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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-55A0016 Original Issue: October 27, 2009 Revision 1: August 25, 2011 ATA System: 5527 SUBJECT: STABILIZERS - Elevator Attach Fittings - Elevator Actuator Fitting Assembly 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 1 of 103
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 2 of 103 BOEING SERVICE BULLETIN 777-55A0016
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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 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 7 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F. Approval ............................................... 1 9 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 2
1. Existing Data .......................................... 2 2
2. Data supplied with this Service Bulletin ............................ 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 2 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 3
2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 6
1. Kits/Parts ............................................ 2 6
2. Parts and Materials Supplied by the Operator ........................ 3 2
3. Parts Modified and Reidentified ................................ 3 3
4. Parts Removed and Not Replaced .............................. 3 4 D. Parts Necessary to Change Spares ................................. 3 4 E. Special Tooling - Price and Availability ............................... 3 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 5 A. GENERAL INFORMATION ..................................... 3 5 B. WORK INSTRUCTIONS ....................................... 3 7 FIGURE 1: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 1] ................ 3 9 FIGURE 2: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 1] .............. 4 4 FIGURE 3: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 1] ................ 5 1 FIGURE 4: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 1] .............. 5 6 FIGURE 5: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 2] ................ 6 3 FIGURE 6: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 2] .............. 6 8 FIGURE 7: ACTUATOR FITTING ASSEMBLIES - REMOVAL [Group 2] ................ 7 5 FIGURE 8: ACTUATOR FITTING ASSEMBLIES - INSTALLATION [Group 2] .............. 8 0 FIGURE 9: MORE WORK NECESSARY ON AIRPLANES CHANGED IN ACCORDANCE WITH THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN - DETAILED INSPECTION ....... 8 7
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Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 3 of 103 BOEING SERVICE BULLETIN 777-55A0016
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FIGURE 10: MORE WORK NECESSARY ON AIRPLANES CHANGED IN ACCORDANCE WITH THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN - FASTENER REPLACEMENT [Group 1] .................................................. 9 0 FIGURE 11: MORE WORK NECESSARY ON AIRPLANES CHANGED IN ACCORDANCE WITH THE ORIGINAL ISSUE OF THIS SERVICE BULLETIN - FASTENER REPLACEMENT [Group 2] .................................................. 9 3 APPENDIX A: FASTENER HOLE LOCATIONS IN FITTING ASSEMBLIES [Group 1] ........... 9 6 APPENDIX B: FASTENER HOLE LOCATIONS IN FITTING ASSEMBLIES [Group 2] .......... 1 0 0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 4 of 103 BOEING SERVICE BULLETIN 777-55A0016
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Commercial Airplanes 777 Service Bulletin ALERT Revision Transmittal SheetNumber: 777-55A0016Original Issue: October 27, 2009 Revision 1: August 25, 2011 ATA System: 5527 SUBJECT: STABILIZERS - Elevator Attach Fittings - Elevator Actuator Fitting Assembly Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with the original issue of this service bulletin, if the installation torque values listed in the original issue of this service bulletin for BACB30NR4K6 and BACB30NR4K7 bolts were used. If any of these bolts were installed with 200 - 250 inch-pounds of torque, do inspections and replace the affected bolts in accordance with Paragraph 1.E., Compliance, Table 1 and Paragraph 3.B., Work Instructions, PART 3.
No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin if the BACB30NR4K6 and BACB30NR4K7 bolts were installed with 78 - 82 inch-pounds of torque as described in 777-55A0016 IN 03.
No airplanes was added to the service bulletin effectivity.
Federal Aviation Administration (FAA) Airworthiness Directive 2007-26-05 is related to this service bulletin.
REASON FOR REVISION This revision is sent to include additional access data, new kit information, and clarification of instructions for accomplishment of the fitting replacement shown in this service bulletin. These changes have resulted from service bulletin validation. The validation results were previously described in 777-55A0016 IN 02.
In addition, this revision is sent to change the installation torque values In Figures 2, 4, 6 and 8. In the Fastener Table for these figures, the installation torque for fastener codes D and E were changed from 200 - 250 inch-pounds to 78 - 82 inch-pounds.
As a part of a service bulletin validation program, the change in this service bulletin was completed on airplane WB375 by Service Bulletin 777-55A0016 Original Issue before the release of Revision 1 of this service bulletin.
The change completed on airplane WB375 by Service Bulletin 777-55A0016 Original Issue is equivalent to Revision 1 of this service bulletin. Airplane WB375 has the configuration of a Group 2 airplane.
References to Boeing Service Related Problem (SRP) 777-SRP-55-0052 were also added.
These sections were changed:
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Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 5 of 103
1. In Paragraph 1.E., Compliance, Table 1 was added to show the actions necessary if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts.
2. The estimate in Paragraph 1.G., Manpower, has been updated based on the additional access required.
New estimates were also added for the inspection and bolt replacement necessary if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts.
3. Weight and balance data was added to Paragraph 1.H., Weight and Balance Changes. This data was previously included in Information Notice 777-55A0016 IN 01.
4. The statement in Paragraph 1.K.2., Damage Tolerance Based Structural Inspections:, has been changed.
New Damage Tolerance Inspections (DTI) are required after actuator fitting replacement in accordance with this service bulletin.
5. In Paragraph 2.A., Material - Price and Availability, price and availability data has been added for new Replacement Top Kits 005W3356-5 and 005W3356-6 and new Supplemental Kits 005W3356-3 and 005W3356-4.
6. In Paragraph 2.C., Parts Necessary for Each Airplane, parts lists have been added for new Replacement Top Kits 005W3356-5 and 005W3356-6 and new Supplemental Kits 005W3356-3 and 005W3356-4.
7. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, parts have been listed that will be necessary if bolts must be replaced if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts.
8. In Paragraph 3.A., General Information, general notes have been added.
9. In Paragraph 3.B., Work Instructions, the existing fitting replacement instructions have been labeled as PART 1 for Group 1 and PART 2 for Group 2. PART 3 has been added for the actions necessary if the installation torque values listed in the original issue of this service bulletin were used to install certain bolts.
10. In Paragraph 3.B., Work Instructions, statements have been added to refer to Paragraph 1.E., Compliance for inspections required after fitting replacement.
11. In Figures 1, 3, 5, and 7, instructions were added for removal of spar upper and lower chord fasteners and the hinge fitting at elevator station 182.29. These parts are removed to give access for replacement of the outboard actuator fitting.
12. In Figures 2, 4, 6, and 8, instructions were added for installation of spar upper and lower chord fasteners and the hinge fitting at elevator station 182.29.
13. In Figures 2, 4, 6, and 8, shim installation instructions have been revised.
14. In the Fastener Table for Figures 2, 4, 6, and 8, the hole diameter information for fastener code C has been changed.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 6 of 103 BOEING SERVICE BULLETIN 777-55A0016
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15. In the Fastener Table for Figures 2, 4, 6, and 8, the washer installation instruction in footnote (b) has been changed to allow installation of only one washer, rather than two, if necessary to ensure proper fastener thread protrusion.
16. New Figure 9 was added to show the inspections that is necessary on airplanes changed in accordance with the original issue of this service bulletin, if the installation torque values listed in the original issue of this service bulletin were used.
17. New Figures 10 and 11 were added to show the bolt replacement that is necessary on airplanes changed in accordance with the original issue of this service bulletin, if the installation torque values listed in the original issue of this service bulletin were used.
The data given in Information Notice 777-55A0016 IN 01, 777-55A0016 IN 02 and 777-55A0016 IN 03 are included in this revision. IN 01 included weight and balance data. IN 02 advised operators of the results of the service bulletin validation. IN 03 advised operators that the installation torque for fastener codes D and E in the Fastener Table for Figures 2, 4, 6, and 8 should be 78 - 82 inch-pounds, not 200 - 250 inch-pounds.
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 October 27, 2009Original Issue:
August 25, 2011Revision 1:
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Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 7 of 103 BOEING SERVICE BULLETIN 777-55A0016
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 8 of 103 BOEING SERVICE BULLETIN 777-55A0016
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-55A0016Original Issue: October 27, 2009 Revision 1: August 25, 2011 ATA System: 5527 SUBJECT: STABILIZERS - Elevator Attach Fittings - Elevator Actuator Fitting Assembly Replacement
THIS BULLETIN 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 SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND This service bulletin gives instructions to replace the elevator actuator fitting assemblies at left and right Elevator Stations 169.79 and 194.79. The new actuator fitting assemblies will give adequate residual strength to react flight loads. Undetected elevator actuator fitting assembly cracks can become large, and result in the fitting becoming detached from the elevator that can result in an unrestrained elevator. An unrestrained elevator is an unacceptable flutter condition which can result in loss of airplane control.
One operator has told Boeing that a cracked left outboard actuator fitting was found on a 777 airplane with 17,346 flight-hours and 14,043 flight-cycles. The crack extended through the lower inboard flange of the fitting and into the vertical flange. Analysis by Boeing indicates that this crack resulted from fatigue due to higher than anticipated stress levels in the fitting flanges.
Accomplishment of this service bulletin will provide an acceptable level of safety to terminate the repeat inspection requirements of Service Bulletin 777-55A0015. If replacement of the actuator support fitting assemblies is not accomplished, operators will be required to continue to do inspections in accordance with Service Bulletin 777-55A0015.
Boeing Service Related Problem (SRP) 777-SRP-55-0040 and 777-SRP-55-0052 are related to this service bulletin.
ACTION (PRR 62777-59S) This service bulletin provides instruction to replace the elevator actuator fitting assemblies at left and right elevator Stations 169.79 and 194.79.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 9 of 103
EFFECTIVITY 777-200, 777-200LR, 777-300 and 777-300ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive 2007-26-05 is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of November 17, 2006. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 10 of 103 BOEING SERVICE BULLETIN 777-55A0016
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 11 of 103 BOEING SERVICE BULLETIN 777-55A0016
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 27, 2009 777-55A0016Revision 1: August 25, 2011 12 of 103 BOEING SERVICE BULLETIN 777-55A0016