### Commercial **Airplanes** 

# 757 Service Bulletin **Number: 757-28-0118** Original Issue: January 12, 2012 ATA System: 2811 **SUBJECT:** FUEL - Fuel Tanks - Access Door Inspection/Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 1 of 20 13.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 2 of 20 **BOEING SERVICE BULLETIN 757-28-0118**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 7 A. Effectivity................................................ 7 1. Airplanes ............................................. 7 2. Spares Affected ......................................... 8 B. Concurrent Requirements....................................... 8 C. Reason................................................. 8 D. Description ............................................... 8 E. Compliance .............................................. 9 F. Approval ................................................ 9 G. Manpower ............................................... 9 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 10 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 11 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 11 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FIGURE 1: ACCESS DOOR INSPECTION - LEFT WING . . . . . . . . . . . . . . . . . . . . . . . . 15 FIGURE 2: ACCESS DOOR INSPECTION - RIGHT WING . . . . . . . . . . . . . . . . . . . . . . . 17 APPENDIX A: GENERAL VISUAL INSPECTION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 19

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 3 of 20 **BOEING SERVICE BULLETIN 757-28-0118**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 4 of 20 **BOEING SERVICE BULLETIN 757-28-0118**

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### Commercial **Airplanes** 

# 757 Service Bulletin **Summary Number: 757-28-0118**  Original Issue: January 12, 2012 ATA System: 2811 **SUBJECT:** FUEL - Fuel Tanks - Access Door Inspection/Replacement **CONCURRENT REQUIREMENTS** Refer to Paragraph 1.B., Concurrent Requirements. **BACKGROUND** This service bulletin provides instructions to inspect the Wing Fuel Tank Access Doors to make sure that Impact Resistant Access Doors are installed in the correct locations and stencils and index markers are applied. Fire can result from damage to a standard access door if it is located where an Impact Resistant Access Door is required. An operator identified a standard access door located where an Impact Resistant Access Door is required. In addition, the operator examined its spares stock and found that some Impact Resistant Access Doors were without stencils. These findings have raised a concern about the possibility of more standard access doors being installed at locations where Impact Resistant Access Doors are required. Impact Resistant Access Doors minimize risk of penetration from engine debris or objects thrown by airplane tires. By accomplishing the inspection in this service bulletin, operators can make sure that stencils and index markers are applied and Impact Resistant Access Doors are installed at the correct locations, providing increased resistance to Wing Fuel Tank penetration. Boeing Service Related Problem (SRP) 757-SRP-57-0225 is related to this service bulletin. **ACTION** Identify the Wing Fuel Tank Access Doors. Do a General Visual Inspection to make sure that Impact Resistant Access Doors are installed in the correct locations. If a standard access door is identified in a location where an Impact Resistant Access Door is required, replace the door with an Impact Resistant Access Door. Do a General Visual Inspection to make sure that stencils and index markers are applied. If a stencil and/or index marker is missing, apply new stencil and/or index marker. **EFFECTIVITY** 757-200/200PF airplanes. Refer to Paragraph 1.A.1, Effectivity. **COMPLIANCE** Refer to Paragraph 1.E., Compliance.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 5 of 20**INDUSTRY SUPPORT INFORMATION** Refer to Paragraph 2.B., Industry Support Information. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 6 of 20 **BOEING SERVICE BULLETIN 757-28-0118**

### Commercial **Airplanes** 

# 757 Service Bulletin **Number: 757-28-0118** Original Issue: January 12, 2012 ATA System: 2811 **SUBJECT:** FUEL - Fuel Tanks - Access Door Inspection/Replacement **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 757 airplanes Line Numbers 1 through 180.

- 1

Airplane Models: 757-200, 757-200PF **Group Variable Number**  1 NA001 - NA028 1 NA191 - NA197 1 NA201 - NA233 1 NA391 - NA394 1 NA401 - NA408 1 NA441 - NA443 1 NA447 1 NA501 - NA538 1 NB001 - NB004 1 NB021 - NB023 1 NB036 - NB038 1 NB051 - NB053

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 7 of 20**Group Variable Number**  1 NB061 - NB063 1 NB071 - NB073 1 NC001 - NC028 1 NC041 - NC042 1 NC901 - NC906 1 ND001 - ND002 1 ND891 2. Spares Affected None. **B. Concurrent Requirements** The service bulletin listed below must be done before or at the same time as this service bulletin: **Description Service Bulletin**  **Company** Main and center tank access door replacement 757-28-0019 Revision 1 Boeing
**C. Reason** This service bulletin provides instructions to inspect the Wing Fuel Tank Access Doors to make sure that Impact Resistant Access Doors are installed in the correct locations and stencils and index markers are applied. Fire can result from damage to a standard access door if it is located where an Impact Resistant Access Door is required. An operator identified a standard access door located where an Impact Resistant Access Door is required. In addition, the operator examined its spares stock and found that some Impact Resistant Access Doors were without stencils. These findings have raised a concern about the possibility of more standard access doors being installed at locations where Impact Resistant Access Doors are required. Impact Resistant Access Doors minimize risk of penetration from engine debris or objects thrown by airplane tires. By accomplishing the inspection in this service bulletin, operators can make sure that stencils and index markers are applied and Impact Resistant Access Doors are installed at the correct locations, providing increased resistance to Wing Fuel Tank penetration. Boeing Service Related Problem (SRP) 757-SRP-57-0225 is related to this service bulletin. **D. Description** Identify the Wing Fuel Tank Access Doors. Do a General Visual Inspection to make sure that Impact Resistant Access Doors are installed in the correct locations. If a standard access door is identified in a location where an Impact Resistant Access Door is required, replace the door with an Impact Resistant Access Door. Do a General Visual Inspection to make sure that stencils and index markers are applied. If a stencil and/or index marker is missing, apply new stencil and/or index marker. The work in this service bulletin is done in the maintenance zone(s) given below.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 8 of 20 **BOEING SERVICE BULLETIN 757-28-0118 Affected Maintenance Zones**  **Zone Model**  531, 541, 631, 641 757-200, 757-200PF **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Boeing recommends that the inspection given in this service bulletin be done within 72 months after the original issue date 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. **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 experienced crews. Adjust the estimate with operator man-hour data if necessary. The estimate does not include lost time. These are 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: MAN-HOURS FOR GENERAL VISUAL INSPECTION PROCEDURE** 
**More Data Elapsed Hours**  **Task Hours Number of Persons**  **Task** (a) 4.0 4.0 1 Figure 1 (a) 4.0 4.0 1 Figure 2 (a) 8.0 8.0 TOTAL FOR EACH AIRPLANE (a) Does not include time to defuel/refuel.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 9 of 20 **BOEING SERVICE BULLETIN 757-28-0118 H. Weight and Balance Changes**  None **I. Electrical Load Data** Not applicable **J. References** 1. Existing Data: a. Boeing Service Bulletin 757-28-0019 b. Boeing Service Related Problem (SRP) 757-SRP-57-0225 c. Standard Overhaul Practices Manual (SOPM) 20-50-10 d. 757 Aircraft Maintenance Manual (AMM) 28-11-01, 28-11-02, 28-26-00 e. 757 Illustrated Parts Catalog (IPC) 28-11-01, 28-11-02 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Nomenclature Engineering Drawing**  DOOR INSTL - FUEL TANK ACCESS, IMPACT RESISTANT 112N6000
**K. Publications Affected** 1. Publications: None. 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.
**L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 10 of 20 **BOEING SERVICE BULLETIN 757-28-0118 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Refer to Paragraph 2.C., Parts Necessary For Each Airplane. **B. Industry Support Information** Boeing warranty remedies are available for 757 airplanes in warranty as of June 19, 2008. For inspection man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Warranty & Product Assurance Contracts. If the condition described in this service bulletin is found during the initial inspection for airplanes in warranty as of that date and additional man-hours or parts are required, send a warranty claim to Boeing Warranty & Product Assurance Contracts. Warranty remedies are not available for continued inspections as described in this Service Bulletin as these actions are considered routine maintenance. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: None 2. Parts and Materials Supplied by the Operator: Refer to Illustrated Parts Catalog (IPC) 757 IPC 28-11-01, 757 IPC 28-11-02 3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None **D. Parts Necessary to Change Spares** None **E. Special Tooling - Price and Availability** None **F. 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 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 11 of 20 **BOEING SERVICE BULLETIN 757-28-0118**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 12 of 20 **BOEING SERVICE BULLETIN 757-28-0118**

BLANK PAGE**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **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. 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 4. If the length of any fastener specified in this service bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. 5. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access doors or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 6. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. **B. WORK INSTRUCTIONS** 1. Defuel the applicable fuel tank. Refer to 757 AMM 28-26-00 as an accepted procedure. 2. Do a General Visual Inspection of the left wing fuel tank access doors to make sure that Impact Resistant Access Doors are installed in the correct locations, in accordance with FIGURE 1.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 13 of 20 **BOEING SERVICE BULLETIN 757-28-0118**3. If one or more standard access doors are found, replace each standard access door with an Impact Resistant access door. Refer to 757 AMM 28-11-01 as an accepted procedure to replace main tank access doors. Refer to 757 AMM 28-11-02 as an accepted procedure to replace center tank access doors. 4. Do a General Visual Inspection of the left wing fuel tank access doors to verify stencils and index markers are applied in accordance with FIGURE 1. 5. If a stencil and/or index marker is missing, apply stencil and/or index marker in accordance with FIGURE 1. 6. Do a General Visual Inspection of the right wing fuel tank access doors to make sure that Impact Resistant Access Doors are installed in the correct locations, in accordance with FIGURE 2. 7. If one or more standard access doors are found, replace each standard access door with an Impact Resistant access door. Refer to 757 AMM 28-11-01 as an accepted procedure to replace main tank access doors. Refer to 757 AMM 28-11-02 as an accepted procedure to replace center tank access doors. 8. Do a General Visual Inspection of the right wing fuel tank access doors to verify stencils and index markers are applied in accordance with FIGURE 2. 9. If a stencil and/or index marker is missing, apply stencil and/or index marker in accordance with FIGURE 2. 10. If one or more access doors were replaced and a leak check has not been done, refuel the applicable fuel tank and check for leaks. Repair if necessary. Refer to 757 AMM 28-11-01 as an accepted procedure to replace main tank access doors. Refer to 757 AMM 28-11-02 as an accepted procedure to replace center tank access doors. 11. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 14 of 20 **BOEING SERVICE BULLETIN 757-28-0118**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 each wing.

**FIGURE 1: ACCESS DOOR INSPECTION - LEFT WING (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 15 of 20 **BOEING SERVICE BULLETIN 757-28-0118 NOTE**  **QTY PART NUMBER**  **NAME TASK**  **STEP** (a) 6
- Access Door Inspect 1 (b)

- - Stencil and Index Marker Inspect 2 (b)

- - Stencil Inspect 3 (b)

- - Index Marker Inspect 4 (a) In accordance with APPENDIX A. (b) If a stencil and/or index marker is missing, apply stencil and/or index marker with BMS 10-60, Polyurethane Gloss Enamel, matching color to existing stencil and/or index marker. Refer to SOPM 20-50-10.

**FIGURE 1: ACCESS DOOR INSPECTION - LEFT WING (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 16 of 20 **BOEING SERVICE BULLETIN 757-28-0118**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 each wing.

**FIGURE 2: ACCESS DOOR INSPECTION - RIGHT WING (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 17 of 20 **BOEING SERVICE BULLETIN 757-28-0118 NOTE**  **QTY PART NUMBER**  **NAME TASK**  **STEP** (a) 6
- Access Door Inspect 1 (b)

- - Stencil and Index Marker Inspect 2 (b)

- - Stencil Inspect 3 (b)

- - Index Marker Inspect 4 (a) In accordance with APPENDIX A. (b) If a stencil and/or index marker is missing, apply stencil and/or index marker with BMS 10-60, Polyurethane Gloss Enamel, matching color to existing stencil and/or index marker. Refer to SOPM 20-50-10.

**FIGURE 2: ACCESS DOOR INSPECTION - RIGHT WING (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 18 of 20 **BOEING SERVICE BULLETIN 757-28-0118**1. Defuel the applicable fuel tank. Refer to 757 AMM 28-26-00 as an accepted procedure. 2. Remove the access door. Refer to 757 AMM 28-11-01 "Main Tank Access Door - Removal/Installation" or 757 AMM 28-11-02 "Center Tank Access Door - Removal/Installation", as applicable, as an accepted procedure. 3. Do a General Visual Inspection of the internal surface of the access door. If the door ends are flat, then the door is an impact resistant access door (Figure A1). If the internal surface of the access door has protruding cast aluminum integral ribs or the door ends are smooth, then the door is a standard access door (Figure A1).

**APPENDIX A: GENERAL VISUAL INSPECTION PROCEDURE (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 19 of 20 **BOEING SERVICE BULLETIN 757-28-0118**Figure A1

**APPENDIX A: GENERAL VISUAL INSPECTION PROCEDURE (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: January 12, 2012 757-28-0118 20 of 20 **BOEING SERVICE BULLETIN 757-28-0118**