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Commercial Airplane Group 777 Service Bulletin Number: 777-55A0010 Revision Transmittal SheetDate: October 26, 2000 Revision 1: April 17, 2001 ATA System: 5500 SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper Additions This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed as shown in the initial release of this service bulletin.
REASON FOR REVISION This revision is sent to do the following:
1. Replace solid rivets with blind rivets in 8 locations on the horizontal stabilizer.
2. Delete instruction to remove the VOR antenna for access.
3. Modify instruction to position rudder and elevator prior to modification.
4. Add instruction to remove additional access panels on vertical and horizontal stabilizers.
5. Add access panel numbers in access / restoration figures.
6. Clarify illustrations with bold lines to show removed panels.
The initial release of this service bulletin was validated at an operator's maintenance facility on an operator's airplane.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
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 Original Release: October 26, 2000 Revision 1: April 17, 2001 777-55A0010 Revision Transmittal Page 1 of 1
No text on this page: it may be a figure. Open the PDF to see it.
Commercial Airplane Group 777 Service Bulletin Number: 777-55A0010 SummaryDate: October 26, 2000 Revision 1: April 17, 2001 ATA System: 5500 SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper Additions
CONCURRENT REQUIREMENTS None
BACKGROUND Accomplishment of this service bulletin will reduce potential high resistance bond paths between the rudder / vertical fin and also between the elevator / horizontal stabilizer. This modification will reduce the potential effects of a large lightning strike on the hydraulic and flight control system in the empennage. A lightning strike to the empennage with high resistance bond paths could cause excessive current on hydraulic lines resulting in pitting at in-line fittings causing pin-hole leaks on hydraulic lines. Leaks due to lightning strikes could lead to loss of hydraulic systems in the empennage which could adversely affect airplane controllability.
In addition, excessive current through the elevator / rudder graphite composite structure can lead to melting / vaporization of epoxy and internal structural damage that will reduce the life of the parts.
Additional bonding jumpers in the empennage will provide a lower resistance path during lightning strikes. Low resistances are important in providing an alternate path for large currents to be "grounded" to the airplane structure instead of damaging hydraulics and / or flight controls.
One operator has told Boeing of two separate reports of lightning strikes which caused hydraulic line leaks in Section 48 of a 777-200. High resistance bond paths between the rudder / vertical fin and also between the elevator / horizontal stabilizer were found during certification testing for the 777-300, and were later found to exist on the 777-200. Airplanes after line number 155 were delivered with additional bonding jumpers installed in production. The initial release of this service bulletin was validated at an operator's maintenance facility on an operator's airplane.
Accomplishment of this service bulletin will make sure that high resistance bond paths are reduced between the rudder / vertical fin and also between the elevator / horizontal stabilizer to reduce the damaging effects of airplane lightning strikes.
Boeing Service Related Problem (SRP) 777-SRP-55-0018 is related to this service bulletin.
ACTION (PRR 61847) Install five bonding jumpers, related ground clips and fasteners to the rudder / vertical fin. Install fourteen (seven per side) bonding jumpers, related ground clips and fasteners to the elevators / horizontal stabilizers. Revise two fasteners from titanium to corrosion resistant steel in the vertical fin tip. Conduct resistance checks of installed bonding jumpers.
EFFECTIVITY All 777-200 airplanes and 777-300 airplanes line numbers 002 through 155.
COMPLIANCE Boeing recommends that operators do this service bulletin as manpower, materials, and facilities are available, but not later than 12 months after the date on this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of March 22, 1999. Please refer to Paragraph 2.B., Industry Support Information.
777-55A0010 Summary Page 1 of 2
BOEING SERVICE BULLETIN 777-55A0010
MANPOWER Total Elapsed Time Airplanes Man-Hours (Hours) 777-200 66 36 777-300 66 36
MATERIAL INFORMATION Boeing Supplied Kits/Parts Refer to Paragraph 2.A., Material - Price and Availability.
INSTALL FOURTEEN (SEVEN PER SIDE) BONDING CONDUCT RESISTANCE CHECKS.
ELEVATORS/HORIZONTAL STABILIZERS.
JUMPERS AND RELATED HARDWARE TO FIN TIP. CONDUCT RESISTANCE CHECKS.
CORROSION RESISTANT STEEL IN THE VERTICAL
REVISE TWO FASTENERS FROM TITANIUM TO HARDWARE TO THE RUDDER/VERTICAL FIN.
INSTALL FIVE BONDING JUMPERS AND RELATED V32373 October 26, 2000 777-55A0010 Revision 1: April 17, 2001 Summary Page 2 of 2
Commercial Airplane Group 777 Service Bulletin Number: 777-55A0010 Date: October 26, 2000 Revision 1: April 17, 2001 ATA System: 5500 SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper Additions
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D624W001, Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR61847 for data about this change.
Airplane Models:
777-200 777-300
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
AEROFLOT (ARO) WB336
AIR FRANCE (AFA) WB311-WB313
ALL NIPPON AIRWAYS (ANA) WA131-WA137 WA221-WA223 WA231-WA232 WB531-WB533
BRITISH AIRWAYS (BAB) WA076-WA080 WB001-WB013
CATHAY PACIFIC AIRWAYS (CAT) WA101-WA104 WB501-WB504
CHINA SOUTHERN AIRLINES (GUN) WA116-WA119 WB121-WB125
EGYPTAIR (EGP) WB151-WB153
EMIRATES (EAD) WA196-WA198 WB101-WB104
JAPAN AIR SYSTEM (JAS) WA206-WA210 October 26, 2000 777-55A0010 Revision 1: April 17, 2001 Page 1 of 52
BOEING SERVICE BULLETIN 777-55A0010
JAPAN AIRLINES (JAL) WA171-WA175 WB591
KOREAN AIR (KAL) WB131-WB133 WB551
KUWAIT AIRWAYS (KUW) WB306-WB307
LAUDA AIR (LAL) WB271
MALAYSIA AIRLINES (MAS) WB161-WB169
SAUDI ARABIAN AIRLINES (SVA) WB276-WB286
SINGAPORE AIRLINES (SIA) WB181-WB186 WB231-WB234
THAI (TII) WA086-WA093
UNITED AIRLINES (UAL) WA002-WA017 WB051-WB068
IDENTIFICATION BY VARIABLE NUMBER WA002-WA017 WA076-WA080 WA086-WA093 WA101-WA104 WA116-WA119 WA131-WA137 WA171-WA175 WA196-WA198 WA206-WA210 WA221-WA223 WA231-WA232 WB001-WB013 WB051-WB068 WB101-WB104 WB121-WB125 WB131-WB133 WB151-WB153 WB161-WB169 WB181-WB186 WB231-WB234 WB271 WB276-WB286 WB306-WB307 WB311-WB313 WB336 WB501-WB504 WB531-WB533 WB551 WB591
2. Spares Affected None October 26, 2000 777-55A0010 Revision 1: April 17, 2001 2
BOEING SERVICE BULLETIN 777-55A0010 B. Concurrent Requirements None C. Reason Accomplishment of this service bulletin will reduce potential high resistance bond paths between the rudder / vertical fin and also between the elevator / horizontal stabilizer. This modification will reduce the potential effects of a large lightning strike on the hydraulic and flight control system in the empennage. A lightning strike to the empennage with high resistance bond paths could cause excessive current on hydraulic lines resulting in pitting at in-line fittings causing pin-hole leaks on hydraulic lines. Leaks due to lightning strikes could lead to loss of hydraulic systems in the empennage which could adversely affect airplane controllability. In addition, excessive current through the elevator / rudder graphite composite structure can lead to melting / vaporization of epoxy and internal structural damage that will reduce the life of the parts.
Additional bonding jumpers in the empennage will provide a lower resistance path during lightning strikes. Low resistances are important in providing an alternate path for large currents to be "grounded" to the airplane structure instead of damaging hydraulics and / or flight controls.
One operator has told Boeing of two separate reports of lightning strikes which caused hydraulic line leaks in Section 48 of a 777-200. High resistance bond paths between the rudder / vertical fin and also between the elevator / horizontal stabilizer were found during certification testing for the 777-300, and were later found to exist on the 777-200. Airplanes after line number 155 were delivered with additional bonding jumpers installed in production. The initial release of this service bulletin was validated at an operator's maintenance facility on an operator's airplane.
Accomplishment of this service bulletin will make sure that high resistance bond paths are reduced between the rudder / vertical fin and also between the elevator / horizontal stabilizer to reduce the damaging effects of airplane lightning strikes.
Revision 1 is sent to do the following:
1. Replace solid rivets with blind rivets in 8 locations on the horizontal stabilizer.
2. Delete instruction to remove the VOR antenna for access.
3. Modify instruction to position rudder and elevator prior to modification.
4. Add instruction to remove additional access panels on vertical and horizontal stabilizers.
5. Add access panel numbers in access / restoration figures.
6. Clarify illustrations with bold lines to show removed parts.
Boeing Service Related Problem (SRP) 777-SRP-55-0018 is related to this service bulletin.
D. Description Install five bonding jumpers, related ground clips and fasteners to the rudder / vertical fin. Install fourteen (seven per side) bonding jumpers, related ground clips and fasteners to the elevators / horizontal stabilizers. Revise two fasteners from titanium to corrosion resistant steel in the vertical fin tip. Conduct resistance checks of installed bonding jumpers.
Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this service bulletin.
October 26, 2000 777-55A0010 Revision 1: April 17, 2001 3
BOEING SERVICE BULLETIN 777-55A0010 An evaluation form is attached to this service bulletin. Please use this form to tell us what you think of the quality of this service bulletin.
E. Compliance Boeing recommends that operators do this service bulletin as manpower, materials, and facilities are available, but not later than 12 months after the date on this service bulletin.
F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and are FAA approved. This service bulletin and the FAA approval were based on the airplane in its original Boeing delivery configuration or as modified by other FAA approved Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin.
NOTE: Joint Airworthiness Requirements (JAR) compliance status may be found in the Service Bulletin Index, Part 1.
G. Manpower The tables below show an estimate of the man-hours necessary to do this change for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator man-hour data if necessary. The estimate does not include lost time. These are some examples of lost time:
- Time to adjust to the workplace
- Time to schedule the work
- Time to examine the work
- Time to cure the materials
- Time to make the parts
- Time to find the tools.
BONDING JUMPER ADDITION TO RUDDER / VERTICAL FIN Task Number of Persons Man-Hours Elapsed Time (Hours) Open Access 1-2 6 3 Install Bonding Jumpers and related hardware 1-2 5 3 Conduct Resistance Checks 1 1 1 Close Access 1-2 6 4 TOTAL FOR EACH AIRPLANE (a) 18 11
(a) Total is for bonding jumper addition to rudder / vertical fin.
October 26, 2000 777-55A0010 Revision 1: April 17, 2001 4
BOEING SERVICE BULLETIN 777-55A0010
BONDING JUMPER ADDITION TO ELEVATORS / HORIZONTAL STABILIZERS Task Number of Persons Man-Hours Elapsed Time (Hours) Open Access 2 16 8 Install Bonding Jumpers and related hardware 2 14 7 Conduct Resistance Checks 1 2 2 Close Access 2 16 8 TOTAL FOR EACH AIRPLANE (a) 48 25
(a) Total is for bonding jumper addition to elevators / horizontal stabilizers on both sides of the airplane.
H. Weight and Balance Changes Change in Weight Change in Moment Airplane (Pounds) (Pound-Inches) 777-200 +6.2 +15128.0 777-300 +6.2 +16299.8 I. Electrical Load Data Not changed J. References
1. Existing Data:
a. Engineering Change Memo PRR 61847
b. 777 Maintenance Manual (AMM) Subjects 55-11-01, 55-15-01, 55-31-01, 55-31-02, 55-35-01, 55-36-01
c. Boeing Standard Overhaul Practices Manual (BSOPM) Subject 20-50-19
d. Boeing Standard Wiring Practices Manual (BSWPM) Subject 20-20-00
2. Data supplied with this service bulletin:
None October 26, 2000 777-55A0010 Revision 1: April 17, 2001 5
BOEING SERVICE BULLETIN 777-55A0010
3. Installation Drawings Used in the Preparation of This Service Bulletin:
Drawing Number Title 183W0001 Elevator Installation 173W0012 Rudder Installation These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators.
K. Publications Changed Publication Chapter-Section 777 Maintenance Manual 05-55 L. Interchangeability and Intermixability of Parts None October 26, 2000 777-55A0010 Revision 1: April 17, 2001 6
BOEING SERVICE BULLETIN 777-55A0010
2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown below. If there is a limit in the quantity (QTY) of kits, a supply sequence is given by Spares.
Unit Price thru Kit Number Name Date QTY Mar 31/01 005W3106-1 Top Kit (a) (a) $2,668.00
(a) Contact Boeing Spares for kit availability data.
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States dollars. Terms: Net 30 days.
Send purchase orders and letters about the supply data to the Director of Spares and refer to this service bulletin number.
B. Industry Support Information Boeing warranty remedies are available for 777 airplanes in warranty as of March 22, 1999. For man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Product Assurance Contracts. The kits for airplanes in warranty as of that date will be supplied at no charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin number and reference the airplane variable number in your purchase order.
C. Parts Necessary For Each Airplane
1. Kits:
To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane.
005W3106 TOP KIT - LIGHTNING PROTECTION OF EMPENNAGE FLIGHT
CONTROL SURFACES -3 -2 -1 Quantity Part Number Name . . - 005W3106-1 Top Kit . - 2 005W3106-2 Horizontal Subkit
- . 1 005W3106-3 Vertical Subkit . 5 . 189W4000-14 Ground Clip 5 4 . 189W4000-32 Ground Clip 2 . . BACB30LH3-5 Bolt 8 12 . BACB30LJ4-4 Bolt 1 1 . BACB30LJ4U7 Bolt . 5 . BACB30NX6K4X Bolt 2 . . BACB30VT6K3 Bolt . 5 . BACC30BH6 Collar October 26, 2000 777-55A0010 Revision 1: April 17, 2001 7
BOEING SERVICE BULLETIN 777-55A0010 (Continued) 005W3106 TOP KIT - LIGHTNING PROTECTION OF EMPENNAGE FLIGHT
CONTROL SURFACES -3 -2 -1 Quantity Part Number Name 2 . . BACC30BP6 Collar . 2 . BACJ40E20-20 Jumper . 1 . BACJ40E20-24 Jumper . 1 . BACJ40E20-26 Jumper 1 1 . BACJ40E20-30 Jumper 2 . . BACJ40E20-36 Jumper 1 . . BACJ40E20-38 Jumper 1 . . BACJ40E20-40 Jumper . 1 . BACJ40E20-44 Jumper . 1 . BACJ40E20-48 Jumper 8 12 . BACN10JC4CD Nut 1 1 . BACN10JC4CM Nut 2 . . BACR15BB6D8C Rivet 1 5 . BACR15BB7AD4C Rivet 3 3 . BACR15BB7AD5C Rivet . 3 . BACR15BB7AD8C Rivet . 4 . BACR15FR6E2R Rivet 4 7 . BACR15FT6KE6C Rivet 1 1 . BACW10BP4APU Washer 8 12 . BACW10BP4DP Washer 1 1 . 189W4000U31 Ground Clip NOTE: The kit has more parts than are necessary for installation. Discard parts that are not used or keep the parts for spares.
2. Parts and Materials Supplied by the Operator:
QTY Part Number Name 24 oz BMS 5-95 Sealant (a)
(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
D. Parts Necessary to Change Spares None E. Existing Parts Accountability None October 26, 2000 777-55A0010 Revision 1: April 17, 2001 8