### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-24-0106**  Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 **SUBJECT:** ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Auxiliary Slat Track. 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 1 of 27 5.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 2 of 27 **BOEING SERVICE BULLETIN 757-24-0106**

BLANK PAGE**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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 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: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FIGURE 1: LEFT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FIGURE 2: RIGHT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 3 of 27 **BOEING SERVICE BULLETIN 757-24-0106**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 4 of 27 **BOEING SERVICE BULLETIN 757-24-0106**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Revision Transmittal Sheet**  **Number: 757-24-0106** Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 **SUBJECT:** ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Auxiliary Slat Track. This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes changed as shown in the Revision 4 of this service bulletin. **REASON FOR REVISION** Revision 5 is sent to add affected maintenance Zones and add an optional blind rivet NAS1398B8AB2 to plug the open hole in the bracket. These sections were changed: 1. Paragraph 1.D., Description: Added Affected Maintenance Zones. 2. Paragraph 1.F., Approval: Changed the paragraph letter for the Alternate Method of Compliance. 3. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added optional blind rivet, part number NAS1398B8AB2. Also corrected the part number of the collar to read BACC30M8U. 4. Paragraph 3.B.7. and 3.B.8., Work Instructions: Added the Inspection Location. 5. Figure 1, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table. 6. Figure 2, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table. The data given in Information Notice 757-24-0106 IN 01 is included in this revision. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 5 of 27**REVISION HISTORY** September 30, 2004 Original Issue: June 23, 2005 Revision 1: April 20, 2006 Revision 2: October 03, 2006 Revision 3: January 04, 2008 Revision 4: July 30, 2009 Revision 5:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 6 of 27 **BOEING SERVICE BULLETIN 757-24-0106**

### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 757-24-0106** Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 **SUBJECT:** ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Auxiliary Slat Track. BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** None. **BACKGROUND** The changes in this service bulletin will prevent possible chafe damage between the number 5 and 6 inboard slat auxiliary tracks and the power feeder wire bundles W3312 and W3412 or W5784 and W5786. The attach points for the support clamps for the power feeder wires in each wing are changed to get the necessary clearance for the power feeder wires. One operator told Boeing they found that the power feeder wire bundle had chafed against the number 6 slat auxiliary track at Front Spar Station (FSS) 148.90. On one airplane two of the three phases of the power feeder wire bundle were worn through to the conductor. The electrical cables had arced against the auxiliary slat track and caused damage to the auxiliary slat track and power feeder wire. This condition can result in a possible ignition source for leaked flammable fluids or a generator trip with loss of power from that generator. The attach bracket for the power feeder wire bundle clamp at FSS 148.90 has two holes where the power feeder wire bundle can be installed. The support clamp for the damaged power feeder wires was attached to the upper hole of the attach bracket. It was found that the lower hole of the attach bracket can be used to give sufficient clearance between the power feeder wire bundle and the auxiliary slat track. This service bulletin gives instructions to do a general visual inspection of the power feeder wire bundles W3312 and W3412 or W5784 and W5786 for chafe damage and to make sure that the support clamps are correctly installed. Support clamps for the power feeder wire bundles are found in the left and right wings at FSS 148.90, near the number 5 and 6 inboard auxiliary slat tracks. Operators should now use the lower hole of the 287N1401-306 bracket to attach the power feeder wire bundle. Rivets are installed in the open holes that are not used in the brackets to prevent use of the holes. If Service Letter 757-SL-24-072 has been done, install rivets in the open holes that are not used in the attach brackets. A similar change was made in production on line number 1024 and subsequent airplanes. The related 757-200 and 757-200PF bulletin is 757-24-0105. Service Letter 757-SL-24-072 is also related to this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 7 of 27Boeing Service Related Problem (SRP) 757-SRP-24-0109 is related to this service bulletin. **ACTION** Get access to the support clamps for the power feeder wire bundles W3312 and W3412 or W5784 and W5786 at FSS148.90 in the left and right wings. Do a general visual inspection of each power feeder wire bundle. Repair damaged wires as necessary. Make sure that the support clamps for the left and right power feeder wire bundles are installed in the lower hole of the 287N1401-306 support brackets. Rivet plug the holes in the bracket that are not used to prevent use, this includes airplanes that have done Service Letter 757-SL-24-072. **EFFECTIVITY** All 757-300 Airplanes. Refer to Service Bulletin Paragraph 1.A.1 for effectivity. **COMPLIANCE** Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2007-03-01 is related to this service bulletin. Boeing recommends that operators do the changes in this service bulletin in 24 months or less from the initial release date of this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of September 5, 2003. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  4.25 7.5 All
**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 8 of 27 **BOEING SERVICE BULLETIN 757-24-0106**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 9 of 27 **BOEING SERVICE BULLETIN 757-24-0106**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 10 of 27 **BOEING SERVICE BULLETIN 757-24-0106**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-24-0106**  Original Issue: September 30, 2004 Revision 5: July 30, 2009 ATA System: 2420 **SUBJECT:** ELECTRICAL POWER - AC Generation - Inspection and Clamp Change of Power Feeder Wire Bundles to Prevent Chafing on the Number 5 and 6 Auxiliary Slat Track. BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 757-300 Airplanes with Wire Bundle W3312 and W3412.

- 1 757-300 Airplanes with Wire Bundle W5784 and W5786

- 2

Airplane Models: 757-300 **Group Variable Number**  1 NL001 - NL002 1 NL006 - NL015 2 NL101 - NL104 2 NL141 2 NL601 - NL607 1 NU701 - NU705 1 NU721 - NU728

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 11 of 27**Group Variable Number**  1 NU731 - NU732 2. Spares Affected None. **B. Concurrent Requirements** None. **C. Reason** The changes in this service bulletin will prevent possible chafe damage between the number 5 and 6 inboard slat auxiliary slat tracks and the power feeder wire bundles W3312 and W3412 or W5784 and W5786. The attach points for the support clamps for the power feeder wires in each wing are changed to get the necessary clearance for the power feeder wires. One operator told Boeing they found that the power feeder wire bundle had chafed against the number 6 auxiliary track at Front Spar Station (FSS) 148.90. On one airplane two of the three phases of the power feeder wire bundle were worn through to the conductor. The electrical cables had arced against the auxiliary slat track and caused damage to the auxiliary slat track and power feeder wire. This condition can result in a possible ignition source for leaked flammable fluids or a generator trip with loss of power from that generator. The attach bracket for the power feeder wire bundle clamp at FSS 148.90 has two holes where the power feeder wire bundle can be installed. The support clamp for the damaged power feeder wires was attached to the upper hole of the attach bracket. It was found that the lower hole of the attach bracket can be used to give sufficient clearance between the power feeder wire bundle and the auxiliary slat track. This service bulletin gives instructions to do a general visual inspection of the power feeder wire bundles W3312 and W3412 or W5784 and W5786 for chafe damage and to make sure that the support clamps are correctly installed. Support clamps for the power feeder wire bundles are found in the left and right wings at FSS 148.90, near the number 5 and 6 inboard auxiliary slat tracks. Operators should now use the lower hole of the 287N1401-306 bracket to attach the power feeder wire bundle. Rivets are installed in the open holes that are not used in the brackets to prevent use of the holes. If Service Letter 757-SL-24-072 has been done, install rivets in the open holes that are not used in the attach brackets. A similar change was made in production on line number 1024 and subsequent airplanes. Optional fastener part numbers are added to Paragraph 2.C.2., Parts and Materials Supplied by the Operator, and to Step 4 of Figures 1 and 2. The related 757-200 and 757-200PF bulletin is 757-24-0105. Service Letter 757-SL-24-072 is also related to this service bulletin. Boeing Service Related Problem (SRP) 757-SRP-24-0109 is related to this service bulletin. Revision 1 is sent to add optional fastener data because after the initial release of this service bulletin an airline told Boeing that they cannot easily get the BACR15FTADR5C rivets.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 12 of 27 **BOEING SERVICE BULLETIN 757-24-0106**Revision 2 is sent to add a spacer part number to the Group 1 and Group 2 Tables given in Paragraph 2.C.2., Parts and Materials Supplied by the Operator. Figures 1 through 2 are changed to add the spacer data to the applicable steps. Revision 3 is sent to correct the compliance recommendation and add more part number data applicable to the spacer. These sections were changed: 1. Paragraph 1.E., Compliance; compliance recommendation is changed to add the word "initial" in the sentence. 2. Paragraph 2.C.2., Parts and Materials Supplied by the Operator; more part number data applicable to the spacer is added. 3. Figures 1 and 2, Step 5, the spacer data is changed to give the complete part number and to give an optional spacer part number. Revision 4 is sent to move airplanes NL101-NL104, NL141, and NL601-NL607 from Group 1 to Group 2. These sections were changed: 1. Summary, Background; added wire bundle W5784 and W5786 data. 2. Summary, Action; added wire bundle W5784 and W5786 data. 3. Summary and Paragraph 1.E., Compliance, and Paragraph 1.F., Approval; added AD data. 4. Paragraph 1.A.1., Planning Information; added Group 2 airplanes to the Group Configuration Table. 5. Paragraph 1.A.1., Reason; added wire bundle W5784 and W5786 data. 6. Paragraph 1.A.1., Description; added wire bundle W5784 and W5786 data. 7. Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added more optional fastener data. 8. Paragraph 3.B., Work Instructions; added wire bundle W5784 and W5786 data. 9. Figures 1, Step 1, added wire bundle W5784 data and added more optional fastener data. 10. Figures 2, Step 1, added wire bundle W5786 data and added more optional fastener data. Revision 5 is sent to add affected maintenance zones and add an optional blind rivet NAS1398B8AB2 to plug the open hole in the bracket. These sections were changed:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 13 of 27 **BOEING SERVICE BULLETIN 757-24-0106**1. Paragraph 1.D., Description: Added Affected Maintenance Zones. 2. Paragraph 1.F., Approval: Changed the paragraph letter for the Alternate Method of Compliance. 3. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added optional blind rivet, part number NAS1398B8AB2. Also corrected the part number of the collar to read BACC30M8U. 4. Paragraph 3.B.7. and 3.B.8., Work Instructions: Added the Inspection Location. 5. Figure 1, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table. 6. Figure 2, Step 4: Added blind rivet, part number NAS1398B8AB2, added optional bolt and nut part numbers, and corrected the part number of the collar to read BACC30M8U. Added note (f) at the bottom of the step table. The data given in Information Notice 757-24-0106 IN 01 is included in this revision. **D. Description** Get access to the support clamps for the power feeder wire bundles W3312 and W3412 or W5784 and W5786 at FSS148.90 in the left and right wings. Do a general visual inspection of each power feeder wire bundle. Repair damaged wires as necessary. Make sure that the support clamps for the left and right power feeder wire bundles are installed in the lower hole of the 287N1401-306 support brackets. Rivet plug the holes in the bracket that are not used to prevent use, this includes airplanes that have done Service Letter 757-SL-24-072. The changes in this service bulletin will not change the Engine Indication and Crew Alerting System (EICAS). Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this service bulletin. Revision 2 - No more work is necessary on airplanes changed as shown in the initial release or Revision 1 of this service bulletin. Revision 3 - No more work is necessary on airplanes changed as shown in the Revision 2 of this service bulletin. Revision 4 - No more work is necessary on airplanes changed as shown in the Revision 3 of this service bulletin. Revision 5 - No more work is necessary on airplanes changed as shown in the Revision 4 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 512, 612 757-300

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 14 of 27 **BOEING SERVICE BULLETIN 757-24-0106 E. Compliance**  Federal Aviation Administration (FAA) Airworthiness Directive FAA AD 2007-03-01 is related to this service bulletin. Boeing recommends that operators do the changes in this service bulletin in 24 months or less from the initial release 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. This service bulletin has been approved by the FAA. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service bulletin as an alternative method of compliance to the requirements of paragraph (g) of FAA AD 2007-03-01. All provisions of FAA AD 2007-03-01 that are not specifically referenced in the above statement remain fully applicable and must be complied with. **G. Manpower** The table below shows an estimate of the task-hours necessary to do this change for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator 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 find the tools. **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

1.5 3.0 2 Open Access 0.25 0.50 2 Inspect 0.50 0.50 1 Figure 1 0.50 0.50 1 Figure 2 1.5 3.0 2 Close Access 4.25 7.5 TOTAL FOR EACH AIRPLANE
**NOTE:** This manpower estimate does not include time to repair any damaged Power Feeder Wires.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 15 of 27 **BOEING SERVICE BULLETIN 757-24-0106 H. Weight and Balance Changes**  None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data: a. Service Related Problem (SRP) 757-SRP-24-0109. b. 757 Aircraft Maintenance Manual (AMM) Subject 06-44-00, 24-22-00, 27-81-00, 32-00-15, 32-00-20, 78-31-00. c. 757 Structural Repair Manual (SRM) Subject 51-40-02. d. Boeing Standard Wiring Practices Manual (SWPM) 20-10-13. e. Boeing Service Letter 757-SL-24-072. f. Boeing Parts Standards Document D-590. g. Boeing Drawing 65-88700. h. Boeing Document D624N001, Service Bulletin Index. 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  Wire Bundle Instl - L Leading Edge and Front Spar. 288N1401 Wire Bundle Instl - R Leading Edge and Front Spar. 288N1402 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 16 of 27 **BOEING SERVICE BULLETIN 757-24-0106 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 5, 2003. 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 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:
**Notes Name**  **QTY Part Number / Specifica-**  **tion** (a) Rivet 2 BACR15FT7AD4R5C or BACR15BB7AD5C or BACR15BB7D5C or BACR15FT7AD5 or BACR15FT7AD5C or BACR15FT7D5C or NASM20470 (b) Spacer 2 BACS18AF4 (Optional: BACS18AF3) (a) (c) Fastener 2 NAS1398B4AB2 or NAS1398B8AB2 (a) (d) Bolt 2 BACB30FM8A2 (e) Collar 2 BACC30M8U (e) Pressure and Environmental Sealant 2 oz BMS5-95 (a) Refer to 757 Structural Repair Manual Chapter 51 for alternative fasteners. (b) The spacer is necessary only if it is not installed under the clamp. (c) Optional to BACR15( ) or NASM20470 Rivets or BACB30FM8A2 Bolt.(d) Optional to BACR15( ) or NASM20470 Rivets or NAS1398B4AB2 or NAS1398B8AB2 Fasteners. (e) Necessary only if BACB30FM8A2 bolt is used.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 17 of 27 **BOEING SERVICE BULLETIN 757-24-0106**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: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 18 of 27 **BOEING SERVICE BULLETIN 757-24-0106 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 — Hole dimensions for standard solid rivets are given in 757 Structural Repair Manual, Chapter 51 — Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, Chapter 51. 4. 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. 5. 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. 6. 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 ensure visual access to all surfaces in the inspection area. This level of inspection is made under normal available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 19 of 27 **BOEING SERVICE BULLETIN 757-24-0106 B. WORK INSTRUCTIONS**  **WARNING:** MAKE SURE THE GROUND LOCK PINS ARE INSTALLED ON ALL THE LANDING GEARS. WITHOUT THE GROUND LOCK PINS, THE LANDING GEAR COULD RETRACT AND CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 1. Install the ground lock pins on the nose and main landing gears. Refer to 757 AMM 32-00-20 **WARNING:** DO THE THRUST REVERSER DEACTIVATION PROCEDURE TO PREVENT THE OPERATION OF THE THRUST REVERSER. ACCIDENTAL OPERATION OF THE THRUST REVERSER CAN CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. 2. Deactivate the thrust reversers for ground maintenance. Refer to 757 AMM 78-31-00 or approved equivalent procedure. **WARNING:** KEEP PERSONS AND EQUIPMENT AWAY FROM ALL CONTROL SURFACES WHEN HYDRAULIC POWER IS SUPPLIED. AILERONS, ELEVATORS, RUDDER, FLAPS, SLATS, SPOILERS AND STABILIZER ARE FULLY POWERED SURFACES. INJURY TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR WHEN HYDRAULIC POWER IS SUPPLIED. **CAUTION:** MAKE SURE THE ACCESS DOOR FOR THE ENGINE STRUT, THE INBOARD FAN COWLING, AND THE THRUST REVERSER COWLING ARE CLEAR FROM MOVEMENT OF THE SLATS. IF THE MOVEMENT OF THE SLATS IS BLOCKED, IT CAN CAUSE DAMAGE TO THE AIRPLANE. 3. Extend the leading edge slats. Refer to 757 AMM 27-81-00 or approved equivalent procedure. 4. Install a DO NOT OPERATE tag on the flap control lever. 5. Remove electrical power. Refer to 757 AMM 24-22-00, or approved equivalent procedure. 6. Remove and keep the lower leading edge access panels shown in the table below. Refer to 757 AMM 06-44-00 or approved equivalent procedure.
**Location Panel Number**  Left Wing 511DB Left Wing 511EB Right Wing 611DB Right Wing 611EB 7. Do a general visual inspection of the power feeder wire bundle W3312 or W5784 in the area of the slat inboard auxiliary track on the left wing. Install the support clamp and plug the hole in the bracket that is not used as given in Figure 1. 8. Do a general visual inspection of the power feeder wire bundle W3412 or W5786 in the area of the slat inboard auxiliary track on the right wing. Install the support clamp and plug the hole in the bracket that is not used as given in Figure 2.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 20 of 27 **BOEING SERVICE BULLETIN 757-24-0106**9. Install the kept lower leading edge access panels shown in the table below. Refer to 757 AMM 06-44-00,or approved equivalent procedure.
**Location Panel Number**  Left Wing 511DB Left Wing 511EB Right Wing 611DB Right Wing 611EB 10. Restore electrical power. Refer to 757 AMM 24-22-00, or approved equivalent procedure. 11. Remove the DO NOT OPERATE tag from the flap control lever. 12. Retract the leading edge slats. Refer to 757 AMM 27-81-00 or approved equivalent procedure. 13. Reactivate the thrust reversers for ground maintenance. Refer to 757 AMM 78-31-00 or approved equivalent procedure. 14. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5: July 30, 2009 21 of 27 **BOEING SERVICE BULLETIN 757-24-0106 FIGURE 1: LEFT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION.**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5 July 30, 2009 22 of 27 **BOEING SERVICE BULLETIN 757-24-0106**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 side of the airplane.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  For damage or wear. Refer to SWPM 20-10-13 for repair. (a) - W3312 or W5784 Power feeder Wire Bundle Inspect 1 Make sure the clamp is installed in the lower hole of the attach bracket. (b) 1 BACC10JU() or BACC10GU() Clamp Inspect 2

1 BACN11AG3 or BACN10FX- () or MS21042L3 Nut Remove /Keep 3

1 BACS18AF() Spacer 1 BACC10JU() or BACC10GU() Clamp

- NAS1149D0332J Washer 1 BACS12GU3K() or NAS1801- 3-() or BACS12HN3() Bolt To plug open hole in the 287N1401-306 bracket. 757 SRM 51-40-02. (f ) 1 BACR15FT7AD4R5C or BACR15BB7AD5C or BACR15BB7D5C or BACR15FT7AD5 or BACR15FT7AD5C or BACR15FT7D5C or NASM20470 or Rivet Install (New) 4

(e) (f) 1 NAS1398B4AB2 or NAS1398B8AB2 Fastener Wet install with BMS5-95. (c) (f) 1 BACB30FM8A2 Bolt (d) 1 BACC30M8U Collar (d)

- BMS5-95 Pressure and Envi- ronmental Sealant Make sure the clamp is installed in the lower hole of the attach bracket. If there is no spacer, add one. 1 BACS12GU3K() or NAS1801- 3-() or BACS12HN3() Bolt Install (Kept) 5

- NAS1149D0332J Washer 1 BACC10JU() or BACC10GU() Clamp 1 BACS18AF4 (Optional: BACS18AF3) Spacer

1 BACN11AG3 or BACN10FX- () or MS21042L3 Nut (a) W3312 is for Group 1 airplanes and W5784 is for Group 2 airplanes.

**FIGURE 1: LEFT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5 July 30, 2009 23 of 27 **BOEING SERVICE BULLETIN 757-24-0106 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) If the clamp is in the correct place, install rivet, fastener, or bolt as given in Step 4. (c) Increase hole size to 0.247-0.250 inch. (d) Necessary only if BACB30FM8A2 bolt is used. (e) Increase hole size to 0.256-0.261 if rivet part number, NAS1398B8AB2 is installed, refer to SRM 51-20-01. (f) Install with head on forward or aft surface of bracket as necessary. Make sure there is no interference with wires, tubes or components.

**FIGURE 1: LEFT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5 July 30, 2009 24 of 27 **BOEING SERVICE BULLETIN 757-24-0106 FIGURE 2: RIGHT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION.**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5 July 30, 2009 25 of 27 **BOEING SERVICE BULLETIN 757-24-0106**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 side of the airplane.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  For damage or wear. Refer to SWPM 20-10-13 for repair. (a) - W3412 or W5786 Power feeder Wire Bundle Inspect 1 Make sure the clamp is installed in the lower hole of the attach bracket. (b) 1 BACC10JU() or BACC10GU() Clamp Inspect 2

1 BACN11AG3 or BACN10FX-() or MS21042L3 Nut Remove /Keep 3

1 BACS18AF() Spacer 1 BACC10JU() or BACC10GU() Clamp

- NAS1149D0332J Washer 1 BACS12GU3K() or NAS1801- 3-() or BACS12HN3() Bolt To plug open hole in the 287N1401-306 bracket. 757 SRM 51-40-02. (f ) 1 BACR15FT7AD4R5C or BACR15BB7AD5C or BACR15BB7D5C or BACR15FT7AD5 or BACR15FT7AD5C or BACR15FT7D5C or NASM20470 or Rivet Install (New) 4

(e) (f) 1 NAS1398B4AB2 or NAS1398B8AB2 Fastener Wet install with BMS5-95. (c) (f) 1 BACB30FM8A2 Bolt (d) 1 BACC30M8U Collar (d)

- BMS5-95 Pressure and Envi- ronmental Sealant Make sure the clamp is installed in the lower hole of the attach bracket. If there is no spacer, add one. 1 BACS12GU3K() or NAS1801- 3-() or BACS12HN3() Bolt Install (Kept) 5

- NAS1149D0332J Washer 1 BACC10JU() or BACC10GU() Clamp 1 BACS18AF4 (Optional: BACS18AF3) Spacer

1 BACN11AG3 or BACN10FX-() or MS21042L3 Nut (a) W3412 is for Group 1 airplanes and W5786 is for Group 2 airplanes.

**FIGURE 2: RIGHT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5 July 30, 2009 26 of 27 **BOEING SERVICE BULLETIN 757-24-0106 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) If the clamp is in the correct place, install rivet, fastener, or bolt as given in Step 4. (c) Increase hole size to 0.247-0.250 inch. (d) Necessary only if BACB30FM8A2 bolt is used. (e) Increase hole size to 0.256-0.261 if rivet part number, NAS1398B8AB2 is installed and refer to SRM 51- 20-01. (f) Install with head on forward or aft surface of bracket as necessary. Make sure there is no interference with wires, tubes or components.

**FIGURE 2: RIGHT WING POWER FEEDER WIRE INSPECTION AND SUPPORT CLAMP INSTALLATION. (SHEET 3 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: September 30, 2004 757-24-0106 Revision 5 July 30, 2009 27 of 27 **BOEING SERVICE BULLETIN 757-24-0106**