Boeing ASB 777-55A0014: Revision 1, text

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Commercial Airplanes 777 Service Bulletin Number: 777-55A0014 Original Issue: May 08, 2008 Revision 1: April 01, 2010 ATA System: 5500 SUBJECT: STABILIZERS - Elevator and Rudder Bond Jumper Bracket 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: May 08, 2008 777-55A0014Revision 1: April 01, 2010 1 of 87

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Original Issue: May 08, 2008 777-55A0014Revision 1: April 01, 2010 2 of 87 BOEING SERVICE BULLETIN 777-55A0014

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Table of Contents

Revision Transmittal Sheet5

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 7 I. Electrical Load Data ......................................... 1 7 J. References .............................................. 1 7

1. Existing Data: ......................................... 1 7

2. Data supplied with this Service Bulletin: ........................... 1 8

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8 K. Publications Affected ........................................ 1 8 L. Interchangeability and Intermixability of Parts ........................... 1 8

2. MATERIAL INFORMATION ........................................ 1 9 A. Material - Price and Availability ................................... 1 9 B. Industry Support Information .................................... 1 9 C. Parts Necessary For Each Airplane ................................. 1 9

1. Kits/Parts: ........................................... 1 9

2. Parts and Materials Supplied by the Operator: ........................ 2 1

3. Parts Modified and Reidentified: ............................... 2 1

4. Parts Removed and Not Replaced: .............................. 2 1 D. Parts Necessary to Change Spares ................................. 2 1 E. Special Tooling - Price and Availability ............................... 2 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 1

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 4 FIGURE 1: LEFT ELEVATOR - BOND JUMPER BRACKET REPLACEMENT [Group 1] ........ 2 6 FIGURE 2: LEFT ELEVATOR - BOND JUMPER BRACKET REPLACEMENT [Group 2] ........ 3 6 FIGURE 3: RIGHT ELEVATOR - BOND JUMPER BRACKET REPLACEMENT [Group 1] ....... 4 6 FIGURE 4: RIGHT ELEVATOR - BOND JUMPER BRACKET REPLACEMENT [Group 2] ....... 5 6 FIGURE 5: RUDDER - BOND JUMPER BRACKET REPLACEMENT [Group 1] ............ 6 6 FIGURE 6: RUDDER - BOND JUMPER BRACKET REPLACEMENT [Group 2] ............ 7 7

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Commercial Airplanes 777 Service Bulletin Revision Transmittal SheetNumber: 777-55A0014Original Issue: May 08, 2008 Revision 1: April 01, 2010 ATA System: 5500 SUBJECT: STABILIZERS - Elevator and Rudder Bond Jumper Bracket Replacement 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 original issue of this service bulletin.

REASON FOR REVISION This revision is sent to incorporate improvements noted during the validation of this service bulletin.

These sections were changed:

1. Summary and Paragraph 1.E, Compliance: Clarified the recommended compliance time.

2. Summary and Paragraph 2.B, Industry Support Information: Revised the warranty statement.

3. Summary and Paragraph 1.G, Manpower: Increased the number of persons and the task-hour estimate for each figure.

4. Paragraph 1.J, References: Added the manuals referenced in the new figure steps.

5. Paragraph 1.K, Publications Affected: Added 777 Maintenance Manual 27-31 and Damage Tolerance Based Structural Inspection statement.

6. Paragraph 2.A, Material - Price and Availability: Updated kit availability, ROLT, and price.

7. Paragraph 2.C.1, Kits/Parts: Added optional part numbers for jumper brackets.

8. Paragraph 2.C.2, Parts and Materials Supplied by the Operator:

a. Specified that the BMS 5-95 sealant should be Class B.

b. Added materials used to restore the airplane's finish.

9. Paragraph 3.B, Work Instructions, Work Packages 1 and 2: Added the upper trailing edge panel to the list of items removed for access.

10. All Figures:

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a. Changed illustrations to better show the task steps.

b. Replaced bracket dimension references with a picture of a typical bracket installation.

c. Combined steps 1 through 5 into new steps 1 and 5.

d. Added steps to remove tee assemblies and trailing edge beams to improve access.

e. Changed the order of the steps to install the jumpers on the bracket before installing the bracket on the elevator or rudder, for ease of installation.

f. Added optional part numbers for jumper brackets.

g. Step 5: Added note “if installed" next to “Remove Shim".

h. Step 6: Added sub-step “Drill Shim".

i. Added steps to the end of the procedure to cap seal the bracket bolt heads and restore the airplane's finish.

j. Note (d): Clarified the requirement for and location of the shim.

k. Note (h): Clarified the assembly order of the jumpers and fasteners.

l. Note (j): Clarified where the resistance measurement is to be made.

m. Notes (h), (i), and (j): Updated SWPM references.

As a part of a service bulletin validation program, this change was completed on airplane WB186 by Service Bulletin 777-55A0014 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane WB186 by Service Bulletin 777-55A0014 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WB186 has the configuration of a Group 1 airplane.

The intent of Information Notice 777-55A0014 IN 01 is incorporated in this revision.

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 May 08, 2008Original Issue:

April 01, 2010Revision 1:

Original Issue: May 08, 2008 777-55A0014Revision 1: April 01, 2010 6 of 87 BOEING SERVICE BULLETIN 777-55A0014

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Commercial Airplanes 777 Service Bulletin SummaryNumber: 777-55A0014Original Issue: May 08, 2008 Revision 1: April 01, 2010 ATA System: 5500 SUBJECT: STABILIZERS - Elevator and Rudder Bond Jumper Bracket Replacement

CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements

BACKGROUND This service bulletin gives instructions to replace single-tabbed bond jumper brackets on the elevators and rudder with two-tabbed brackets. These brackets are part of the lightning protection ground path for the horizontal and vertical stabilizers. At this time, two bond jumpers are attached to the single tab, which creates a single high-resistance ground path. If this ground path is lost because the tab is broken or damaged, a lightning strike could cause excessive current in the adjacent structure, hinges, and hydraulic tubes, which could cause them to fail. More importantly, a lightning strike could cause excessively high voltage transients in the Actuator Control Electronics (ACE) wire bundles, which could cause damage to the ACE units or unwanted effects such as uncommanded motion of the flight control surfaces. No ACE failures have been reported as a result of a lightning strike. However, if these brackets are not replaced, loss of the lightning protection ground path could result in possible loss of airplane control in the event of a lightning strike.

An operator reported two failures of the single-tabbed bracket on the rudder. In the most recent case, the bracket was discolored and melted, the tab was completely severed and burned, and the bond jumpers were detached from the bracket. The operator also reported a similar failure of the ground clip that connects the other end of the jumpers to the vertical stabilizer. Boeing determined that the root cause of these failures was a combination of electromagnetic forces on the jumpers and resistive heating of the bracket and ground clip during lightning strikes. Fatigue loading after initial damage from the lightning strikes could also have contributed to the failures.

When tested in the lightning lab, multiple large-magnitude lightning strikes were necessary to cause the single-tabbed bracket to fail, but the two-tabbed bracket survived many more large-magnitude lightning strikes with almost no damage. The two-tabbed bracket will provide a second ground path and reduce the current flow and mass at each tab. This will lower the overall resistance of the lightning protection ground path and reduce the possibility of total loss of the ground path due to failure of a single tab.

Boeing Service Related Problem (SRP) 777-SRP-55-0037 is related to this service bulletin.

ACTION Get access to the single-tabbed brackets on the elevators and rudder. Remove the bond jumpers, replace the single-tabbed brackets with two-tabbed brackets, and install new bond jumpers. Do resistance tests of the new brackets and bond jumpers.

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EFFECTIVITY 777-200/-300 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.

Boeing recommends that the change given in this service bulletin be done within 4 years after the original issue date of 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.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

10.521.0All

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 777-55A0014

REMOVE BOND JUMPERS, REPLACE SINGLE-TABBED BRACKETS WITH TWO-TABBED BRACKETS, AND INSTALL NEW BOND JUMPERS. 1457014 DO RESISTANCE TESTS OF THE NEW BRACKETS AND BOND JUMPERS.

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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.

DESCRIPTIONCONFIGURATIONGROUP 777-200/-300 airplanes, line numbers 2-155-1 777-200/-300 airplanes, line numbers 1, 156-309-2 Airplane Models:

777-200, 777-300 GroupVariable Number 2WA001 1WA002 - WA017 1WA076 - WA080 1WA086 - WA093 1WA101 - WA104 1WA116 - WA119 1WA131 - WA137 1WA171 - WA175 1WA196 - WA198 1WA206 - WA210

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GroupVariable Number 2WA211 - WA212 1WA221 - WA223 1WA231 - WA232 2WA241 - WA247 2WA261 - WA266 1WB001 - WB013 2WB014 - WB021 2WB031 - WB039 1WB051 - WB068 2WB069 - WB076 1WB101 - WB104 2WB105 - WB106 1WB121 - WB125 1WB131 - WB133 2WB134 - WB135 1WB151 - WB153 1WB161 - WB169 2WB170 - WB171 1WB181 - WB186 2WB187 - WB188 1WB231 - WB234 2WB235 1WB271 2WB272 1WB276 - WB286 2WB291 - WB300 1WB306 - WB307 1WB311 - WB313 2WB314 - WB323 1WB336 2WB337 2WB366 - WB367 2WB371 - WB386

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