25 R

(TYPICAL)

0.82

DIA 0.19

0.20

X 0.12 RADIUS

CL BEND UP 90 DEGREES

V35305

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 of the off-wing escape

system. The left side of the off-wing escape system is shown, the right side is opposite and has an equal

number of parts.

STEP TASK NAME MATERIAL QTY NOTES

1 Cut Flat Stock 4130, Alloy Steel

Sheet, Annealed per

MIL-S-18729

1 Stock Dimensions: 0.063 x 1.6 x

1.8

Refer to SRM 51-30-01

2 Drill Hole - - 2 For Part ll airplanes, drill forward

hole only, see figure above.

Drill aft hole to match existing

hole in the compartment door.

3 Bend Flat Stock - - 1 Up 90 degrees with a 0.12

radius

4 Apply Cadmium Plate QQ-P-416, Type 2.

Class 2

1

Layer

Refer to BSOPM 20-42-05

Primer BMS10-11, Type 1,

Color - Green

(Optional Yellow)

1

Layer

Per BAC5736. Refer to BSOPM

20-41-02.

Enamel BMS10-11, Type 2,

Color - BAC702,

White Gloss

1

Layer

Per BAC5736. Refer to BSOPM

20-41-02.

5 Part Mark Door Sensor

Target

284N1085-27

(-28 opposite)

1 Refer to BSOPM 20-50-10.

FIGURE 11. FABRICATION INSTRUCTIONS FOR DOOR SENSOR TARGET

October 10, 1996 SHEET 1 OF 1 757-25-0182

Revision 2: January 11, 2001 51

Commercial

Airplane

Group

757

Service Bulletin

Number: 757-25-0182 Evaluation Form Date: October 10, 1996

Revision 2: January 11, 2001

ATA System: 2565

Prepared By:

SUBJECT: EQUIPMENT/FURNISHINGS - Emergency - Off-Wing Escape System - Modification Of The

Door Latch System And The Sensor Installation

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