### 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

FWDR80931

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 NecessaryBMS 10-11, Type 1 (b) Primer, Color - Green (Optional Yellow)
As NecessaryBMS 10-11, Type 2 (c) Enamel, Color - BAC702, White Gloss
As NecessaryQQ-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

10LOCK WIRE 

## A LEFT SIDE SHOWN RIGHT SIDE OPPOSITE DOOR LATCH TUBE CARRIER B SEE OFF-WING ESCAPE SLIDE PACK DOOR LATCH FITTING
DOOR LATCH FITTING

FWDR80905

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



### INBD FWD 3 PRIMER 2 8 DRIP WASHER

BEARING 4 LOCKBASE RETAINER



## B SHAFT ASSEMBLY

5

SPRING RETAINER

1 7SPRING RETAINING RING

FITTING ASSEMBLY AFT SHAFT STA 1179.90R80863

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



### 5 1 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 TUBEV35143

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.
STEPTASK NAME PART NUMBER QTYNOTES 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) BOLTV35177

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

9 7

8 7 7 7 5

3

3 4

3

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 1160R85280

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



### A SEE OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

OFF-WING ESCAPE SLIDE PACKOVERWING EMERGENCY EXIT HATCH

FWD FITTING (AFT) FITTING (FORWARD) DOOR LATCH

DOOR LATCH

LEFT SIDE SHOWN RIGHT SIDE OPPOSITEV35193

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 2BRACKET 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 STAV35200

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 36 4 BOLT 6

35 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 LATCHV35155

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 6 45 3 7 OFF-WING ESCAPE SLIDE COMPARTMENT DOOR 1147 STA

FASTENERS 6

SEALANT 7 STA 1160

DOOR LATCH TUBE NOT SHOWN VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT 

## AINBD

FWDV40099

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 Target284N1085-27 (-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 Target284N1085-27 (-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



### A SEE OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

OFF-WING ESCAPE SLIDE PACKOVERWING EMERGENCY EXIT HATCH

FWD FITTING (AFT) FITTING (FORWARD) DOOR LATCH

DOOR LATCH

LEFT SIDE SHOWN RIGHT SIDE OPPOSITEV35202

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 20.10 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 1147V35201

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

A SEE

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 5 4 3 2 1 BRACKET

3RIVET 3

INBD 

## A-A INTERCOSTAL CURVED

FILLER 3BRACKET ASSEMBLY

3CHORD 3 7

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT DOOR LATCH TUBE NOT SHOWN FWD



## AINBD ADHESIVE, SHIM GROMMET WIRE, RIVET

0.30 0.40 3

SCREW 1 5 1 4

MARKER
COLLARS BOLTS, 2 STA 1160 1147 STA

6

A AV40101

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 intercostal149N7523-141 (-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) BOLTR84862

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



## ADOOR SENSOR PROXIMITY SWITCH

SHIM, FASTENERS BRACKET ASSEMBLY, SCREW

VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT 1147 STA

FWD

INBD 1170 STA STA 1160V35171

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



### A SEE OFF-WING ESCAPE SLIDE COMPARTMENT DOOR

OFF-WING ESCAPE SLIDE PACKOVERWING EMERGENCY EXIT HATCH

FWD FITTING (FORWARD)

FITTING (AFT) DOOR LATCH

DOOR LATCH

LEFT SIDE SHOWN RIGHT SIDE OPPOSITEV40102

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 SENSORDOOR SENSOR TARGET

A

DOOR LATCH TUBE NOT SHOWN VIEW SHOWN INSIDE ESCAPE SLIDE COMPARTMENT SWITCH PROXIMITY

STA 1160

INBD 1147 STA

BRACKET 1 SHIM 2

0.05 MINV35204

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/RelocateBracket (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



### 1.00 3 3

0.24 EICAS DISPLAY 1

PSEU

GAP
2V39617

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 5 4 1 FORWARD HOLE

1.171.50

0.46 0.35

OML 1.72 1.30 0.500.40

0.25 R (TYPICAL) 0.82 DIA 0.19 0.20

X 0.12 RADIUS CL BEND UP 90 DEGREESV35305

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 LayerPer BAC5736. Refer to BSOPM 20-41-02.
Enamel BMS10-11, Type 2, Color - BAC702, White Gloss 1 LayerPer 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
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