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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0083 Original Issue: April 20, 2017 ATA System: 5363 5373 SUBJECT: FUSELAGE - Section 46 and 47 Structure - Inspection for Corrosion or Crack Caused by Vacuum Waste System Contents Spill or Leak 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 © 2017 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Unpublished Work.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: April 20, 2017 777-53A0083 1 of 61
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 20, 2017 777-53A0083 2 of 61 BOEING SERVICE BULLETIN 777-53A0083
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected14
B. Concurrent Requirements14
C. Reason14
D. Description15
E. Compliance16
F. Approval24
G. Manpower24
H. Weight and Balance Changes25
I. Electrical Load Data25
J. References25
1. Existing Data:25
2. Data Supplied with this Service Bulletin:25
3. Installation Drawings Used in the Preparation of this Service Bulletin:25
K. Publications Affected26
L. Interchangeability and Intermixability of Parts26
M. Software Accomplishment Summary26
2. MATERIAL INFORMATION27
A. Material - Price and Availability27
B. Industry Support Information27
C. Parts Necessary for Each Airplane27
1. Kits/Parts27
2. Parts and Materials Supplied by the Operator27
3. Parts Modified and Reidentified27
4. Parts Removed and Not Replaced27
D. Parts Necessary to Change Spares27
E. Special Tooling - Price and Availability28
F. Special Tooling Necessary to do this Service Bulletin28
3. ACCOMPLISHMENT INSTRUCTIONS29
A. GENERAL INFORMATION29
B. WORK INSTRUCTIONS31
FIGURE 1: INTERNAL AND EXTERNAL DETAILED INSPECTION38
FIGURE 2: CLEANING AND NEUTRALIZATION43
FIGURE 3: RESTORATION49
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE, TABLE 1: OPERATOR'S
MAINTENANCE PROCEDURES AND AIRPLANE MAINTENANCE RECORD REVIEW FOR
VACUUM WASTE SYSTEM CONTENTS SPILL AND LEAK53
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE, TABLE 2: INTERNAL AND
EXTERNAL DETAILED INSPECTIONS OF THE AFT FUSELAGE STRUCTURE FOR ANY
CORROSION OR CRACK55
APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE, TABLE 3: INTERNAL AND
EXTERNAL DETAILED INSPECTIONS OF THE AFT FUSELAGE STRUCTURE FOR ANY
CORROSION OR CRACK59
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.
Original Issue: April 20, 2017 777-53A0083 4 of 61 BOEING SERVICE BULLETIN 777-53A0083
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0083Original Issue: April 20, 2017 ATA System: 5363 5373 SUBJECT: FUSELAGE - Section 46 and 47 Structure - Inspection for Corrosion or Crack Caused by Vacuum Waste System Contents Spill or Leak
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None
BACKGROUND This service bulletin is issued to inspect the lower aft fuselage structure for any corrosion or crack and to raise awareness that, a vacuum waste system spill or leak is acidic and corrosive. This service bulletin also ensures operators are aware that Boeing maintenance procedure changes have occurred and verifies these changes have been updated to the operator's maintenance programs. Failure to clean and neutralize a vacuum waste system spill or leak will result in corrosion to the airplane structure such as the skin, stringers and frames. If not corrected, undetected corrosion of the fuselage skin, stringers and frames can cause fatigue cracks, which can result in possible rapid decompression and loss of structural integrity.
Corrosion was found during pre-flight, post-flight walk around inspections as well as scheduled internal and external inspections on nine different airplanes. The corrosion was found in the lower left side of the aft fuselage from Station 1790 to Station 2033.5 from stringer S-34L to S-49R. The corrosion was caused by a failure to clean and neutralize vacuum waste system acidic and corrosive contents spill or leak which allows for the breakdown of protective finishes and accelerates the corrosion reaction rate. Seven of the nine airplanes had additional corrosion found after initial corrosion repair was accomplished in an adjacent area. Five of the seven airplanes reported second additional corrosion finding after the first additional finding in an adjacent area. The additional corrosion findings were detected as early as 300 days after the previous corrosion finding. Vacuum waste system residue, on the structure or in the insulation blankets, becomes reactivated with moisture developed during flight and causes this additional corrosion. Exfoliation corrosion of aluminum structure can result in a fatigue cracks. One airplane reported a 13 inch skin exfoliation flake from Station 1790 to Station 1811, from stringer S-41L to S-42L. The exfoliating or flaking effect of the intergranular corrosion originated on the inner surface of the skin and stringer.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Prior to the release of revised Aircraft Maintenance Manuals (AMM) and a new Structural Repair Manual (SRM) these manuals did not give explicit instructions that the acid neutralization was necessary for a vacuum waste system contents spill or leak. Vacuum waste system contents spill and leak neutralization procedures have been revised in the AMM and SRM. This service bulletin is to correct any vacuum waste system spill or leak that may not have been cleaned and neutralized before these changes. The revised procedures are to ensure vacuum waste system contents spills and leaks are clean and neutralized correctly in the future. Airplanes after Line Number (LN) 1446 are not included in the effectivity of this service bulletin. Sufficient time was allowed for full incorporation of these procedures into the operator's maintenance program for all airplanes after LN 1446. The following Boeing maintenance documents clarify the requirement.
– Added Structural Repair Manual (SRM) 777-200 SRM 51-20-18 and 777-300 SRM 51-20-18, General - Correction Procedures For the Leakage of Vacuum Waste System, to define the necessary procedure to avoid damage or to correct damage after a spill or leak of vacuum waste system contents. These contents are acidic and corrosive and will cause damage to protective finishes and result in structural corrosion.
– Revised 777 AMM 05-51-57, 777 AMM 51-00-57, and 777 AMM 51-05-01 procedures for after acid spills to include the contents of the vacuum waste system.
– Issued MOM-MOM-16-0699-01B and Boeing Service Letter 777-SL-53-011 to request operators incorporate these maintenance document changes into the operator's maintenance procedures. Additionally structural maintenance, system maintenance, and operational requirements personnel should be trained and knowledgeable on how to apply the new or revised Boeing procedures when vacuum waste system spills or leaks occur.
This service bulletin is related to 777 FTD 38-08004, 777 FTD 51-09001, and 777 FTD 53-15001.
Boeing Service Related Problem (SRP) 777-SRP-53-0484 is related to this service bulletin.
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 Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications 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/PartsNoKits/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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ACTION This service bulletin is divided into work packages.
REVIEW THE REQUIREMENTS FOR EACH WORK PACKAGE TO DETERMINE ALL THE NECESSARY ACTIONS.
WORK PACKAGE 1 reviews the operator's maintenance procedures used to clean and neutralize vacuum waste system spills and leaks and reviews the airplane maintenance records to see if all vacuum waste system spills and leaks were cleaned and neutralized using the necessary procedure. Based on the results of the maintenance procedure and airplane record review do WORK PACKAGE 2 or WORK PACKAGE 3.
WORK PACKAGE 2 does an internal and external detailed inspection for any corrosion or crack and resulting actions for airplanes that found CONDITION 1 or CONDITION 2.1 in WORK PACKAGE 1.
WORK PACKAGE 3 does an internal and external detailed inspection for any corrosion or crack and resulting actions for airplanes that found CONDITION 2.2 in WORK PACKAGE 1.
EFFECTIVITY 777-200/-200LR/-300/-300ER 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.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and repair given in this service bulletin.
MANPOWER Total Elapsed Hours Total Task HoursAirplanes
26.25105.00777-200/-200LR/-300/-300ER Refer to Paragraph 1.G., Manpower for detailed information
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 777-53A0083
ALERT ALERT -REVIEW MAINTENANCE PROCEDURES.
-IF THE MAINTENANCE PROCEDURES ARE NOT ACCEPTABLE,
UPDATE MAINTENANCE PROCEDURES TO THE BOEING APPROVED PROCEDURE.
-DO INTERNAL AND EXTERNAL DETAILED INSPECTIONS FOR ANY CORROSION OR CRACK.
- REPAIR ANY CORROSION OR CRACK FOUND -CLEAN AND NEUTRALIZE THE INSPECTION AREA.
STA 2000 STA STA 2033.5 STA 1979 1958 1937 STA STA STA 2017 1916 1895 STA 1874 STA 1853 STA STA 1832 STA STA 1790 1811 STA 1769 S-34L S-35L ~S-38L ~S-40L -S-43L
- S-49L ~S-46L 2520121 *S-49R Original Issue: April 20, 2017 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 777-53A0083 Work - See page 1 for details. 8 of 61
Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0083 Original Issue: April 20, 2017 ATA System: 5363 5373 SUBJECT: FUSELAGE - Section 46 and 47 Structure - Inspection for Corrosion or Crack Caused by Vacuum Waste System Contents Spill or Leak
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to 777-200/-200LR/-300/-300ER Airplanes, line numbers 1-1446 in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D624W001 PART 4 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 777-200/-200LR/-300/-300ER airplanes.-1 Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER GroupVariable Number 1WA001 - WA017 1WA076 - WA080 1WA086 - WA093 1WA101 - WA104 1WA116 - WA119 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1WA131 - WA137 1WA171 - WA175 1WA196 - WA198 1WA206 - WA212 1WA221 - WA223 1WA231 - WA232 1WA241 - WA250 1WA261 - WA266 1WA281 - WA283 1WA301 - WA304 1WB001 - WB021 1WB031 - WB046 1WB051 - WB088 1WB101 - WB106 1WB121 - WB125 1WB131 - WB148 1WB151 - WB155 1WB161 - WB177 1WB181 - WB194 1WB201 - WB215 1WB231 - WB247 1WB271 - WB273 1WB276 - WB286 1WB291 - WB302 1WB306 - WB307 1WB311 - WB337 1WB341 - WB342 1WB366 - WB368 1WB371 - WB388 1WB406 1WB411 - WB413 1WB416 - WB439 1WB446 - WB453 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1WB476 1WB481 - WB484 1WB501 - WB512 1WB531 - WB537 1WB551 - WB554 1WB591 - WB597 1WB601 - WB606 1WB611 - WB622 1WB631 - WB638 1WB646 - WB649 1WC051 - WC073 1WC101 - WC104 1WC111 - WC120 1WC221 - WC224 1WC241 - WC243 1WC281 - WC290 1WC301 - WC308 1WC361 - WC364 1WC371 - WC374 1WC381 - WC395 1WC441 1WC446 - WC449 1WC456 - WC459 1WC486 - WC493 1WC506 - WC508 1WC521 - WC522 1WC531 - WC536 1WC546 - WC548 1WC556 1WC566 - WC567 1WC571 - WC574 1WC581 1WC586 - WC587 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1WC591 - WC595 1WD001 - WD002 1WD011 - WD018 1WD031 - WD036 1WD046 - WD055 1WD066 - WD075 1WD081 - WD089 1WD091 1WD096 1WD101 - WD106 1WD111 - WD112 1WD116 - WD117 1WD121 - WD122 1WD501 - WD513 1WD521 - WD541 1WD546 - WD554 1WD561 - WD573 1WD581 - WD599 1WD606 - WD609 1WD621 - WD632 1WD651 - WD665 1WD671 - WD677 1WD691 - WD709 1WD741 - WD752 1WD761 - WD771 1WD786 - WD788 1WD796 - WD837 1WD846 - WD867 1WD871 - WD904 1WD911 - WD918 1WD921 - WD957 1WD966 - WD970 1WD981 - WD982 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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