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Commercial Airplanes 777 Service Bulletin Number: 777-54A0024 Original Issue: April 01, 2010 Revision 1: November 04, 2010 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 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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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2.0
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Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 1 8 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 1
1. Existing Data .......................................... 2 1
2. Data supplied with this Service Bulletin ............................ 2 1
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 1 K. Publications Affected ........................................ 2 1 L. Interchangeability and Intermixability of Parts ........................... 2 2
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary For Each Airplane ................................. 2 3
1. Kits/Parts ............................................ 2 3
2. Parts and Materials Supplied by the Operator ........................ 2 6
3. Parts Modified and Reidentified ................................ 2 6
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 0 FIGURE 1: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - INTERNAL GVI INSPECTION . . 36 FIGURE 2: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - INTERNAL GVI INSPECTION . . 39 FIGURE 3: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - DET INSPECTION ........ 4 2 FIGURE 4: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - INTERIOR DET INSPECTION . . 46 FIGURE 5: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - EXTERIOR DET INSPECTION . 50 FIGURE 6: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - EXTERIOR DET INSPECTION . 52 FIGURE 7: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - PREPARATION .......... 5 4 FIGURE 8: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE REMOVALS . 61 FIGURE 9: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE REMOVALS . 64 FIGURE 10: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - REPLACEMENT ......... 6 8
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FIGURE 11: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE INSTALLATION .................................................. 7 7 FIGURE 12: STRUT NO. 1 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE INSTALLATION .................................................. 8 3 FIGURE 13: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - PREPARATION .......... 8 9 FIGURE 14: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE REMOVALS . 96 FIGURE 15: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE REMOVALS . 99 FIGURE 16: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - REPLACEMENT ......... 1 0 3 FIGURE 17: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - ELECTRICAL SIDE INSTALLATION ................................................. 1 1 2 FIGURE 18: STRUT NO. 2 - SYSTEM DISCONNECT ASSEMBLY - HYDRAULIC SIDE INSTALLATION ................................................. 1 1 8 APPENDIX A: SCOPE OF WORK ...................................... 1 2 4
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Commercial Airplanes 777 Service Bulletin Revision Transmittal SheetNumber: 777-54A0024Original Issue: April 01, 2010 Revision 1: November 04, 2010 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 No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION As a part of a service bulletin validation program, Part 4 was completed on airplane WC117 by Service Bulletin 777-54A0024 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane WC117 by Service Bulletin 777-54A0024 Original Issue is equivalent to the release of Revision 1 of this service bulletin.
This revision is sent to:
1. Revise the threshold to accomplish Part 4 - System Disconnect Assembly Replacement (Terminating Action) after hydraulic coking and heat damage is found in Condition 2B. The original threshold was from the time that hydraulic contamination was found, when it should have been from the time hydraulic fluid coking and/or heat damage is found. Condition 2A allows for repeat inspections if hydraulic fluid contamination is found and no hydraulic fluid coking and/or heat damage is found at the same interval as the threshold for accomplishing Part 4 in Condition 2B. Therefore, it is possible that the threshold from when accomplishment of Part 4 is required in Condition 2B would be exceeded by the time hydraulic fluid coking and/or heat damage was found. The intent was to require the accomplish Part 4 within the threshold after Condition 2B is found.
2. Revise a marker in the kit. A typographical error in a part number in the kit resulted in the wrong marker in the kit and the wrong callout in the service bulletin.
3. Revise circle note for installing the left side drain fitting for the strut no. 2 disconnect box. The same circle note was inadvertently used for both the left and right side drain fittings when two separate circle notes were required.
4. Revise the requirement to jack the airplane to level the airplane. The requirement for the leveling compound is to level the airplane. In many cases the airplane can be leveled without jacking.
5. Clarify that the shims between the disconnect box and the strut lower spar are only required if necessary to meet the pull-up requirements.
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6. Add application of prepack of sealant between the "chimney" and the lower spar to match original installation.
7. Add the rubber seal blocks for the power feeder cables to the operator supplied materials. During the validation, the rubber seal blocks were damaged.
8. Increased the amount of sealant, BMS 5-63 specified in the operator supplied materials to match the quantity needed during the validation.
9. Replace the statements in access and restoration with new General Note. Add new General Note describing access used in the validation.
The following sections were changed.
1. Summary.
Part 4 - System Disconnect Assembly Replacement (Terminating Action) - Revised step from jack airplane to level airplane.
2. Planning Information.
a. Paragraph 1.D., Description - Part 4 - System Disconnect Assembly Replacement (Terminating Action)
- Revised step from jack airplane to level airplane.
b. Paragraph 1.E., Compliance - Revised threshold for accomplishment of Part 4 in Condition 2B.
c. Paragraph 1.G., Manpower - Part 4 - System Disconnect Assembly Replacement (Terminating Action)
- Revised step from jack airplane to level airplane.
3. Material Information.
a. Paragraph 2.A., Material - Price and Availability - Added rubber seal blocks for the power feeder cables.
b. Paragraph 2.C.1., Kits/Parts.
(1) Revised marker part number.
(2) Added rubber seal blocks for the power feeder cables.
c. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Increased the amount of sealant, BMS 5-63.
4. Accomplishment Instructions.
a. Paragraph 3.A., General Information.
(1) General Note 10. - Added new note to allow revised access.
(2) General Note 13. - Added new note to provide information on the condition of access on the validation airplane.
b. Paragraph 3.B., Work Instructions.
(1) Part 4 - System Disconnect Assembly Replacement (Terminating Action).
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(a) Deleted access and restoration notes from steps 2 and 6. This information is now in Paragraph
3.A., General Information, General Note 10.
(b) Changed jacking of the airplane to level the airplane in steps 3 and 5.
(2) Figures.
(a) FIGURE 7 - Step Table, Step 8 - Changed marker part number.
(b) FIGURE 10.
1) Illustration - Section A-A - Added location where prepack of sealant is required.
2) Step Table.
a) Step 4 and Step 7 - Shims A, B, C, and D - Added shim if and as required to obtain required pull-up.
b) Step 7 - Added application of prepack sealant between chimney and strut lower spar.
(c) FIGURE 13 - Illustration - View D - Revised circle note.
1) Illustration - View D - Revised circle note for drain fitting.
2) Step Table, Step 8 - Changed marker part number.
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:
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Commercial Airplanes 777 Service Bulletin SummaryNumber: 777-54A0024Original Issue: April 01, 2010 Revision 1: November 04, 2010 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.
ACTION (PRR 62777-62S) Part 1 - Hydraulic Fluid Contamination Inspection
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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.
EFFECTIVITY 777-200 and -300 Airplanes powered by Pratt and Whitney (PW) Engines. Refer to Paragraph 1.A., Effectivity, 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 available for airplanes in warranty as of October 25, 2007. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Elapsed HoursTotal Task Hours
10.2010.20Part 1 - Hydraulic Fluid Contamination Inspection
10.2010.20Part 2 - Interior Detailed Inspection (DET)
15.0015.00Part 3 - Exterior Detailed Inspection (DET)
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Elapsed HoursTotal Task Hours
117.50296.00Part 4 - System Disconnect Assembly Replacement (Terminating Action)
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 777-54A0024 PART 1:
DO A GVI OF THE INTERIOR
FOR HYDRAULIC FLUID
CONTAMINATION PART 2:
DO A DET OF THE INTERIOR
FOR HYDRAULIC FLUID
CRACKS, AND ETCHING OR COKING, HEAT DAMAGE PITTING.
STRUT LOWER PART 4:
SPAR REPLACE SYSTEM
DISCONNECT ASSEMBLY PART 3:
DO A DET OF THE
EXTERIOR FOR CRACKS Original Issue: April 01, 2010 Revision 1: November 04, 2010 777-54A0024
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 124