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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0075 Original Issue: January 14, 2015 ATA System: 5380 SUBJECT: FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2015 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: January 14, 2015 777-53A0075 1 of 232
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 2 of 232 BOEING SERVICE BULLETIN 777-53A0075
ALERTALERT
BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 1 B. Concurrent Requirements ...................................... 1 1 C. Reason ................................................ 1 1 D. Description .............................................. 1 1 E. Compliance .............................................. 1 2 F. Approval ............................................... 1 5 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 1 9 J. References .............................................. 1 9
1. Existing Data: ......................................... 1 9
2. Data Supplied with this Service Bulletin: ........................... 1 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 9 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 0 M. Software Accomplishment Summary ................................ 2 0
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 2 C. Parts Necessary for Each Airplane ................................. 2 2
1. Kits/Parts ............................................ 2 2
2. Parts and Materials Supplied by the Operator ........................ 2 7
3. Parts Modified and Reidentified ................................ 2 7
4. Parts Removed and Not Replaced .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 1 FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL ...................... 3 6 FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL ..................... 4 0 FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION .......................................... 4 4 FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION .......................................... 4 8 FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION ................... 5 2 FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION ................... 5 7 FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 1] ............................................ 6 2 FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 1] ............................................ 7 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 3 of 232 BOEING SERVICE BULLETIN 777-53A0075
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FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 2] ............................................ 8 2 FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 2] ............................................ 9 2 FIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION ....................... 1 0 2 FIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION ....................... 1 0 7 FIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION [Group 1] .......... 1 1 2 FIGURE 14: RIGHT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION [Group 1] ......... 1 1 5 FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 1] . 118 FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 1] . 140 FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 2] . 161 FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 2] . 181 FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION ..................................... 2 0 1 FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION ..................................... 2 0 4 FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION
- SKIN PANEL INSTALLATION ............................... 2 0 7 FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION
- SKIN PANEL INSTALLATION ............................... 2 1 2 FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION ........................................ 2 1 7 FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION ........................................ 2 2 2 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD .... 2 2 7 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: POST-REPAIR DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD ................................................. 2 3 0 APPENDIX C: BOEING PART DEMAND INTENT .............................. 2 3 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 4 of 232 BOEING SERVICE BULLETIN 777-53A0075
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0075Original Issue: January 14, 2015 ATA System: 5380 SUBJECT: FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin is sent to give instructions for inspections of the left and right side forward outer chords of the Body Station (STA) 2370 pivot bulkhead for cracks. Cracks in the STA 2370 pivot bulkhead forward outer chords that are not found and repaired can become large and result in a severed forward outer chord. Since the horizontal stabilizer is attached to the STA 2370 bulkhead at two pivot locations, this damage could result in the loss of horizontal stabilizer control.
One operator reported finding cracks in the outer flanges of the left and right side forward outer chords of the STA 2370 pivot bulkhead on three airplanes. The cracks were fatigue cracks caused by a stress concentration which is generated at the transition radius of the forward outer flange of the chord prior to the chord splice at the upper longeron. Cracks were found on three 777-200 airplanes with 31,384 flight cycles (39,142 flight hours), 31,504 flight cycles (39,797 flight hours) and 32,181 flight cycles (38,758 flight hours).
Accomplishment of the inspections in this service bulletin will help ensure that STA 2370 pivot bulkhead forward outer chord cracks are found and repaired before they can become large and result in damage that could result in the loss of horizontal stabilizer control.
Boeing Service Bulletin (SB) 777-53-0076 gives instructions for a modification that is terminating action to the repeat inspections given in this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 53-13001 is related to this service bulletin.
Boeing Service Related Problem (SRP) 777-SRP-53-0455 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 5 of 232
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYes (a)Weight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required
(a) Only if the repair was done.
ACTION (PRR 62777-97S) Do a Detailed and HFEC inspection of the Station 2370 pivot bulkhead forward chord in accordance with Part 1, for any crack.
If any crack is found, and any crack found is less than or equal to 0.160 inch, do one of the following options on the affected side of the airplane:
1. Do the terminating action in accordance with SB 777-53-0076.
2. Do the repair of the Station 2370 pivot bulkhead forward chord in accordance with PART 2 and the post-repair Detailed and HFEC inspection in accordance with PART 3.
If any crack is found, and any crack found is greater than 0.160 inch, do the terminating action in accordance with SB 777-53-0076.
EFFECTIVITY 777-200/-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
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.
Refer to Paragraph 1.E., Compliance.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 6 of 232 BOEING SERVICE BULLETIN 777-53A0075
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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of November 20, 2013. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
10.5014.50All Airplanes - Inspection
24.0544.85Group 1 Airplanes - Small Crack Repair - One Side of the airplane
22.3043.10Group 2 Airplanes - Small Crack Repair - One Side of the airplane
8.5010.50All Airplanes - Post-Repair Inspection
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX C of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 7 of 232 BOEING SERVICE BULLETIN 777-53A0075
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BOEING SERVICE BULLETIN 777-53A0075
ALERT ALERT LEFT AND RIGHT SIDE:
DO A DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD STA IN ACCORDANCE WITH PART 1, FOR ANY CRACK.
2370 IF ANY CRACK IS FOUND, AND ANY CRACK FOUND S LESS THAN OR EQUAL TO 0.160 INCH, DO ONE
OF THE FOLLOWING OPTIONS ON THE AFFECTED SIDE OF THE AIRPLANE:
1. DO THE TERMINATING ACTION IN ACCORDANCE WITH SB 777-53-0076
2. DO THE REPAIR OF THE STATION 2370 PIVOT
BULKHEAD FORWARD CHORD IN ACCORDANCE WITH PART 2, AND THE POST-REPAIR DETAILED
AND HFEC INSPECTION IN ACCORDANCE WITH PART 3.
IF ANY CRACK IS FOUND, AND ANY CRACK FOUND IS GREATER THAN 0.160 INCH, DO THE
TERMINATING ACTION IN ACCORDANCE WITH SB 777-53-0076.
2357294 Original Issue: January 14, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 777-53A0075 Work - See page 1 for details. 8 of 232
Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0075 Original Issue: January 14, 2015 ATA System: 5380 SUBJECT: FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to 777-200/-300 Airplanes, line numbers 1-244 in 2 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-97S for data about this change.
Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 777 Airplanes, line numbers 1 through 40-1 777 Airplanes, line numbers 41 through 244-2 Airplane Models:
777-200, 777-300 GroupVariable Number 1WA001 - WA017 1WA076 - WA080 1WA086 - WA087 2WA088 - WA093 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 9 of 232
GroupVariable Number 1WA101 - WA104 1WA116 - WA117 2WA118 - WA119 1WA131 - WA135 2WA136 - WA137 1WA171 - WA173 2WA174 - WA175 1WA196 - WA197 2WA198 2WA206 - WA212 2WA221 - WA223 2WA231 - WA232 2WA241 - WA245 2WB001 - WB020 2WB031 2WB051 - WB072 2WB101 - WB106 2WB121 - WB125 2WB131 - WB133 2WB151 - WB153 2WB161 - WB171 2WB181 - WB188 2WB231 - WB235 2WB271 - WB272 2WB276 - WB286 2WB291 - WB297 2WB306 - WB307 2WB311 - WB318 2WB336 - WB337 2WB366 2WB371 - WB383 2WB406 2WB411 - WB413 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 10 of 232 BOEING SERVICE BULLETIN 777-53A0075
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GroupVariable Number 2WB416 - WB426 2WB446 - WB448 2WB501 - WB506 2WB531 - WB535 2WB551 - WB553 2WB591 - WB595 2WB601 - WB602 2WB611 - WB615
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason This service bulletin is sent to give instructions for inspections of the left and right side forward outer chords of the Body Station (STA) 2370 pivot bulkhead for cracks. Cracks in the STA 2370 pivot bulkhead forward outer chords that are not found and repaired can become large and result in a severed forward outer chord. Since the horizontal stabilizer is attached to the STA 2370 bulkhead at two pivot locations, this damage could result in the loss of horizontal stabilizer control.
One operator reported finding cracks in the outer flanges of the left and right side forward outer chords of the STA 2370 pivot bulkhead on three airplanes. The cracks were caused by stress concentration which is generated at the transition radius of the forward outer flange of the chord prior to the chord splice at the upper longeron. Cracks were found on three 777-200 airplanes with 31,384 flight cycles (39,142 flight hours), 31,504 flight cycles (39,797 flight hours) and 32,181 flight cycles (38,758 flight hours).
Accomplishment of the inspections in this service bulletin will help ensure that STA 2370 pivot bulkhead forward outer chord cracks are found and repaired before they can become large and result in damage that could result in the loss of horizontal stabilizer control.
Boeing Service Bulletin (SB) 777-53-0076 gives instructions for a modification that is terminating action to the repeat inspections given in this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 53-13001 is related to this service bulletin.
Boeing Service Related Problem (SRP) 777-SRP-53-0455 is related to this service bulletin.
D. Description Do a Detailed and HFEC inspection of the Station 2370 pivot bulkhead forward chord in accordance with Part 1, for any crack.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 11 of 232 BOEING SERVICE BULLETIN 777-53A0075
ALERTALERT
If any crack is found, and any crack found is less than or equal to 0.160 inch, do one of the following options on the affected side of the airplane:
1. Do the terminating action in accordance with SB 777-53-0076.
2. Do the repair of the Station 2370 pivot bulkhead forward chord in accordance with PART 2 and the post-repair Detailed and HFEC inspection in accordance with PART 3.
If any crack is found, and any crack found is greater than 0.160 inch, do the terminating action in accordance with SB 777-53-0076.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 313, 314777-200 Group 2:
Affected Maintenance Zones ZoneModel 313, 314777-200, 777-300 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.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.
Logic diagrams showing compliance tasks and compliance times are included as aids in APPENDIX A and APPENDIX B.
The conditions and associated actions given in the Compliance tables below can be different on the left and right sides of the airplane. The inspections and actions must be done on both sides. Because the conditions found may not be the same on both sides of the airplane, the required actions may be different between the left and right side of the airplane. The actions done must obey the compliance tables for each side of the airplane.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075 12 of 232 BOEING SERVICE BULLETIN 777-53A0075