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Commercial Airplanes 777 Service Bulletin Number: 777-54A0024 Original Issue: April 01, 2010 Revision 2: January 23, 2014 ATA System: 5454 SUBJECT: NACELLES / PYLONS - Strut Fireseal and Firewall - Pratt and Whitney Engines - System Disconnect Assembly - Inspection and Replacement 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 © 2010 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Unpublished Work.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 01, 2010 777-54A0024Revision 2: January 23, 2014 1 of 147
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 2 of 147 BOEING SERVICE BULLETIN 777-54A0024
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary ..................................................... 1 1
1. PLANNING INFORMATION ........................................ 1 5 A. Effectivity ............................................... 1 5
1. Airplanes ............................................ 1 5
2. Spares Affected ........................................ 1 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F. Approval ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 5 I. Electrical Load Data ......................................... 2 5 J. References .............................................. 2 5
1. Existing Data: ......................................... 2 5
2. Data Supplied with this Service Bulletin: ........................... 2 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 6 K. Publications Affected ........................................ 2 6 L. Interchangeability and Intermixability of Parts ........................... 2 6 M. Software Accomplishment Summary ................................ 2 6
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 8 C. Parts Necessary for Each Airplane ................................. 2 8
1. Kits/Parts ............................................ 2 8
2. Parts and Materials Supplied by the Operator ........................ 3 2
3. Parts Modified and Reidentified ................................ 3 3
4. Parts Removed and Not Replaced .............................. 3 3 D. Parts Necessary to Change Spares ................................. 3 3 E. Special Tooling - Price and Availability ............................... 3 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - INTERNAL GVI INSPECTION . . 43 FIGURE 2: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - INTERNAL GVI INSPECTION . . 46 FIGURE 3: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - DET INSPECTION ........ 4 9 FIGURE 4: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - INTERIOR DET INSPECTION . . 53 FIGURE 5: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - EXTERIOR DET INSPECTION . 57 FIGURE 6: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - EXTERIOR DET INSPECTION . 59 FIGURE 7: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - PREPARATION .......... 6 1 FIGURE 8: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE REMOVALS . 69 FIGURE 9: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE REMOVALS . 72 FIGURE 10: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - REPLACEMENT ......... 7 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 3 of 147 BOEING SERVICE BULLETIN 777-54A0024
FIGURE 11: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE INSTALLATION .................................................. 8 5 FIGURE 12: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE INSTALLATION .................................................. 9 1 FIGURE 13: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - PREPARATION .......... 9 8 FIGURE 14: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE REMOVALS . 106 FIGURE 15: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE REMOVALS . 109 FIGURE 16: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - REPLACEMENT ......... 1 1 3 FIGURE 17: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE INSTALLATION ................................................. 1 2 2 FIGURE 18: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE INSTALLATION ................................................. 1 2 8 FIGURE 19: STRUT 1 - MORE WORK REQUIRED - COVER PLATE FASTENERS - DET INSPECTION ................................................. 1 3 5 FIGURE 20: STRUT 2 - MORE WORK REQUIRED - COVER PLATE FASTENERS - DET INSPECTION ................................................. 1 3 8 FIGURE 21: STRUT 1 - MORE WORK REQUIRED - COVER PLATE FASTENERS - FASTENER INSTALLATION AND DET OF ELECTRICAL COMPONENTS .............. 1 4 1 FIGURE 22: STRUT 2 - MORE WORK REQUIRED - COVER PLATE FASTENERS - FASTENER INSTALLATION AND DET OF ELECTRICAL COMPONENTS .............. 1 4 4 APPENDIX A: SCOPE OF WORK ...................................... 1 4 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 4 of 147 BOEING SERVICE BULLETIN 777-54A0024
Commercial Airplanes 777 Service Bulletin Revision Transmittal SheetNumber: 777-54A0024Original Issue: April 01, 2010 Revision 2: January 23, 2014 ATA System: 5454 SUBJECT: NACELLES / PYLONS - Strut Fireseal and Firewall - Pratt and Whitney Engines - System Disconnect Assembly - Inspection and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2011-09-11 is related to this service bulletin.
More work is necessary on the airplanes changed in accordance with the Original Issue or Revision 1 of this service bulletin. These airplanes need to inspect the top and side cover plates in accordance with PART 5 - MORE WORK REQUIRED - COVER PLATE FASTENERS - DET INSPECTION within the compliance time in Table 2 in Paragraph 1.E., Compliance. If missing fasteners are found, install cover plate fasteners, do a DET of the electrical components, and repair any damaged electrical components found in accordance with PART 6 - MORE WORK REQUIRED - COVER PLATE FASTENERS - FASTENER INSTALLATION AND DET OF ELECTRICAL COMPONENTS at the compliance time in Table 2 in Paragraph 1.E., Compliance.
REASON FOR REVISION This revision is sent to:
1. Add cover plate attach bolts to the kits, which are part of the system disconnect assembly, and the instructions to install them. This results in the need for new replacement and supplemental kits which include the bolts. Subsequent to the release of Revision 1 of this service bulletin, an operator reported that the side and top cover plates were only temporarily installed with 2 bolts per cover plate, additional bolts were not in the kits, and the service bulletin did not provide instructions to install the remaining bolts. This will also require the addition of Part 5 and Part 6 in the service bulletin for operators that have accomplished the change in the service bulletin and did not transfer the existing bolts securing the cover plates on the old system disconnect assembly to the new system disconnect assembly.
2. Add optional leveling compound.
3. Add reference to Federal Aviation Administration (FAA) Airworthiness Directive AD 2011-09-11.
4. Make minor corrections; a) Correct access panel callouts in Part 4. Strut no. 2 panels were inadvertently labeled with strut no 1. labels. Delete access panel 432AR and 442AR which access the strut forward dry bay and not the area above the system disconnect box; b) Add removal of the main fuel line o-ring to hydraulic side removals for strut no. 2, same as strut no. 1.
5. Add optional disconnection of the hydraulic lines inside the strut to make replacement of system disconnect assembly easier.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 5 of 147
6. Update document to current service bulletin format standards.
These sections were changed:
1. Summary
a. Background - Add Summary Evaluation Table to meet current service bulletin format standards.
b. Action - Add Part 5 and Part 6.
c. Compliance - Add reference to FAA AD 2011-09-11 and the effective date of the AD.
d. Manpower - Add Part 5 and Part 6.
e. Illustration - Add Part 5 and Part 6.
2. Planning Information
a. Paragraph 1.C., Reason - Add reason for revision information.
b. Paragraph 1.D., Description
(1) Add Part 5 and Part 6.
(2) Add compliance information related to this revision.
c. Paragraph 1.E., Compliance
(1) Add Table 2 to for Part 5 and Part 6.
(2) Add reference to FAA AD 2011-09-11 and the effective date of the AD.
(3) Revise compliance time from "after the original issue date of this service bulletin" to "after the effective date of FAA AD 2011-09-11.
d. Paragraph 1.F., Approval - Add paragraph that shows this revision has been approved as an Alternate Method of Compliance (AMOC) to FAA AD 2011-09-11.
e. Paragraph 1.G., Manpower - Add Part 5 and Part 6.
f. Paragraph 1.J.1., Existing Data - Add FAA AD 2011-09-11.
g. Paragraph 1.M., Software Accomplishment Summary - Add new section to meet current service bulletin format standards.
3. Material Information
a. Paragraph 2.A., Material - Price and Availability - Add new replacement and supplemental kits which include the cover plate attach bolts.
b. Paragraph 2.C.1., Kits/Parts - Add new replacement and supplemental kits which include the cover plate attach bolts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 6 of 147 BOEING SERVICE BULLETIN 777-54A0024
c. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Add optional leveling compound
4. Accomplishment Instructions
a. Paragraph 3.A., General Information
(1) Delete Note 1. to meet current service bulletin format standards.
(2) Revise Note 4. to meet current service bulletin format standards.
(3) Add Note 6. to meet current service bulletin format standards.
(4) Revise Note 7. to meet current service bulletin format standards.
(5) Add Note 15. to meet current service bulletin format standards.
(6) Add Note 16. to meet current service bulletin format standards.
(7) Add Note 17. to meet current service bulletin format standards.
b. Paragraph 3.B., Work Instructions
(1) Add section title to original high level work flow.
(2) Add new high level work instruction section and title. This adds Condition 4 and Condition 5, that call out Part 5 and Part 6.
(3) PART 4, Step 2.c. - Correct access panel part numbers.
c. FIGURE 7
(1) Illustrations - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(2) Step Table
(a) Step 2 - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(b) Step 5 - Add optional leveling compound.
(3) Fastener code Table - Add fastener code table and example of fastener symbol for the cover plate attach fasteners.
d. FIGURE 8
(1) Step Table
(a) Step 3 - Add optional disconnection of the hydraulic lines inside the strut to make replacement of system disconnect assembly easier.
e. FIGURE 10 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 7 of 147 BOEING SERVICE BULLETIN 777-54A0024
(1) Step Table
(a) Step 13 - Add optional leveling compound.
f. FIGURE 11
(1) Illustrations - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(2) Step Table
(a) Step 12 - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(3) Fastener code Table - Add fastener code table and example of fastener symbol for the cover plate attach fasteners.
g. FIGURE 12
(1) Illustrations - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(2) Step Table
(a) Step 7, Step 8, and Step 9 - Add connection of hydraulic lines inside strut, if disconnected.
(b) Step 15 - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(3) Fastener code Table - Add fastener code table and example of fastener symbol for the cover plate attach fasteners.
h. FIGURE 13
(1) Illustrations - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(2) Step Table
(a) Step 2 - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(b) Step 5 - Add optional leveling compound.
(3) Fastener code Table - Add fastener code table and example of fastener symbol for the cover plate attach fasteners.
i. FIGURE 14
(1) Illustrations - Add option to disconnect hydraulic lines and main fuel line inside the strut to make replacement of system disconnect assembly easier.
(2) Step Table Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 8 of 147 BOEING SERVICE BULLETIN 777-54A0024
(a) Step 2 - Add removal of main fuel line o-ring which was inadvertently omitted.
(b) Step 3 - Add optional disconnection of the hydraulic lines and main fuel line inside the strut to make replacement of system disconnect assembly easier.
j. FIGURE 16
(1) Step Table
(a) Step 13 - Add optional leveling compound.
k. FIGURE 17
(1) Illustrations - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(2) Step Table
(a) Step 12 - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(3) Fastener code Table - Add fastener code table and example of fastener symbol for the cover plate attach fasteners.
l. FIGURE 18
(1) Illustrations - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(2) Step Table
(a) Step 7, Step 8, and Step 9 - Add connection of hydraulic lines inside strut, if disconnected.
(b) Step 15 - Add installation of the cover plate attach fasteners that are not part of the system disconnect assembly.
(3) Fastener code Table - Add fastener code table and example of fastener symbol for the cover plate attach fasteners.
m. FIGURE 19 - New figure for strut no. 1 to accomplish the more work requirements to inspect the side and top cover plate fasteners to determine if fasteners are missing.
n. FIGURE 20 - New figure for strut no. 2 to accomplish the more work requirements to inspect the side and top cover plate fasteners to determine if fasteners are missing.
o. FIGURE 21 - New figure for strut no. 1 to accomplish the more work requirements, to install the missing fasteners, fillet seal the cover plates, and inspect the electrical connectors for damage.
p. FIGURE 22 - New figure for strut no. 2 to accomplish the more work requirements, to install the missing fasteners, fillet seal the cover plates, and inspect the electrical connectors for damage.
q. APPENDIX A - Add New Part 5 and Part 6.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 9 of 147 BOEING SERVICE BULLETIN 777-54A0024
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 April 01, 2010Original Issue:
November 04, 2010Revision 1:
January 23, 2014Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 10 of 147 BOEING SERVICE BULLETIN 777-54A0024
Commercial Airplanes 777 Service Bulletin SummaryNumber: 777-54A0024Original Issue: April 01, 2010 Revision 2: January 23, 2014 ATA System: 5454 SUBJECT: NACELLES / PYLONS - Strut Fireseal and Firewall - Pratt and Whitney Engines - System Disconnect Assembly - Inspection and Replacement
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of the inspections and replacement of the system disconnect assembly will detect and prevent cracking of the system disconnect assembly. Cracks in the system disconnect area may allow fire in the engine area to enter the strut. This could result in an uncontained engine strut fire.
Several operators have reported system disconnect boxes that have been contaminated with hydraulic fluid as detailed in service bulletin 777-54-0023. In addition, 1 operator has reported finding cracks in the system disconnect assembly bulkheads and lower skin panel. Subsequent analysis at Boeing found hydrogen embrittlement of the system disconnect assembly bulkheads and lower skin panel. The system disconnect assembly is made from titanium and is located near the hot engine core of the engine where temperatures can exceed 270 degrees Fahrenheit. The presence of hydraulic fluid and temperature above 270 degrees Fahrenheit can result in hydrogen embrittlement of the titanium system disconnect assembly. Hydrogen embrittlement combined with a high sonic vibration environment can result in cracking of the system disconnect assembly.
The system disconnect assembly is a box where hydraulic, fuel, and electrical connections are made between the engine and the strut. This box acts as firewall between the engine compartment and the strut. The engine compartment has a dedicated fire extinguishing system while the strut does not. The strut is considered a flammable leakage zone where flammable fluids may be present. These fluids are subsequently drained from the strut and system disconnect box. Cracking of the system disconnect assembly could allow a fire into the strut if a fire was present in the engine compartment. If a fire was able to enter the strut and flammable fluid was present, and since the strut does not have a dedicated fire suppression system, it is possible an uncontained engine strut fire could result.
Inspection of the system disconnect assembly will show the presence of coked hydraulic fluid or cracking. The presence of coked hydraulic fluid is an indication that hydrogen embrittlement may have occurred. Replacement of the titanium system disconnect assembly with an Inconel system disconnect assembly will eliminate the potential for hydrogen embrittlement and subsequent cracking.
Boeing Service Related Problem (SRP) 777-SRP-54-0125 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: April 01, 2010 777-54A0024Revision 2: January 23, 2014 11 of 147
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 ChangesYesWeight 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 ACTION (PRR 62777-62S) Part 1 - Hydraulic Fluid Contamination Inspection Open the thrust reversers. Remove the thermal blankets. Remove the cover plates and do a General Visual Inspection (GVI) of the interior of the strut disconnect assembly for hydraulic fluid contamination. Install the cover plate. Install the thermal blankets. Close the thrust reversers.
Part 2 - Interior Detailed Inspection (DET) Open the thrust reversers. Remove the thermal blankets. Remove the cover plates and do a Detailed Inspection (DET) of the interior of strut disconnect assembly for hydraulic fluid coking, heat discoloration, cracks, and etching or pitting. Install the cover plate. Install the thermal blankets. Close the thrust reversers.
Part 3 - Exterior Detailed Inspection (DET) Open the thrust reversers. Remove the thermal blankets. Do a DET of the exterior of the strut disconnect assembly for cracks. Install the thermal blankets. Close the thrust reversers.
Part 4 - System Disconnect Assembly Replacement (Terminating Action) Prepare the new system disconnect assembly for installation (apply sealant, install drain fittings and drain screens, install markers). Remove the engine. Remove the thrust reverser. Remove the access panels. Remove the precooler. Remove the thermal blankets. Level airplane. Replace system disconnect assembly. Lower airplane from jacks, if required. Install access panels. Install thermal blankets. Install precooler. Install thrust reverser. Install engine.
PART 5 - MORE WORK REQUIRED - COVER PLATE FASTENERS - DET INSPECTION Open the thrust reversers. Remove the thermal blankets. Inspect the side and top cover plates to determine if all cover plate attach fasteners have been installed. Install the thermal blankets. Close the thrust reversers.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 01, 2010 777-54A0024Revision 2: January 23, 2014 12 of 147 BOEING SERVICE BULLETIN 777-54A0024