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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0075 Original Issue: January 14, 2015 Revision 1: December 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Unpublished Work.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 777-53A0075Revision 1: December 14, 2015 1 of 248
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075Revision 1: December 14, 2015 2 of 248 BOEING SERVICE BULLETIN 777-53A0075
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Table of Contents
Revision Transmittal Sheet5
S u m m a r y9
1. PLANNING INFORMATION ........................................ 1 5 A . E f f e c t i v i t y ............................................... 1 5
1. Airplanes ............................................ 1 5 2 . S p a r e s A f f e c t e d ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F . A p p r o v a l ............................................... 2 2 G. Manpower .............................................. 2 3 H. Weight and Balance Changes .................................... 2 6 I. Electrical Load Data ......................................... 2 6 J . R e f e r e n c e s .............................................. 2 6
1. Existing Data: ......................................... 2 6
2. Data Supplied with this Service Bulletin: ........................... 2 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 7 K. Publications Affected ........................................ 2 7 L. Interchangeability and Intermixability of Parts ........................... 2 7 M. Software Accomplishment Summary ................................ 2 7
2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 3 0 C. Parts Necessary for Each Airplane ................................. 3 0 1 . K i t s / P a r t s ............................................ 3 0
2. Parts and Materials Supplied by the Operator ........................ 3 4
3. Parts Modified and Reidentified ................................ 3 5
4. Parts Removed and Not Replaced .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 9 FIGURE 1: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL ...................... 4 3 FIGURE 2: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL ..................... 4 7 FIGURE 3: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION .......................................... 5 1 FIGURE 4: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - DET AND HFEC INSPECTION .......................................... 5 5 FIGURE 5: LEFT SIDE - STA 2370 SKIN PANEL INSTALLATION ................... 5 9 FIGURE 6: RIGHT SIDE - STA 2370 SKIN PANEL INSTALLATION ................... 6 4 FIGURE 7: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 1] ............................................ 6 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 8: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 1] ............................................ 7 9 FIGURE 9: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 2] ............................................ 8 9 FIGURE 10: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD - PART REMOVAL [Group 2] ............................................ 9 9 FIGURE 11: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION ....................... 1 0 9 FIGURE 12: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD OUTER CHORD AND ADJACENT STRUCTURE - HFEC AND DET INSPECTION ....................... 1 1 4 FIGURE 13: LEFT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION [Group 1] .......... 1 1 9 FIGURE 14: RIGHT SIDE - STA 2370 - SPLICE ANGLE - MODIFICATION [Group 1] ......... 1 2 2 FIGURE 15: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 1] . 125 FIGURE 16: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 1] . 147 FIGURE 17: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 2] . 167 FIGURE 18: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - REPAIR [Group 2] . 187 FIGURE 19: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION ..................................... 2 0 7 FIGURE 20: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD - POST-REPAIR DET AND HFEC INSPECTION ..................................... 2 1 0 FIGURE 21: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION
- SKIN PANEL INSTALLATION ............................... 2 1 3 FIGURE 22: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR INSPECTION
- SKIN PANEL INSTALLATION ............................... 2 1 8 FIGURE 23: LEFT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION ........................................ 2 2 3 FIGURE 24: RIGHT SIDE - STA 2370 PIVOT BULKHEAD FORWARD CHORD POST-REPAIR - SKIN PANEL INSTALLATION ........................................ 2 2 9 FIGURE 25: LEFT SIDE - STA 2370 SKIN PANEL REMOVAL ...................... 2 3 5 FIGURE 26: RIGHT SIDE - STA 2370 SKIN PANEL REMOVAL ..................... 2 3 9 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD .... 2 4 3 APPENDIX B: L OGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: POST-REPAIR DETAILED AND HFEC INSPECTION OF THE STATION 2370 PIVOT BULKHEAD FORWARD CHORD ................................................. 2 4 6 APPENDIX C: BOEING PART DEMAND INTENT .............................. 2 4 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT Revision Transmittal SheetNumber: 777-53A0075Original Issue: January 14, 2015 Revision 1: December 14, 2015 ATA System: 5380 SUBJECT: FUSELAGE - Section 48 - Station 2370 Pivot Bulkhead Forward Outer Chord - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2015-NM-026-AD, is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue was previously done:
None.
REASON FOR REVISION This revision is sent to make changes identified during the validation of the Original Issue of this service bulletin and to clarify or correct issues identified by operators since the Original Issue.
As a part of a service bulletin validation program, this inspection was completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue before the release of Revision 1 of this service bulletin. The inspection completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WA174 has the configuration of a Group 2 airplane.
These sections were changed:
1. In Summary, Background, revised the description of the unsafe condition, revised the number of operator reports, added a service history table, added a description of the completed service bulletin validation.
2. In Summary, Action, revised the paragraph.
3. In Summary, Compliance, added FAA Notice of Proposed Rule Making (NPRM) reference.
4. In Summary, Manpower, added a reference to Paragraph 1.G., Manpower.
5. In Summary, Material Information, added "Operator Supplied Parts/Materials".
6. In Summary, revised the summary illustration.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075Revision 1: December 14, 2015 5 of 248
7. In Paragraph 1.C., Reason, revised the description of the unsafe condition, revised the number of operator reports, added a service history table, added paragraphs to give a description of the completed service bulletin validation and to give the reason for this revision.
8. In Paragraph 1.D., Description, revised the paragraph, added paragraph to give the effects of this revision on airplanes on which Original Issue was previously done.
9. In Paragraph 1.E., Compliance, added NPRM reference, revised the paragraph above Table 1, revised Table 1 and Table 2.
10. In Paragraph 1.G., Manpower, revised the tables.
11. In Paragraph 1.H., Weight and Balance Changes, revised the table to give weight and balance changes.
12. In Paragraph 1.J., References, revised the reference list.
13. In Paragraph 2.A., Material - Price and Availability, revised top kit dates and quantities, added Reorder Lead Time (ROLT) and revised price information.
14. In Paragraph 2.C.1., Kits/Parts, revised the top kit parts lists.
15. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, deleted the duplicate paragraph above the table.
16. In Paragraph 2.C.3., Parts Modified and Reidentified, added table for Group 1 airplanes, added paragraph for Group 2 airplanes.
17. In Paragraph 3.A., General Information, deleted notes that are not applicable, revised note 17. and note 18.
18. In Paragraph 3.B., Work Instructions, revised the work instructions.
19. In Figure 5 and Figure 6, revised the illustrations and the fastener code table.
20. In Figure 7, Figure 8, Figure 9 and Figure 10, revised the illustrations and the step table.
21. In Figure 11, Figure 12, Figure 13 and Figure 14, revised the illustrations.
22. In Figure 15, Figure 16, Figure 17, Figure 18, Figure 21, Figure 22, Figure 23 and Figure 24, revised the illustrations, the step table and the fastener code table.
23. Added Figure 25 and Figure 26 to give instructions for skin panel removal after the small crack repair was installed.
24. In Appendix A, revised the table and the flag note, revised the logic diagram.
25. In Appendix B, revised the table and the flag note.
26. In Appendix C, revised Part Demand Intent.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Pages with no vertical lines have no changes.
REVISION HISTORY January 14, 2015Original Issue:
December 14, 2015Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0075Original Issue: January 14, 2015 Revision 1: December 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 cause the loss of horizontal stabilizer control, resulting in loss of controllability of the airplane.
Two operators have reported finding cracks in the outer flanges of the left and right side forward outer chords of the STA 2370 pivot bulkhead on a total of eleven 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.
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.
The table below shows the crack findings and related service data that have been reported to Boeing.
Service History Crack Length (Inches)Crack LocationFlight HoursFlight CyclesModel
1.4 and 3.3Left Side39,14231,384777-200
2.93Right Side Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 14, 2015 777-53A0075Revision 1: December 14, 2015 9 of 248
Service History Crack Length (Inches)Crack LocationFlight HoursFlight CyclesModel
2.3Left Side39,79731,504777-200
2.2Right Side
2.5Left Side38,75832,181777-200
2.3Right Side
2.5Left Side37,18229,383777-200
2.5Right Side
2.2Left Side34,29124,653777-300
2.2Right Side
2.25Left Side40,07435,011777-200
2.2Right Side
2.5Left Side33,56824,251777-300
2.03Right Side
2.35Left Side38,45530,462777-200
2.2Right Side
2.2Left Side39,16630,826777-200
2.4Right Side
2.5Left Side40,58833,809777-200
2.4Right Side
1.2Left Side63,94017,530777-300
1.65Right Side 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.
As a part of a service bulletin validation program, this inspection was completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue before the release of Revision 1 of this service bulletin. The inspection completed on airplane WA174 by Service Bulletin 777-53A0075 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WA174 has the configuration of a Group 2 airplane.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data 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 no crack found is greater than 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 found is greater than 0.160 inch, do the terminating action in accordance with SB 777-53-0076.
If no crack is found, repeat PART 1, or 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 Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2015-NM-026-AD, is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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 Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Operator Supplied Parts/Materials.
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 777-53A0075Revision 1: December 14, 2015 12 of 248 BOEING SERVICE BULLETIN 777-53A0075