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Commercial Airplanes 777 Service Bulletin Number: 777-53A0054 Original Issue: August 07, 2008 Revision 1: November 04, 2010 ATA System: 5300 SUBJECT: FUSELAGE - Body Station 132.5 to Body Station 2150 - External Inspection of the Fuselage Skin for External Scribe Lines 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.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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Original Issue: August 07, 2008 777-53A0054Revision 1: November 04, 2010 1 of 91
3.0
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Original Issue: August 07, 2008 777-53A0054Revision 1: November 04, 2010 2 of 91 BOEING SERVICE BULLETIN 777-53A0054
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 4 F. Approval ............................................... 2 4 G. Manpower .............................................. 2 4 H. Weight and Balance Changes .................................... 2 7 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 8
1. Existing Data .......................................... 2 8
2. Data supplied with this Service Bulletin ............................ 2 8
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 8 K. Publications Affected ........................................ 2 8 L. Interchangeability and Intermixability of Parts ........................... 2 8
2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 2 9 C. Parts Necessary For Each Airplane ................................. 2 9
1. Kits/Parts ............................................ 2 9
2. Parts and Materials Supplied by the Operator ........................ 2 9
3. Parts Modified and Reidentified ................................ 2 9
4. Parts Removed and Not Replaced .............................. 2 9 D. Parts Necessary to Change Spares ................................. 2 9 E. Special Tooling - Price and Availability ............................... 2 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1 A. GENERAL INFORMATION ..................................... 3 1 B. WORK INSTRUCTIONS ....................................... 3 3 FIGURE 1: EXTERNAL DOUBLER INSPECTION LOCATIONS - GROUP 1 AIRPLANES [Group 1] . 46 FIGURE 2: EXTERNAL DOUBLER INSPECTION LOCATIONS - GROUP 2 AIRPLANES [Group 2] . 47 FIGURE 3: EXTERNAL DOUBLER INSPECTION LOCATIONS - GROUP 3 AIRPLANES [Group 3] . 48 FIGURE 4: EXTERNAL DOUBLER INSPECTION LOCATIONS - GROUP 4 AIRPLANES [Group 4] . 49 FIGURE 5: ZONE 1 - GROUP 3 AND 4 AIRPLANES [Group 3-4] .................... 5 0 FIGURE 6: ZONE 2 - GROUP 1 AND 2 AIRPLANES [Group 1-2] .................... 5 1 FIGURE 7: ZONE 2 - GROUP 3 AND 4 AIRPLANES [Group 3-4] .................... 5 2 FIGURE 8: ZONE 3 - GROUP 1 AIRPLANES [Group 1] ......................... 5 3 FIGURE 9: ZONE 3 - GROUP 2 AIRPLANES [Group 2] ......................... 5 4 FIGURE 10: ZONE 3 - GROUP 3 AIRPLANES [Group 3] ......................... 5 5 FIGURE 11: ZONE 3 - GROUP 4 AIRPLANES [Group 4] ......................... 5 6
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FIGURE 12: ZONE 4 - GROUP 1 AND 2 AIRPLANES [Group 1-2] .................... 5 7 FIGURE 13: ZONE 4 - GROUP 3 AND 4 AIRPLANES [Group 3-4] .................... 5 8 FIGURE 14: INSPECTION FOR SCRIBE LINES AT EXTERNAL REPAIR DOUBLER LOCATIONS . . 59 FIGURE 15: INSPECTION FOR SCRIBE LINES AT LAP JOINT LOCATIONS .............. 6 0 FIGURE 16: INSPECTION FOR SCRIBE LINES AT BUTT JOINT LOCATIONS ............. 6 1 FIGURE 17: INSPECTION FOR SCRIBE LINES AROUND THE FORWARD LARGE CARGO DOOR HINGES
- GROUP 1 AND 3 AIRPLANES [Group 1, 3] ......................... 6 3 FIGURE 18: INSPECTION FOR SCRIBE LINES AROUND THE FORWARD AND AFT LARGE CARGO DOOR HINGES - GROUP 2 AND 4 AIRPLANES [Group 2, 4] ............... 6 6 FIGURE 19: INSPECTION FOR CRACKS AT SCRIBE LINES AT EXTERNAL REPAIR DOUBLER LOCATIONS OR AT LAP JOINT LOCATIONS ........................ 6 9 FIGURE 20: INSPECTION FOR CRACKS AT SCRIBE LINES AT BUTT JOINT LOCATIONS ..... 7 2 FIGURE 21: INSPECTION FOR CRACKS AT SCRIBE LINES AROUND THE FORWARD LARGE CARGO DOOR HINGES - GROUP 1 AND 3 AIRPLANES [Group 1, 3] ............... 7 4 FIGURE 22: INSPECTION FOR CRACKS AT SCRIBE LINES AROUND THE FORWARD AND AFT LARGE CARGO DOOR HINGES - GROUP 2 AND 4 AIRPLANES [Group 2, 4] ........... 7 8 APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN . 82 APPENDIX B: SCRIBE SAMPLE ....................................... 9 0
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Commercial Airplanes 777 Service Bulletin Revision Transmittal SheetNumber: 777-53A0054Original Issue: August 07, 2008 Revision 1: November 04, 2010 ATA System: 5300 SUBJECT: FUSELAGE - Body Station 132.5 to Body Station 2150 - External Inspection of the Fuselage Skin for External Scribe Lines This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes which have not been stripped or repainted, but have had decals installed or removed across affected lap joints, large cargo door hinges, or external doublers. If those airplanes had previously been determined to not require inspections in accordance with the original issue of this service bulletin, do the lap joint, large cargo door hinge, and external doubler inspections in accordance with Paragraph 3.B., PART 11 at the applicable time for the affected decal locations.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making FAA NPRM 2009-NM-004-AD is related to this service bulletin.
No airplanes were added to this service bulletin effectivity.
REASON FOR REVISION This revision is sent to include information about scribe lines that may exist in the fuselage skin around external decals that may have been installed or removed. Only the inspection areas described in the original issue of this service bulletin (external doubler locations, Zone 1, Zone 2, Zone 3, Zone 4, and large cargo door hinge locations) require inspections for scribe lines, which may include scribe lines associated with the installation or removal of decals.
References to FAA Notice of Proposed Rule Making FAA NPRM 2009-NM-004-AD were added to this service bulletin.
The data given in Information Notice 777-53A0054 IN 01 is included in this revision. IN 01 included clarification of the notes in Paragraph 1.E., Compliance, and corrections for various typographic errors.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY August 07, 2008Original Issue:
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Commercial Airplanes 777 Service Bulletin SummaryNumber: 777-53A0054Original Issue: August 07, 2008 Revision 1: November 04, 2010 ATA System: 5300 SUBJECT: FUSELAGE - Body Station 132.5 to Body Station 2150 - External Inspection of the Fuselage Skin for External Scribe Lines
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions for the inspection and repair of scribe lines in the fuselage skin at certain lap joints, butt joints, and external repair doublers, and around the large cargo door hinges. Fatigue cracks can develop in the skin at scribe line locations. Fatigue cracks in the skin that remain undetected could grow large and cause sudden decompression and the inability to sustain limit load.
A scribe line is a narrow, shallow, distinct line of damage (up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal. A more detailed definition of a scribe line is included in Paragraph 3.B., Accomplishment Instructions.
At the time this service bulletin was originally released, only one 777 airplane has been found with scribe damage by one operator. On this airplane, scribe lines were found around the edges of the area where a large decal had been installed. The operator believed that the scribe lines were made when the decal was removed. No cracks were found at the scribe line locations. On other airplane models, scribe lines appear to have been made when sealant was removed as part of preparation of the airplane for repainting, and have in some cases resulted in significant cracking.
Subsequent to the original issue of this service bulletin, it was determined that scribe lines could occur when decals are installed or removed, even on airplanes that had not previously been stripped or repainted.
Accomplishment of the inspections shown in this service bulletin will help make sure that fatigue cracks that can form in the fuselage skin at scribe lines are found and repaired before they can become large and cause sudden loss of cabin pressure.
Boeing Service Related Problem (SRP) 777-SRP-53-0243 is related to this service bulletin.
ACTION The lap joint and butt joint locations that should be inspected are divided into four zones to address the most critical areas first and to give less critical areas appropriately reduced compliance requirements. In addition to these four zones, detailed inspections are also required at certain external doubler locations and around the large cargo door hinges.
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At the times shown in Paragraph 1.E., Compliance, start to do detailed inspections for scribe lines in the affected areas. If no scribe lines are found in that area, no more inspections are necessary in that affected area. If scribe lines are found, do detailed, eddy current or ultrasonic inspections of the scribes lines for cracks. If cracks are found, repair before further flight. If no cracks are found, repair the scribe lines. As an alternative to scribe line repair, if the scribe lines are no more than 0.006 inch deep restore the finish in the area and do the inspections for cracks again at the times shown in this service bulletin.
EFFECTIVITY 777-200, 777-200LR, 777-300, and 777-300ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making FAA NPRM 2009-NM-004-AD, is related to this service bulletin.2009-NM-004-AD
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None.
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Original Issue: August 07, 2008 777-53A0054Revision 1: November 04, 2010 8 of 91 BOEING SERVICE BULLETIN 777-53A0054
Commercial Airplanes 777 Service Bulletin Number: 777-53A0054 Original Issue: August 07, 2008 Revision 1: November 04, 2010 ATA System: 5300 SUBJECT: FUSELAGE - Body Station 132.5 to Body Station 2150 - External Inspection of the Fuselage Skin for External Scribe Lines
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP 777-200 and 777-200LR airplanes through line number 660 with a small aft cargo door.
-1 777-200 and 777-200LR airplanes through line number 660 with a large aft cargo door.
-2 777-300 and 777-300ER airplanes through line number 660 with a small aft cargo door.
-3 777-300 and 777-300ER airplanes through line number 660 with a large aft cargo door.
-4 Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER GroupVariable Number 2WA001 - WA017 1WA076 - WA080 1WA086 - WA093 1WA101 - WA104
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GroupVariable Number 1WA116 - WA119 1WA131 - WA137 1WA171 - WA175 1WA196 - WA198 1WA206 - WA212 2WA221 - WA223 2WA231 - WA232 1WA241 - WA250 2WA261 - WA266 1WA281 - WA283 1WA301 - WA304 1WB001 2WB002 - WB021 2WB031 - WB046 2WB051 - WB088 1WB101 - WB106 1WB121 - WB125 1WB131 - WB144 1WB151 - WB155 1WB161 - WB177 1WB181 - WB194 1WB201 - WB215 1WB231 - WB247 1WB271 - WB272 2WB273 1WB276 - WB285 2WB286 2WB291 - WB302 2WB306 - WB307 2WB311 - WB337 2WB341 - WB342 2WB366 - WB368 2WB371 - WB388
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GroupVariable Number 1WB406 2WB411 - WB413 1WB416 - WB439 2WB446 - WB453 1WB476 2WB481 - WB484 4WB501 - WB512 3WB531 - WB537 3WB551 - WB554 3WB591 - WB597 3WB601 - WB606 3WB611 - WB622 4WB631 - WB638 4WB646 - WB649 1WC051 - WC073 2WC101 - WC104 1WC111 - WC119 2WC221 - WC222 2WC241 - WC243 2WC281 - WC290 2WC301 - WC308 2WC361 - WC364 1WC371 - WC374 2WC381 - WC395 1WC441 1WC446 - WC449 2WC456 - WC459 2WC486 - WC493 2WC506 - WC508 2WC521 - WC522 2WC531 - WC534 2WC546 - WC547 2WC556
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GroupVariable Number 2WC566 - WC567 1WD001 - WD002 1WD011 - WD013 2WD031 - WD032 2WD046 3WD501 - WD506 4WD521 - WD536 4WD546 - WD552 4WD561 - WD570 4WD581 - WD592 4WD606 - WD609 4WD621 - WD632 4WD651 - WD657 4WD671 - WD675 3WD691 - WD700 4WD741 - WD745 4WD761 - WD765 3WD786 - WD787 3WD826 - WD828
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason This service bulletin gives instructions for the inspection and repair of scribe lines in the fuselage skin at certain lap joints, butt joints, and external repair doublers, and around the large cargo door hinges.
Fatigue cracks can develop in the skin at scribe lines. Fatigue cracks in the skin can become large and cause a sudden loss of cabin pressure and the inability to sustain limit load.
At the time this service bulletin was originally released, only one 777 airplane has been found with scribe damage by one operator. On this airplane, scribe lines were found around the edges of the area where a large decal had been installed. The operator believed that the scribe lines were made when the decal was removed. No cracks were found at the scribe line locations. On other airplane models, scribe lines appear to have been made when sealant was removed as part of preparation of the airplane for repainting.
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Original Issue: August 07, 2008 777-53A0054Revision 1: November 04, 2010 12 of 91 BOEING SERVICE BULLETIN 777-53A0054