February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 55 

### Commercial **Airplane Group**  

# 757 Service Bulletin
**Number: 757-57-0061** Date: February 06, 2003 Revision 1 May 24, 2007 ATA System: 5710 2810 **SUBJECT:** WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series) 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.**BLANK PAGE** February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

BLANK PAGE**Table of Contents** February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

**Table of Contents** Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 15 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 16 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 17 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 18 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FIGURE 1: Open Access - Air Conditioning Duct Removal - Group 1, Group 2 and Group 3 . . . . . . 29 FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1 . 30 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1 35 FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3 . . . . . . . . 42 FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3 . . . . . . . 45 FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2 . . . . . . . . . . . . 50 FIGURE 7: Close Access - Air Conditioning Duct Installation - Group 1, Group 2 and Group 3. . . . . 52 APPENDIX A: Record of Thickness Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3**Table of Contents** February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

BLANK PAGEFebruary 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 55 

### Commercial **Airplane Group**  

# 757 Service Bulletin
**Number: 757-57-0061** 

### Revision Transmittal Sheet Date: February 06, 2003 Revision 1: May 24, 2007 ATA System: 5710 2810 **SUBJECT:** WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series) This Revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** More work is necessary on airplanes changed as shown in the initial release of this service bulletin. **REASON FOR REVISION** Revision 1 is sent to add a group of airplanes that may have been delivered with improperly mixed secondary fuel vapor barrier sealant and to provide new thickness measurement inspection limits. This revision also corrects and clarifies inspection points on the front spar and top surface of the Center Wing Box. Paragraph 1.E., Compliance, has been changed from 4 years to 5 years in order to align better with heavy maintenance checks. 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. The data given in Information Notice 757-57-0061 R00 IN01 is included in this revision. The Information Notice advised operators about the errors in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. **REVISION HISTORY** Original Issue: February 6, 2003 Revision 1: May 24, 2007February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

BLANK PAGEFebruary 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 55 

### Commercial **Airplane Group**  

# 757 Service Bulletin
**Number: 757-57-0061** 

### Summary Date: February 06, 2003 Revision 1 May 24, 2007 ATA System: 5710 2810 **SUBJECT:** WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series)
**CONCURRENT REQUIREMENTS** None. **BACKGROUND** Inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied to the outboard corners of the front spar. More inspections found defective examples of the Secondary Fuel Barrier applied along the front spar and the upper panel. The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure. When the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from fuel leaks or fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener holes or cracks in the structure and pass into the passenger compartment. There are no reports of fuel leaks or fumes in the passenger compartment. This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front spar and upper panel. The inspections will identify locations where the secondary fuel barrier is not satisfactory. A new layer of secondary fuel barrier will be applied if it is necessary. A satisfactory secondary fuel barrier will keep fuel leaks or fumes out of the pressurized cabin. Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

**ACTION** Get access to the front spar and the top of the Wing Center Section by removal of the seats, floor covers, floor panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If necessary, remove the bulkhead lining for more access. Examine the specified locations where the Secondary Fuel Barrier is applied. Look for examples of missing, peeled, non-continuous or non-transparent secondary fuel barrier. Make sure the applied thickness of the secondary fuel barrier is between the specified limits. Remove the corrosion inhibitor compound if it is necessary, then clean the area where the new layer of secondary fuel barrier will be applied. Install all the components that were removed for access. Do system tests as necessary. **EFFECTIVITY** Airplane Model 757-300; Line numbers 804 thru 964; divided into three groups. **COMPLIANCE** Boeing recommends the inspection of the Secondary Fuel Barrier at the next regularly scheduled heavy maintenance check. Apply the secondary fuel barrier, if it is necessary, no later than five years after the release of this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of September 22, 2000. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER** See Paragraph 1.G Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

900 STA
1040 STA

NEW LAYER OF SECONDARY FUEL BARRIER. IF DEFECTIVE, REMOVE AND APPLY A SECONDARY FUEL BARRIER. SPAR FOR DEFECTIVE APPLICATION OF EXAMINE THE UPPER PANEL AND FRONTV87883February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

BLANK PAGEFebruary 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 55 

### Commercial **Airplane Group**  

# 757 Service Bulletin
**Number: 757-57-0061** Date: February 06, 2003 Revision 1: May 24, 2007 ATA System: 5710 2810 **SUBJECT:** WINGS - Center Wing Box - Inspection of the Application of Secondary Fuel Barrier on the Front Spar and Upper Panel (-300 Series)
**1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D6-24N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

Airplane models: 757-300 IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER ARKIA ISRAELI AIRLINES (ARK) 3 NU731–NU732 **GROUP CONFIGURATION DESCRIPTION** 1 - 757-300 Airplanes that must complete the whole bulletin 2 - 757-300 Airplanes that only require inspection of the front spar center section. 3 - 757-300 Airplanes previously in Group 1 that could have fuel vapor barrier material applied that was thinned with lacquer thinner. 1 Group 3 Airplanes that have not incorporated the previous release of service bulletin 757-57- 0061. 2 Group 3 Airplanes that have incorporated the previous release of service bulletin 757-57- 0061.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
CONDOR (CDF) 1 NU701–NU705 NU721–NU723 NU728 3 NU724–NU727 THOMAS COOK AIRLINES UK (JMA) 2 NL001–NL002 IDENTIFICATION BY VARIABLE NUMBER

2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** Inspections of the Wing Center Section at Boeing did not find the Secondary Fuel Barrier applied to the outboard corners of the front spar. More inspections found defective examples of the Secondary Fuel Barrier applied along the front spar and the upper panel. The Secondary Fuel Barrier is applied to areas of the center section that are subject to cabin pressure. When the secondary fuel barrier is applied satisfactorily, it protects the pressurized cabin areas from fuel leaks or fumes. If the secondary fuel barrier is defective, fuel or fumes can leak through fastener holes or cracks in the structure and pass into the passenger compartment. There are no reports of fuel leaks or fumes in the passenger compartment. This service bulletin will examine where and how the Secondary Fuel Barrier is applied to the front spar and upper panel. The inspections will identify locations where the secondary fuel barrier is not satisfactory. A new layer of secondary fuel barrier will be applied if it is necessary. A satisfactory secondary fuel barrier will keep fuel leaks or fumes out of the pressurized cabin. **NOTE:** A satisfactory secondary fuel barrier is described in the Accomplishment Instructions, Part III - Inspection of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3 - Configuration 1. Boeing Service Related Problem (SRP) 757-SRP-28-0067 is related to this service bulletin. **Variable Group** NL001–NL002 2 NU701–NU705 1 NU721–NU723 1 NU724–NU727 3 NU728 1 NU731–NU732 3February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**
Revision 1 is sent to add a group of airplanes that may have been delivered with improperly mixed secondary fuel vapor barrier sealant and to provide new thickness measurement inspection limits. This revision includes the correct special tooling requirements for the accomplishment of the service bulletin, and provides clarifications and corrections to inspection points on the Front Spar and Upper Panel. **D. Description** Get access to the front spar and the top of the Wing Center Section by removal of the seats, floor covers, floor panels and cabin lining at, or adjacent to, Body Stations (BS) 900 thru 1040. If necessary, remove the bulkhead lining for more access. Examine the specified locations where the Secondary Fuel Barrier is applied. Look for examples of missing, peeled, non-continuous or non-transparent secondary fuel barrier. Make sure the applied thickness of the secondary fuel barrier is between the specified limits. Remove the corrosion inhibitor compound if it is necessary, then clean the area where the new layer of secondary fuel barrier will be applied. Install all the components that were removed for access. Do system tests as necessary. The airplane effectivity is divided into three groups. The airplanes in Group 1 and Group 3, Configuration 1 must complete all of the service bulletin. The airplanes in Group 2 will only do work on the Front Spar. The airplanes in Group 3, Configuration 2 must be checked to determine if the vapor barrier meets the new thickness requirements. Revision 1 - More work is necessary on airplanes changed as shown in the initial release of this service bulletin. The airplanes in Group 3, Configuration 2 must be checked to determine if the vapor barrier meets the new thickness requirements. PLEASE SEND A REPORT OF YOUR INSPECTION PROGRAM. ALSO, SEND THE INSPECTION RESULTS WHEN EACH INSPECTION IS COMPLETE Send your report to: BOEING COMMERCIAL AIRPLANES GROUP ATTENTION: MANAGER, AIRLINE SUPPORT **E. Compliance** Boeing recommends the inspection of the Secondary Fuel Barrier at the next regularly scheduled heavy maintenance check. Apply the secondary fuel barrier, if it is necessary, no later than five years after the release of this service bulletin. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/ JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other 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.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

**NOTE:** Joint Airworthiness Requirements (JAR) compliance status may be found in the Service Bulletin Index, Part 1. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this bulletin for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-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. Group 1 and Group 3, Configuration 1 ONLY

Group 2 ONLY

Group 3, Configuration 2 ONLY **Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 13.0 6.5 Inspection 2 8.0 4.0 Thickness Measurement 1 6.0 6.0 Secondary Fuel Barrier Application 1 6.5 6.5 Close Access 2 15.0 7.5 TOTAL FOR EACH AIRPLANE 48.5 30.5

**Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 4.0 2.0 Inspection 2 8.0 4.0 Secondary Fuel Barrier Application 1 6.5 6.5 Close Access 2 6.0 3.0 TOTAL FOR EACH AIRPLANE 24.5 15.5

**Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 13.0 6.5 Thickness Measurement 1 6.0 6.0February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

**H. Weight and Balance Changes**

**I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Miscellaneous Retrofit Requirement (MRR) MRR 5574-1067 b. Service Related Problem (SRP) 757-SRP-28-0067 c. Boeing Document D6-56722, Customer Cost Benefit Methodology Guide d. 757 Maintenance Manual (AMM) Subjects 20-10-11, 20-10-12, 21-00-00, 21-00-01, 21-21-00, 21-23-06, 24-41-00, 25-21-02, 25-25-01, 25-27-01, 25-50-03, 25-50-04, 28-11-00, 36-00-00 and 53-01-01. e. 757 Structural Repair Manual (SRM) Subject 57-10-10 f. Boeing Standard Overhaul Practices Manual (BSOPM) 20-41-05, 20-50-19 and 20-60-01 g. 757 Maintenance Planning Document (MPD) Item Number CP53-124-01I h. FAA Airworthiness Directive 98-19-05, Amendment 39-10747 i. Boeing Parts Standards Document D-590 j. Boeing Drawing 65-88700 2. Data supplied with this Service Bulletin: None. Secondary Fuel Barrier Application 1 6.5 6.5 Close Access 2 15.0 7.5 TOTAL FOR EACH AIRPLANE 40.5 26.5

**Airplane Change in Weight**  **(Pounds) Change in Moment**  **(Pound-Inches)** 757-300 + 1 + 1, 000 **Task Number of**  **Persons Task-Hours Elapsed Hours**February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 55 

### BOEING SERVICE BULLETIN 757-57-0061 3. Installation Drawings Used in the Preparation of this Service Bulletin:

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 Affected** None. **L. Interchangeability and Intermixability of Parts** Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

**Drawing Number Title** 110N0004 Seal Application - Secondary Fuel Barrier Coating, Wing, Center Section 112N2010 Terminal Fitting Installation - Wing / Body Joint, Front Spar 144N2101 Bulkhead Installation, Front Spar Body Station 900 140N3002 Corrosion Inhibiting Compound Instl - FuselageFebruary 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

**2. MATERIAL INFORMATION A. Material - Price and Availability**  None. **B. Industry Support Information** Boeing warranty remedies are available for 757 airplanes in warranty as of September 22, 2000. For inspection man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. If the condition described in this service bulletin is found during the inspection for airplanes in warranty as of that date and additional man-hours and kits, parts, and/or special tools are required, send a warranty claim to Boeing Commercial Airplanes Group - Warranties. Please refer to this service bulletin number and reference the airplane variable numbers in your purchase order. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None. 2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **Part Number / Specification QTY Name Notes** 180 to 400 grit 20 Sheets Abrasive Paper, Aluminum Oxide BMS 5-81, Type II 40 oz. Sealant, Secondary Fuel Barrier (a) BMS 3-23, Type II, Class 2 1 Pint Organic Corrosion Inhibiting Compound (a) BMS 3-29 1 Pint Advanced Organic Corrosion Inhibiting Compounds (CIC) (a) BMS 3-35 1 Pint Heavy Duty Corrosion Inhibiting Compound (a) BMS 10-11, Type I 1 Pint Chemical and Solvent Resistant Finish (a) BMS 5-95, Type 1, Class B-1/2, B-2 or B-4 1 Pint Pressure and Environmental Sealant - Chromate Type (a) (b) (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (b) Refer to BSOPM 20-50-19February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
**E. Special Tooling - Price and Availability** The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Tool price and supply data are not given. **F. Special Tooling Necessary to do this Service Bulletin** To get the Non-Conductive Coating Thickness Gage shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available. **Tool Number Name** 602-816 Dualscope MP20 (a) (b) 602-128 ETA 3.3H Probe (a) (b) (a) The Dualscope with probe are an example of a Non-Conductive Coating Thickness Gage (NCCTG). The use of any NCCTG is permitted, but it must have a thickness range from 0.001 - 0.045 inches. (b) Fisher Technology (9U437) 750 Marshall Phelps Rd. Windsor, CT 06095-2199February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. The work instructions are divided into work packages. Task-Hours and Elapsed-Hours for each package are given in Paragraph 1.G., Manpower. You can do each work package independently. 4. 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. 5. For approved fastener and process material substitutions, refer to 757 Structural Repair Manual, Chapter 51, Alternate fasteners are given in 757 Structural Repair Manual Chapter 51 and Boeing Drawing 65-88700 6. Refer to the Boeing Standard Wiring Practices Manuals 20-10-11 and 20-10-12 for the wire installation procedures. 7. If the length of fasteners specified in this service bulletin do not meet the installation standards, fasteners of the same specification, or an approved substitute, one grip length longer or shorter may be used. 8. Detailed Visual Inspection - An intensive examination of a specific item, installation or assembly to detect damage, failure or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate access procedures may be required. **B. WORK INSTRUCTIONS** 1. For Group 1, Group 2 and Group 3, Configuration 1 airplanes, do Part I through Part VIII as applicable. 2. For Group 3, Configuration 2 airplanes, do Part IX. **PART I - Open Access - Group 1 and Group 3, Configuration 1** 1. Supply external power to the airplane, as given in AMM 24-41-00.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
2. Release the pressure from the pneumatic system; refer to AMM 36-00-00. 3. Set the L And R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to AMM 21-00-00. a. Make sure the PACK OFF lights come on. b. Put a DO-NOT-OPERATE tag on the selectors. 4. Set the L And R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel P5. Refer to AMM 21-00-01. a. Make sure the INOP lights go on, and the ON lights go off. b. Put a DO-NOT-OPERATE tag on the switch-lights. 5. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section. a. Between BS 900 and 1040, remove: (1) The passenger seats, as referenced in AMM 25-25-01. (2) The floor covering, as referenced in AMM 25-27-01. (3) The floor panels, as referenced in AMM 25-50-04 and 53-01-01. (4) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02. b. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1. c. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in AMM 25-50-03. **PART II - Open Access - Group 2** 1. Supply external power to the airplane, as given in AMM 24-41-00. 2. Release the pressure from the pneumatic system; refer to AMM 36-00-00. 3. Set the L And R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to AMM 21-00-00. a. Make sure the PACK OFF lights come on. b. Put a DO-NOT-OPERATE tag on the selectors. 4. Set the L And R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel P5. Refer to AMM 21-00-01. a. Make sure the INOP lights go on, and the ON lights go off. b. Put a DO-NOT-OPERATE tag on the switch-lights.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061** 5. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section. a. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1. b. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in AMM 25-50-03. **Part III - Inspection of the Secondary Fue l Barrier - Group 1, Group 2 and Group 3,**  **Configuration 1** 1. Do a Detailed Visual Inspection of the Front Spar and the Upper Panel. Refer to Figure 2 and Figure 3 for the specified location of the application. a. Look for signs of missing, peeled, non-continuous or non-transparent secondary fuel barrier. (1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to examine in Paragraph 1.b. (2) If defective surfaces are found, the secondary fuel barrier is NOT permitted. Record the location. Repair as given in Part V - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1. b. Look for small air bubbles, air pockets or blister-like areas, or solid particles in the secondary fuel barrier or between the secondary fuel barrier and the structure. (1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to examine the surface as directed in Paragraph 1.c. (2) If some small air bubbles or non-metallic solid particles are found, they must NOT break the continuity of the application of the secondary fuel barrier. If there are no more than 2 (two) occurrences in a 12 inch by 12 inch area the application is permitted. Continue to examine the surface as directed in Paragraph 1.c if this statement is correct. (3) Air pockets or blister-like areas between the secondary fuel barrier and the structure are NOT permitted. Record the location and repair as given in Part V – Repair of the Secondary Fuel Barrier – Group 1, Group 2 and Group 3, Configuration 1. **NOTE:** Solid metallic particles are not acceptable. Record the location and repair as given in Part V – Repair of the Secondary Fuel Barrier – Group 1, Group 2 and Group 3, Configuration 1. (4) If small air bubbles, air pockets or non-metallic solid particles break the continuity of the application of the secondary fuel barrier, the application is NOT permitted. Record the location. Repair as given in Part V - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1. Continue to examine in the surface as directed in Paragraph 1.c. c. Look for fillet sealant, primer, corrosion inhibiting compound or other finishes that are applied on top of the Secondary Fuel Barrier. (1) If no defective surfaces are found, the secondary fuel barrier is permitted. Continue to do the Accomplishment Instructions.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
(2) If defective surfaces are found, and the structure below can be seen, it is a permitted secondary fuel barrier. Continue to do the Accomplishment Instructions. (3) If defective surfaces are found, but the structure below cannot be seen, it is NOT a permitted secondary fuel barrier. Record the location and repair as given in Part V - Repair of the Secondary Fuel Barrier - Group 1and Group 3, Configuration 1. d. Look for missing fillet (cap) seals common to the fastener locations shown in Figure 2, View J-J. (1) If all the locations are cap sealed, no work is necessary. Continue to do the Accomplishment Instructions. (2) If there are locations that are not cap sealed, record the location. Repair as given in Part V - Repair of the Secondary Fuel Barrier - Group 1 and Group 3, Configuration 1. **Part IV - Thickness Measurement Inspection - Group 1 and Group 2** 1. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figures 4 and 5. 2. Make sure the thickness is 0.007 - 0.022 inch. (This includes a 0.002 inch layer of primer.) Refer to Figure 2. a. If the thickness is less than 0.007 inch, apply more Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. b. If the thickness is more than 0.022 inch, it must have a transparent quality. A transparent quality makes it easy to see a crack that starts below the structure. An applied secondary fuel barrier that is not transparent must be removed. Repair as given in Part V - Repair of Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1. c. If the thickness is more than 0.042 inch, the secondary fuel barrier is NOT permitted. Repair as given in Part V - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1. **NOTE:** Do NOT measure on top of the other sealants. There is no limit to the thickness of secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant). 3. Record the thickness data in the Inspection Worksheets given in Appendix A and keep the worksheet with the airplane maintenance records for future reference. **Part IV(a) - Thickness Measurement Inspection - Group 3, Configuration 1** 1. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figure 4 and Figure 5. **NOTE:** The thickness measurements below includes a 0.002 inch layer of primer. a. If the thickness is less than 0.007 inch, apply a minimum of 0.005 inch new Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**
b. If the thickness is greater than 0.012 inch, but less than or equal to 0.017 inch, apply a minimum of 0.005 inch new Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. **NOTE:** Thicknesses between 0.007 inch and 0.012 inch do not require the application of the additional 0.005 inch secondary fuel barrier. Overcoating is allowed in this thickness range to make the repair of adjacent areas more efficient. c. If the thickness is greater than 0.017 inch, but less than or equal to 0.037 inch it must have a transparent quality and it must be overcoated with a minimum of 0.005 inch of new Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. **NOTE:** A transparent quality makes it easy to see a crack in the structure. An applied secondary fuel barrier that is not transparent must be removed. Repair as given in Part V - Repair of Secondary Fuel Barrier - Group 1, Group 2 and Group 3 - Configuration 1. d. If the thickness is more than 0.037 inch, the secondary fuel barrier is NOT permitted. Repair as given in Part VI - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3 - Configuration 1. **NOTE:** Do NOT measure on top of the other sealants. There is no limit to the thickness of secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant). 2. Record the thickness data in the Inspection Worksheets given in Appendix A and keep the worksheet with the airplane maintenance record for future reference. **Part V - Repair of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1** 1. Repair the Secondary Fuel Barrier at the locations noted in Part III - Inspection of the Secondary Fuel Barrier - Group 1, Group 2 and Group 3, Configuration 1; and in Part IV - Thickness Measurement Inspection - Group 1 and Group 2; and in Part IV(a) - Thickness Measurement Inspection - Group 3, Configuration 1. a. Remove the secondary fuel barrier as given in AMM 28-11-00.. **NOTE:** 757 AMM 28-11-00 does not directly address removal of large areas of BMS 5-81 sealant. It is permissible to remove the bulk of the sealant with the use of plastic or wooden scrapers. Boeing production typically uses plastic scrapers. b. If not already applied, apply a cap seal to the top side of the fasteners as specified in BSOPM 20-50-19. Refer to Figure 2, View J-J. c. Apply the secondary fuel barrier as given in AMM 28-11-00. **Part VI - Inspection and Application of the Secondary Fuel Barrier - Group 2** 1. Do a Detailed Visual Inspection of the Front spar and the Upper Panel to ensure that the application covers the minimum area specified in Figure 6. a. Make sure the Secondary Fuel Barrier is applied a minimum of 1.50 inches below the lowest fastener that passes through the front spar web and the lower chord.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 55 

### BOEING SERVICE BULLETIN 757-57-0061 b. If the Secondary Fuel Barrier does not cover the minimum specified area, apply as given in AMM 28-11-00. **Part VII - Close Access - Group 1 and Group 3 - Configuration 1** 1. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section. a. Install the air conditioning ducts on the mix manifold as shown in Figure 7. b. Do a leak test of the air conditioning ducts as given in AMM 21-23-06 "Do the Riser Duct Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser duct. c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in AMM 25-50-03. d. Between BS 900 and 1040, install: (1) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02. (2) The floor panels, as referenced in AMM 25-50-04 and 53-01-01. (3) The floor covering, as referenced in AMM 25-27-01. (4) The passenger seats, as referenced in AMM 25-25-01. 2. Set the L And R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. Refer to AMM 21-00-01. a. Remove the DO-NOT-OPERATE tag from the switch-lights. b. Make sure the INOP lights go off, and the ON lights go on. 3. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to AMM 21-00-00. a. Remove the DO-NOT-OPERATE tag from the selectors. b. Make sure the PACK OFF lights go off. 4. Put the pneumatic system back to service condition. Refer to AMM 36-00-00. 5. Put the electrical power back to service condition, as given in AMM 24-41-00. 6. Put the airplane back to a serviceable condition. **Part VIII - Close Access - Group 2** 1. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section. a. Install the air conditioning ducts on the mix manifold as shown in Figure 7.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**
b. Do a leak test of the air conditioning ducts as given in AMM 21-23-06 "Do the Riser Duct Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser duct. c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in AMM 25-50-03. 2. Set the L And R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. Refer to AMM 21-00-01. a. Remove the DO-NOT-OPERATE tag from the switch-lights. b. Make sure the INOP lights go off, and the ON lights go on. 3. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to AMM 21-00-00. a. Remove the DO-NOT-OPERATE tag from the selectors. b. Make sure the PACK OFF lights go off. 4. Put the pneumatic system back to service condition. Refer to AMM 36-00-00. 5. Put the electrical power back to service condition, as given in AMM 24-41-00. 6. Put the airplane back to a serviceable condition. **PART IX - Thickness Measurement Inspection - Group 3 - Configuration 2 Airplanes** 1. Review the maintenance records for the airplane to determine if there was a minimum of 0.005 inch new Secondary Fuel Barrier applied. If a minimum of 0.005 inch new Secondary Fuel Barrier was applied, then no further action is required in that area. 2. If the thickness of the Secondary Fuel Barrier can not be determined from the maintenance records, or if there was not a minimum of 0.005 inch of new Secondary Fuel Barrier added, then go to Step 3. 3. Supply external power to the airplane, as given in AMM 24-41-00. 4. Release the pressure from the pneumatic system; refer to AMM 36-00-00. 5. Set the L And R Pack selectors to the OFF position, on the pilot’s overhead panel P5. Refer to AMM 21-00-00. a. Make sure the PACK OFF lights come on. b. Put a DO-NOT-OPERATE tag on the selectors. 6. Set the L And R RECIRC FAN switch-lights to the OFF position, on the pilot’s overhead panel P5. Refer to AMM 21-00-01. a. Make sure the INOP lights go on, and the ON lights go off.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 55 

### BOEING SERVICE BULLETIN 757-57-0061 b. Put a DO-NOT-OPERATE tag on the switch-lights. 7. Get access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section. a. Between BS 900 and 1040, remove: (1) The passenger seats, as referenced in AMM 25-25-01. (2) The floor covering, as referenced in AMM 25-27-01. (3) The floor panels, as referenced in AMM 25-50-04 and 53-01-01. (4) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02. b. Remove the air conditioning ducts from the mix manifold at the locations shown in Figure 1. c. Remove the aft bulkhead lining from the forward cargo compartment, as referenced in AMM 25-50-03. 8. Measure the thickness of the secondary fuel barrier applied to the locations specified in Figure 4 and Figure 5. **NOTE:** The thickness measurements below includes a 0.002 inch layer of primer. a. If the thickness is less than 0.007 inch, apply a minimum of 0.005 inch new Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. b. If the thickness is greater than 0.012 inch, but less than or equal to 0.017 inch, apply a minimum of 0.005 inch new Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. **NOTE:** Thicknesses between 0.007 inch and 0.012 inch do not require the application of the additional 0.005 inch secondary fuel barrier. Overcoating is allowed in this thickness range to make the repair of adjacent areas more efficient. c. If the thickness is greater than 0.017 inch, but less than or equal to 0.037 inch it must have a transparent quality and it must be overcoated with a minimum of 0.005 inch of new Secondary Fuel Barrier as given in Part X - Application of More Secondary Fuel Barrier. **NOTE:** A transparent quality makes it easy to see a crack in the structure. An applied secondary fuel barrier that is not transparent must be removed. Repair as given in Step 10. d. If the thickness is more than 0.037 inch, the secondary fuel barrier is NOT permitted. Repair as given in Step 10. **NOTE:** Do NOT measure on top of the other sealants. There is no limit to the thickness of secondary fuel barrier applied on top of BMS 5-95 (Pressure and Environmental Sealant, Chromate Type) and BMS 5-142 (Low -Density Sealant). 9. Record the thickness data in the Inspection Worksheets given in Appendix A and keep the worksheet with the airplane maintenance records for future reference.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061** 10. Repair the Secondary Fuel Barrier where removal and reapplication is required. a. Remove the secondary fuel barrier as given in AMM 28-11-00. **NOTE:** 757 AMM 28-11-00 does not directly address removal of large areas of BMS 5-81 sealant. It is permissible to remove the bulk of the sealant with the use of plastic or wooden scrapers. Boeing production typically uses plastic scrapers. b. If not already applied, apply a cap seal to the top side of the fasteners as specified in BSOPM 20-50-19. Refer to Figure 2, View J-J. c. Apply the secondary fuel barrier as given in AMM 28-11-00. 11. Close access to the forward side of the Front Spar and the Upper Panel of the Wing Center Section. a. Install the air conditioning ducts on the mix manifold as shown in Figure 7. b. Do a leak test of the air conditioning ducts as given in AMM 21-23-06 "Do the Riser Duct Installation Test", except feel for leaks at the duct joints at the mix manifold, and at the riser duct. c. Install the aft bulkhead lining from the forward cargo compartment, as referenced in AMM 25-50-03. d. Between BS 900 and 1040, install: (1) The sidewall lining (panels and carpet risers), as referenced in AMM 25-21-02. (2) The floor panels, as referenced in AMM 25-50-04 and 53-01-01. (3) The floor covering, as referenced in AMM 25-27-01. (4) The passenger seats, as referenced in AMM 25-25-01. 12. Set the L And R RECIRC FAN switch-lights to the ON position, on the pilot’s overhead panel P5. Refer to AMM 21-00-01. a. Remove the DO-NOT-OPERATE tag from the switch-lights. b. Make sure the INOP lights go off, and the ON lights go on. 13. Set the L And R Pack selectors to the ON position, on the pilot’s overhead panel P5. Refer to AMM 21-00-00. a. Remove the DO-NOT-OPERATE tag from the selectors. b. Make sure the PACK OFF lights go off. 14. Put the pneumatic system back to service condition. Refer to AMM 36-00-00. 15. Put the electrical power back to service condition, as given in AMM 24-41-00.February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
16. Put the airplane back to a serviceable condition. **PART X - Application of More Secondary Fuel Barrier** 1. Lightly sand the area with 180 grit aluminum oxide or finer abrasive paper. Remove as little of the sealant film as possible. Do not sand to bare metal. 2. Remove residue with clean wipers. 3. Prepare the secondary fuel barrier sealant (BMS 5-81, Type II) as given in AMM 28-11-00. 4. Apply one or two layers of BMS 5-81, Type II sealant with a flat, bristle brush. Take all reasonable precautions to prevent or minimize sag areas. a. For horizontal surfaces, let the sealant dry a minimum of 1/2 hour between layers. b. For vertical surfaces, let the sealant dry a minimum of 2 hours between layers. 5. Refer to AMM 28-11-00 for cure rates.**FIGURE 1: Open Access - Air Conditioning Duct Removal - Group 1, Group 2 and Group 3** February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061 FIGURE 1: Open Access - Air Conditioning Duct Removal - Group 1, Group 2 and Group 3** 

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one airplane. **STEP TASK NAME REFERENCES QTY NOTES** 1 Disconnect Duct Assembly 21-21-00 2 At each end; put covers over all open duct ends. 2 Remove Duct Assembly - 2 - FWD COMPARTMENT TO PASSENGER (2 EACH SIDE) 1 2

CONNECTOR SERVICE GROUND AIR MIX MANIFOLDV88483

**(SHEET 1 OF 1) FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
**FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1**

FWD 900 STA

0 BL 45.50

RBL

45.50 LBL 900 STA

1 SPAR FRONT A A
B B

0 BL 24.75 LBL 24.75

RBL 45.50 LBL 45.50

RBL



### A-A G C J J

F 70.50

RBL 70.50 LBL

3 FUEL BARRIER SECONDARY 2V87884 I I D

D C G E E F

H H

**(SHEET 1 OF 5) FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

FUEL BARRIER SECONDARY FUEL BARRIER SECONDARY

TYPICAL



### C-C FUEL BARRIER SECONDARY LOWER CHORD

CAP SEAL TYPICAL



### D-D FUEL BARRIER SECONDARY SPAR WEB FRONT

FRONT SPAR MIN 1.50 INBD UPPER PANEL FITTING SHEAR

2 3 2 3 MIN 1.00

TYPICAL



### B-B

2 3

FWD MIN 1.0 MIN 1.0

MIN 1.0 MIN 1.0

FITTING SIDE 2 3

FWDV87885

**(SHEET 2 OF 5) FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

1.00 MIN

TYPICAL OUTBOARD OF BBL 45.50 

### E-E FUEL BARRIER SECONDARY 1.50

TYPICAL INBOARD OF BBL 45.50 

### F-F FUEL BARRIER SECONDARY

1.00 MIN FUEL BARRIER SECONDARY

TYPICAL



### G-G MIN 1.00 FRONT SPAR

SKIN LOWER CHORD FRONT SPAR 1.00 MIN STIFFENER

SPAR FRONT

CHORD-BODY 2 3

FWD STIFFENER

SPAR FRONT CHORD-BODY 2 3

FWD

2 3

INBD FWD FITTING SIDE 0.50 MINV87886

**(SHEET 3 OF 5) FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

FUEL BARRIER SECONDARY OF BBL 45.50 TYPICAL OUTBOARD 

### H-H MIN 0.50

FUEL BARRIER SECONDARY

FRONT SPAR WEB

TYPICAL



### I-I STIFFENER 1.00 MIN 1.00 MIN FUEL BARRIER SECONDARY

INBD FWD

4 (7 PLACES) CAP SEAL

TYPICAL



### J-J 2 3

FWD 2 3

FWD CHORD ANGLE SPLICE SPAR FRONT

3 2N78545

**(SHEET 4 OF 5) FIGURE 2: Inspection - Secondary Fuel Barrier - Front Spar - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 55 

### BOEING SERVICE BULLETIN 757-57-0061 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one airplane. **STEP TASK NAME REFERENCES QTY NOTES** 1 Clean Front Spar - Remove dirt/debris from the area 2 Identify Secondary Fuel Barrier Visual Inspection - (a)

3 Examine Front Spar Detailed Visual Inspection - (b) (c) Remove Corrosion Inhibiting Compound BMS 3-23 or BMS 3-29 or BMS 3-35 - This is only necessary if it is difficult to identify a layer of Secondary Fuel Barrier. Refer to BSOPM 20-41-05 and 20-60-01 for removal. 4 Verify Cap Seal 7 See View J-J (a) Look for a glossy finish, a clear to brown (or yellow) color, and a rubber-like texture. (b) Use a flashlight. Hold it 10 to 20 degrees to the inspection area. (c) Look for defective layers of secondary fuel barrier as specified in Part III - Inspection of the Secondary Fuel Barrier - Group 1, in the Work Instructions.

**(SHEET 5 OF 5) FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061 FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1** 

FWD 900 STA 1040 STA

0 BL 24.75

RBL 45.50

RBL 70.50

RBL

24.75 LBL 45.50 LBL

70.50

LBL 900 STA

1 TOP PANEL
208.1 WL 1040 STAV87887 B E E

H H D D

B 

### C C A A

G G M M O
O P
P N N

**(SHEET 1 OF 7) FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

RIGHT SIDE SHOWN, LEFT SIDE SAME 

### A-A TYPICAL EDGE PANEL CHORD UPPER PANEL SKIN

PLUS MIN 1.00

STA 975.5 TO 1040 TYPICAL BEAM 

### B-B LOWER CHORD FLOOR BEAM WEB BEAM FLOOR

PANEL UPPER



### C-C ASSEMBLY PLUG

MIN 0.50

PANEL UPPER

TYPICAL ALL BRACKETS 

### D-D PANEL UPPER BRACKET SUPPORT MIN 1.00 MIN 0.75 2 3 BEAM CREASE

3 2

2 3 INBD

FWD 3 2 FWD FUEL BARRIER SECONDARY

FUEL BARRIER SECONDARY

FUEL BARRIER SECONDARY FUEL BARRIER SECONDARYV87888

**(SHEET 2 OF 7) FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

E-E

F-F

RIGHT SIDE SAME LEFT SIDE SHOWN, 

### G-G SPLICE LONGERON

AND SEALANT COMPOUND EXISTING F F BEAM STUB

MIN 1.00 PANEL UPPER CHORD PLUS

MIN 0.25 2 3 70.50 RBL 70.50

RBL

INBD FWD PANEL UPPER BEAM STUB

CHORD PLUS 2 3 INBD

MIN 2.00

INBD 900 STA
SKIN BODY

CHORD PLUS FRAME

PANEL UPPER

SPAR FRONT 2 3 208.10 WL FUEL BARRIER SECONDARY

FUEL BARRIER SECONDARY

FUEL BARRIER SECONDARY SEALANT EXISTINGV87889

**(SHEET 3 OF 7) FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

INBD

FWD PANEL UPPER REAR SPAR 1.00 MIN 1.00 MIN MIN 1.00 MIN 1.00 1040 STA

FRAME FITTING KICK 2 3

MIN 2.00 MIN 1.00 MIN 1.00 70.50 LBL

PANEL UPPER
KICK FITTING FRAME

UPPER CHORD REAR SPAR 1040 STA 2 3 70.50

LBL 45.50

LBL 24.75

LBL 0 BL

BEAM FLOOR
CHORD PLUS PANEL UPPER 1024 STA MIN 1.00

BEAM FLOOR BEAM FLOOR 1040 STA

INBD FWD 2 3 2 3

DO NOT BLOCK DRAIN PATH -

OF KICK FITTING TYPICAL OUTSIDE WALLS 

### I-I

SEALANT EXISTING 

### H-H

J-J FRAMEV87890 L L

K K

I I

J J

**(SHEET 4 OF 7) FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

MIN 1.00 MIN 1.00

SPAR REAR 1040 STA FITTING KICK

PANEL UPPER SPACER FRAME

SEAL INJECTION FILLET AND EXISTING

FWD 2 3

FWD SPAR REAR PANEL UPPER BEAM WEB FLOOR FITTING

SEAL PRE-PACK

DECK PRESSURE

ANGLE ATTACH 1040 STA

MIN 1.00

MIN 1.00 2 3

DO NOT BLOCK DRAIN PATH -

FWD 2 3 SEAL INJECTION FILLET AND EXISTING

PANEL UPPER PLUS CHORD DOUBLE

MIN 1.00 MIN 0.75
SPAR FRONT 900 STA DO NOT BLOCK DRAIN PATH -

RIGHT SIDE SAME LEFT SIDE SHOWN, 

### M-M OF KICK FITTING TYPICAL, INSIDE WALLS 

### K-K

L-L MIN 1.00

MIN 2.00 MIN 0.75 PANEL UPPER SEAL INJECTION FILLET AND EXISTING 1040 STA 2 3

MIN 2.00 PLUS CHORD DOUBLE

SPAR REAR

RIGHT SIDE SAME LEFT SIDE SHOWN, 

### N-N FWDV87891

**(SHEET 5 OF 7) FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

24.75

RBL

208.1 WL

MIN 1.00 BEAM FLOOR

UPPER PANEL
TYPICAL FROM STA 900 TO STA 975.5 

### O-O

MIN 1.00 MIN 1.00 FITTING TENSION

UPPER PANEL BEAM FLOOR

(15 PLACES) TYPICAL AT TENSION TIE FITTINGS 

### P-P 2 3

2 3N78557

**(SHEET 6 OF 7) FIGURE 3: Inspection - Secondary Fuel Barrier - Upper Panel - Group 1 and Group 3, Configuration 1**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one airplane. **STEP TASK NAME REFERENCES QTY NOTES** 1 Clean Upper Panel - Remove dirt/debris from the area 2 Identify Secondary Fuel Barrier Visual Inspection - (a)

3 Examine Upper Panel Detailed Visual Inspection - (b) (c) Remove Corrosion Inhibiting Compound BMS 3-23 or BMS 3-29 or BMS 3-35 - This is only necessary if it is difficult to identify a layer of Secondary Fuel Barrier. Refer to BSOPM 20-41-05 and 20-60-01 for removal. (a) Look for a glossy finish, clear to brown (or yellow) color, and a rubber-like texture. (b) Use a flashlight. Hold it 10 to 20 degrees to the inspection area. (c) Look for defective layers of secondary fuel barrier as specified in Part III - Inspection of the Secondary Fuel Barrier - Group 1, in the Work Instructions.

**(SHEET 7 OF 7) FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
**FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3**

BFAW (BODY FRAME ASSEMBLY WEB) BFS (BODY FRAME STIFFENER) FSS (FRONT SPAR STIFFENER) FSW (FRONT SPAR WEB) 

### INSPECTION POINTS (SEE APPENDIX A)

A A B

C C B

FWD 0 BL 70.50

RBL

70.50 LBL 900 STA

1

FSW 1
FSS 5 FSS 1

BFAW 2

FSS 10 FSS 6

BFS 4

BFS 3 FSS 15 FSS 11

FSS 20 FSS 16

FSS 25 FSS 21 FSS 26

FSS 30 FRONT SPAR

FSS 35 FSS 31

FSS 40 FSS 36 FSW INSPECTION POINTS) (TYPICAL BETWEEN 5.0 4.0

FSS 46 FSS 41

FSS 45 FSS 50 FSS 55 FSS 51

FSS 59 14 FSW

BFS 2

FSS 64 BFS 1 BFAW 1 FSS 60 FSS 56 900 STAV87892

**(SHEET 1 OF 3) FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

TYPICAL FSW (14 PLACES) X X/2 0.5 FRONT SPAR WEB

TYPICAL FSS (64 PLACES) STIFFENER STIFFENER

TYPICAL



### A-A

TYPICAL 

### C-C FRAME ASSY SEAL CAP

SKIN FRONT SPAR

TYPICAL



### D-D

X X/2 SPAR (2 PLACES) TYPICAL BFAW

FRONT ASSY FRAME

X

X/2 UPPER PANEL

TYPICAL



### B-B

(4 PLACES) TYPICAL BFS

FRAME FRONT

(TYPICAL) STRINGER ASSY

SKIN (TYPICAL) CAP SEAL SPAR OF STIFFENER ONLY INSPECT THIS SIDE

D D

FWD

INBD FWD 1 2 1 2

1 2

1 2V87893

**(SHEET 2 OF 3) FIGURE 4: Inspection - Thickness Measurements - Front Spar - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 55 

### BOEING SERVICE BULLETIN 757-57-0061 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one airplane. **STEP TASK NAME REFERENCES QTY NOTES** 1 Clean Front Spar Remove dirt/debris from the area

2 Measure/ Make Sure/ Record Secondary Fuel Barrier (a) (b) (c) Front Spar Web FSW 14 See View A-A Front Spar Stiffeners FSS 64 See View A-A Body Frame Assy Web BFAW 2 See View B-B Body Frame Stiffener BFS 4 See Views C-C and D-D(a) Use a Non-Conductive Coating Thickness Gage to measure the thickness of the applied secondary fuel barrier. (Refer to Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.) (b) Deleted - See Accomplishment Instructions for thickness limits. (c) Record the measurements on the Inspection Worksheets in Appendix A.

**(SHEET 3 OF 3) FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**
**FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3**

FWD E

E A

A C

C 900 STA

0 BL 24.75

RBL 45.50

RBL 70.50

RBL

24.75 LBL 45.50 LBL

70.50

LBL 900 STA TOP PANEL 1040 STA

208.1 WL 1040 STA LSOB (LEFT SIDE OF BODY) RSOB (RIGHT SIDE OF BODY) 

### INSPECTION POINTS

FB (FLOOR BEAM) LTP (LEFT TOP PANEL) RTP (RIGHT TOP PANEL) (SEE APPENDIX A)

LSOB 10

LSOB 1 FB 50

FB 41 LTP 8

LTP 5 FB 40 LTP 4

FB 31 LTP 1 FB 21 FB 30 RTP 14

RTP 11 FB 20

FB 11 FB 10 RTP 10

RTP 7 FB 1 RSOB 1 RSOB 10
1

RTP 1 RTP 6

LTP 9 LTP 14V87894

**(SHEET 1 OF 5) FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

5.0 5.0 3.0
3.0 11.0 13.0 (TYPICAL) 11.0 (TYPICAL) 13.0



### TYPICAL FLOOR BEAM INSPECTION POINT UPPER PANEL



### B-B FLOOR BEAM 0.50 OF THE WEB ONLY INSPECT THIS SIDE B B

FWD

INBD 900 STA 920 STA 940 STA 960 STA 984 STA 996 STA 1020 STA 1032.3 STA 1040 STA

INSPECTION POINTS TYPICAL FLOOR BEAM 

### A-A FLOOR BEAM 10 PLACES PER 2 1

2 1V87895

**(SHEET 2 OF 5) FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

PANEL UPPER

5.0 

### C-C PLUS CHORD

LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE TYPICAL SIDE-OF-BODY INSPECTION POINTS 10 PLACES BEAM STUB LSOB 10 LSOB 1 1020 STA 1000 STA 980 STA 960 STA 920 STA SPAR REAR FRONT SPAR

5.0 3.0 (TYPICAL) 11.0 13.0 (TYPICAL)

3.0 11.0 13.0

BEAM CREASE

CHORD PLUS SKIN BODY 0.5 CENTER SECTION UPPER PANEL OF



### D-D 940 STA

D

D

FWD INBD

UP INBD 2 1

2 1V87896

**(SHEET 3 OF 5) FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 55 

### BOEING SERVICE BULLETIN 757-57-0061

(16 PLACES) TYPICAL UPPER PANEL INSPECTION POINTS FLOOR BEAM

FLOOR BEAM PANEL



### E-E SPAR REAR 996 STA 984 STA
FB

UPPER TO FLOOR BEAM WEB FLOOR BEAM WEB
TYPICAL X/2 X 26.0 24.0 26.0 24.0 (TYPICAL)
RBL

24.75 RBL 45.50

FWD 2 1V87897

**(SHEET 4 OF 5) FIGURE 5: Inspection - Thickness Measurements - Upper Panel - Group 1 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one airplane. **STEP TASK NAME REFERENCES QTY NOTES** 1 Clean Front Spar and Upper Panel Remove dirt/debris from the area

2 Measure/ Make Sure/ Record Secondary Fuel Barrier - (a) (b) (c) Floor Beam FB 50 10 locations each, on the right and left side. See View A-A and B-B Side of Body RSOB and LSOB 20 10 locations each, on the right and left side. See Views C-C and D-D Upper Panel RTP and LTP 16 8 locations each, on the right and left side. See View E-E(a) Use a Non-Conductive Coating Thickness Gage to measure the thickness of the applied secondary fuel barrier. (Refer to Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin.) (b) Deleted - See Accomplishment Instructions for thickness limits. (c) Record the measurements on the Inspection Worksheets in Appendix A.

**(SHEET 5 OF 5) FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
**FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2**

FUEL BARRIER SECONDARY

LOWER CHORD FRONT SPAR SPAR WEB FRONT

MIN 1.5

TO FRONT SPAR WEB AND LOWER CHORD

TYPICAL MINIMUM COVERAGE COMMON 

### B-B A-A MIN 1.5

FWD FWD

1 FRONT SPAR WEB LOWER CHORD FRONT SPAR 166 WL SPAR FRONT ALLOWED OVERSPRAY 0 BL 24.75

RBL 45.50

RBL 70.50

RBL

24.75 LBL
45.50 LBL
70.50 LBL 900 STA

900 STA

0 BL 24.75 LBL 24.75

RBL

1V87898 B B A

A

**(SHEET 1 OF 2) FIGURE 6: Inspection and Application of the Secondary Fuel Barrier - Group 2**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061** The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one airplane. **STEP TASK NAME PART NUMBER QTY NOTES** 1 Measure / Make Sure Secondary Fuel Barrier BMS 5-81 - It must be a minimum of 1.50 inches

**(SHEET 2 OF 2) FIGURE 7: Close Access - Air Conditioning Duct Installation - Group 1, Group 2 and Group 3**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
**FIGURE 7: Close Access - Air Conditioning Du ct Installation - Group 1, Group 2 and Group 3** 

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for one airplane. **STEP TASK NAME REFERENCES QTY NOTES** 1 Install Duct Assembly 21-21-00 2 - 2 Connect Duct Assembly - 2 At each end; put covers over all open duct ends. FWD COMPARTMENT TO PASSENGER (2 EACH SIDE) 1 2

CONNECTOR SERVICE GROUND AIR MIX MANIFOLDV88491

**(SHEET 1 OF 1) APPENDIX A: Record of Thickness Measurements**  February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**

**APPENDIX A: Record of Thickness Measurements** Record the thickness measurements from Figures 3 and 4 on the following worksheets. FRONT SPAR - STIFFENERS (FSS)

FRONT SPAR - WEB (FSW)

BODY FRAME - STIFFENER (BFS)

BODY FRAME ASSEMBLY WEB (BFAW) FSS 1 0. in. FSS 17 0. in. FSS 33 0. in. FSS 49 0. in. FSS 2 0. in. FSS 18 0. in. FSS 34 0. in. FSS 50 0. in. FSS 3 0. in. FSS 19 0. in. FSS 35 0. in. FSS 51 0. in. FSS 4 0. in. FSS 20 0. in. FSS 36 0. in. FSS 52 0. in. FSS 5 0. in. FSS 21 0. in. FSS 37 0. in. FSS 53 0. in. FSS 6 0. in. FSS 22 0. in. FSS 38 0. in. FSS 54 0. in. FSS 7 0. in. FSS 23 0. in. FSS 39 0. in. FSS 55 0. in. FSS 8 0. in. FSS 24 0. in. FSS 40 0. in. FSS 56 0. in. FSS 9 0. in. FSS 25 0. in. FSS 41 0. in. FSS 57 0. in. FSS 10 0. in. FSS 26 0. in. FSS 42 0. in. FSS 58 0. in. FSS 11 0. in. FSS 27 0. in. FSS 43 0. in. FSS 59 0. in. FSS 12 0. in. FSS 28 0. in. FSS 44 0. in. FSS 60 0. in. FSS 13 0. in. FSS 29 0. in. FSS 45 0. in. FSS 61 0. in. FSS 14 0. in. FSS 30 0. in. FSS 46 0. in. FSS 62 0. in. FSS 15 0. in. FSS 31 0. in. FSS 47 0. in. FSS 63 0. in. FSS 16 0. in. FSS 32 0. in. FSS 48 0. in. FSS 64 0. in.

FSW 1 0. in. FSW 8 0. in. FSW 2 0. in. FSW 9 0. in. FSW 3 0. in. FSW 10 0. in. FSW 4 0. in. FSW 11 0. in. FSW 5 0. in. FSW 12 0. in. FSW 6 0. in. FSW 13 0. in. FSW 7 0. in. FSW 14 0. in.

**Left Side Right Side** BFS 3 0. in. BFS 1 0. in. BFS 4 0. in. BFS 2 0. in.

**Left Side Right Side** BFAW 2 0. in. BFAW 1 0. in.**APPENDIX A: Record of Thickness Measurements** February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 55 

### BOEING SERVICE BULLETIN 757-57-0061
SIDE OF BODY (SOB)

UPPER PANEL (TP) **Left Side Right Side** LSOB 1 0. in. RSOB 1 0. in. LSOB 2 0. in. RSOB 2 0. in. LSOB 3 0. in. RSOB 3 0. in. LSOB 4 0. in. RSOB 4 0. in. LSOB 5 0. in. RSOB 5 0. in. LSOB 6 0. in. RSOB 6 0. in. LSOB 7 0. in. RSOB 7 0. in. LSOB 8 0. in. RSOB 8 0. in. LSOB 9 0. in. RSOB 9 0. in. LSOB 10 0. in. RSOB 10 0. in.

**Left Side Right Side** LTP 1 0. in. RTP 1 0. in. LTP 2 0. in. RTP 2 0. in. LTP 3 0. in. RTP 3 0. in. LTP 4 0. in. RTP 4 0. in. LTP 5 0. in. RTP 5 0. in. LTP 6 0. in. RTP 6 0. in. LTP 7 0. in. RTP 7 0. in. LTP 8 0. in. RTP 8 0. in. LTP 9 0. in. RTP 9 0. in. LTP 10 0. in. RTP 10 0. in. LTP 11 0. in. RTP 11 0. in. LTP 12 0. in. RTP 12 0. in. LTP 13 0. in. RTP 13 0. in. LTP 14 0. in. RTP 14 0. in.**APPENDIX A: Record of Thickness Measurements** February 06, 2003 Revision 1: May 24, 2007 757-57-0061 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 55 

### BOEING SERVICE BU **LLETIN 757-57-0061**
FLOOR BEAM (FB) FB 1 0. FB 11 0. FB 21 0. FB 31 0. FB 41 0. FB 2 0. FB 12 0. FB 22 0. FB 32 0. FB 42 0. FB 3 0. FB 13 0. FB 23 0. FB 33 0. FB 43 0. FB 4 0. FB 14 0. FB 24 0. FB 34 0. FB 44 0. FB 5 0. FB 15 0. FB 25 0. FB 35 0. FB 45 0. FB 6 0. FB 16 0. FB 26 0. FB 36 0. FB 46 0. FB 7 0. FB 17 0. FB 27 0. FB 37 0. FB 47 0. FB 8 0. FB 18 0. FB 28 0. FB 38 0. FB 48 0. FB 9 0. FB 19 0. FB 29 0. FB 39 0. FB 49 0. FB 10 0. FB 20 0. FB 30 0. FB 40 0. FB 50 0.