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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-55A0017 Original Issue: May 20, 2010 ATA System: 5518 2741 SUBJECT: STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon Lined Bushing 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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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Original Issue: May 20, 2010 777-55A0017 1 of 55
4.0
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Original Issue: May 20, 2010 777-55A0017 2 of 55 BOEING SERVICE BULLETIN 777-55A0017
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 9 I. Electrical Load Data ......................................... 1 9 J. References .............................................. 1 9
1. Existing Data .......................................... 1 9
2. Data supplied with this Service Bulletin ............................ 2 0
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 0 K. Publications Affected ........................................ 2 0 L. Interchangeability and Intermixability of Parts ........................... 2 0
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 2 C. Parts Necessary For Each Airplane ................................. 2 2
1. Kits/Parts ............................................ 2 2
2. Parts and Materials Supplied by the Operator ........................ 2 2
3. Parts Modified and Reidentified ................................ 2 3
4. Parts Removed and Not Replaced .............................. 2 3 D. Parts Necessary to Change Spares ................................. 2 3 E. Special Tooling - Price and Availability ............................... 2 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: INSPECTION AND MEASUREMENT OF BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHINGS .................................. 3 1 FIGURE 2: INSPECTION AND MEASUREMENT OF HORIZONTAL STABILIZER JACKSCREW FITTING KARON LINED BUSHINGS .................................. 3 3 FIGURE 3: INSPECTION AND MEASUREMENT OF UPPER GIMBAL - BRAKE HOUSING AND UPPER GIMBAL - BULKHEAD SUPPORT KARON LINED BUSHINGS ............... 3 5 FIGURE 4: INSPECTION AND MEASUREMENT OF TRIM ACTUATOR PRIMARY BRAKE HOUSING KARON LINED BUSHINGS .................................. 3 7 FIGURE 5: INSPECTION AND MEASUREMENT OF LOWER GIMBAL KARON LINED BUSHINGS . 39 FIGURE 6: INSPECTION AND MEASUREMENT OF PINS ....................... 4 1 FIGURE 7: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING REMOVAL . . 43 FIGURE 8: BULKHEAD SUPPORT JACKSCREW FITTING INTERMEDIATE SLEEVE REPLACEMENT .................................................. 4 6
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Original Issue: May 20, 2010 777-55A0017 3 of 55 BOEING SERVICE BULLETIN 777-55A0017
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FIGURE 9: BULKHEAD SUPPORT JACKSCREW FITTING KARON LINED BUSHING INSTALLATION .................................................. 5 0 FIGURE 10: KARON LINED BUSHING SERVICE WEAR LIMITS ..................... 5 5
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Original Issue: May 20, 2010 777-55A0017 4 of 55 BOEING SERVICE BULLETIN 777-55A0017
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-55A0017Original Issue: May 20, 2010 ATA System: 5518 2741 SUBJECT: STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon Lined Bushing Inspection and 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 None.
BACKGROUND Accomplishment of work given in this service bulletin will find damage to Karon lined bushings and pins in the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) and HSTA attachment locations on the airplane structure.
There are twenty-four (24) Karon lined bushings and six (6) pins in the fuselage, horizontal stabilizer, HSTA upper and lower gimbals, and HSTA primary brake housing. If the Karon liners in the bushings are damaged, this may cause the Karon liners to completely disbond from the bushings. The completely disbonded Karon liners may migrate out of the joint causing excessive joint clearance. A joint with excessive clearance would result in fatigue cracking of the pins. The fatigue cracking of the pins in the HSTA and HSTA attachment locations on the airplane structure can compromise the structural integrity of the joints resulting in loss of controllability of the airplane.
The 24 Karon lined bushings are installed in the following joint locations: BULKHEAD SUPPORT JACKSCREW
FITTING, HORIZONTAL STABILIZER JACKSCREW FITTING, UPPER GIMBAL - BRAKE HOUSING, UPPER GIMBAL - BULKHEAD SUPPORT, TRIM ACTUATOR PRIMARY BRAKE HOUSING, AND LOWER GIMBAL.
The bore of the bushings is lined with Karon, a material that is intended to reduce friction and resist wear.
Research tests have shown that Karon liners would not wear in service; therefore, lubrication and inspection of these would not be necessary.
During a scheduled inspection of the HSTA components for 777-200, one operator found a Karon lined bushing in the HORIZONTAL STABILIZER JACKSCREW FITTING with Karon liner broken into five pieces. The broken Karon liner had worn and disbonded from the bushing. The broken Karon liner of the bushing was found on an airplane that had accumulated 35,145 flight hours and 5,335 fight cycles.
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Original Issue: May 20, 2010 777-55A0017 5 of 55
Boeing analysis shows that the broken Karon lined bushing was one of the 149 bushings that used an early manufacturing process, which has since been improved. However, further investigation and analysis by Boeing show that Karon lined bushings in the HSTA and HSTA attachment locations on the airplane structure using both the early and the improved process could wear in service. The analysis also shows that the wear of the Karon liner may cause excessive joint clearance, which could lead to fatigue cracking of the pins.
Accomplishment of the inspection in this service bulletin will find any disbond, tear, or wear in the 24 Karon lined bushings; any gouge, crack, or wear in the 6 pins; and any gouge or crack in the fail-safe components in the HSTA and HSTA attachment locations on the airplane structure. The inspection will make sure that Karon lined bushings and pins are returned to the design standard.
Boeing Service Related Problem (SRP) 777-SRP-55-0042 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) article 777 FTD 55-07001 ACTION Airplane Work
1. Remove hydraulic pressure, hydraulic power, and install safety tags to the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA).
2. Gain access to HSTA area and remove the HSTA.
3. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. If any disbond or tear is found, or the ID is greater than the allowable MAXIMUM DIAMETER on the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the bushings; then no bushing replacement is necessary.
4. Install the HSTA that is in a known serviceable condition or has been overhauled in accordance with this service bulletin.
NOTE: If the replacement HSTA is not in a known serviceable condition, then do a Detailed Inspection and measurement of the Karon lined bushings and pins; and a Detailed Inspection of the fail-safe components of the replacement HSTA in accordance with this service bulletin before further flight.
Refer to Paragraph 3.A., General Information, for the applicable known serviceable conditions.
5. Do the Horizontal Stabilizer Trim Actuator Installation Test.
6. Close access and put the airplane back to a serviceable condition.
7. Repeat the Detailed Inspection and measurement of the Karon lined bushings at the time in accordance with Paragraph 1.E., Compliance.
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Original Issue: May 20, 2010 777-55A0017 6 of 55 BOEING SERVICE BULLETIN 777-55A0017
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Component (Horizontal Stabilizer Trim Actuator, HSTA) Work
1. Disassemble the HORIZONTAL STABILIZER TRIM ACTUATOR (HSTA) as necessary.
2. Do a Detailed Inspection and measurement of the Karon lined bushings for any disbond, tear, or wear. Do a Detailed Inspection and measurement of the pins for any gouge, crack, or wear. Do a Detailed Inspection of the fail-safe components for any gouge or crack.
3. If any disbond or tear is found, or the ID is greater than the MAXIMUM DESIGN DIMENSION on the Karon lined bushings; then a bushing replacement is necessary. If no disbond, tear, and wear are found on the bushings; then no bushing replacement is necessary.
4. If any gouge or crack is found, or the OD is less than the MINIMUM DESIGN DIMENSION on the pins; then a pin replacement or refurbishment is necessary. If any gouge or crack is found on the fail-safe components, then a replacement or refurbishment is necessary.
For any cracked pins that are found during the Detailed Inspection, replace the pin and do a magnetic particle inspection of the fail-safe components as applicable. If any crack is found on the fail-safe components during a magnetic particle inspection, then replacement is necessary.
If no gouge, crack, and wear are found on the pins; then a replacement or refurbishment is not necessary.
If no gouge and crack are found on the fail-safe components, then a replacement or refurbishment is not necessary.
5. Assemble the HSTA.
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 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 March 3, 2007. Please refer to Paragraph
2.B., Industry Support Information.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability
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Original Issue: May 20, 2010 777-55A0017 7 of 55 BOEING SERVICE BULLETIN 777-55A0017
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BOEING SERVICE BULLETIN 777-55A0017
ALERT ALERT STA 2245.70 00000000
BULKHEAD SUPPORT
JACKSCREW FITTING
UPPER GIMBAL
TRIM ACTUATOR
PRIMARY
BRAKE HOUSING
HORIZONTAL
STABILIZER
TRIM ACTUATOR (HSTA)
REMOVE THE HORIZONTAL
STABILIZER TRIM ACTUATOR (HSTA). DO A DETAILED
INSPECTION AND MEASUREMENT OF
KARON LINED BUSHINGS IN THE
BULKHEAD SUPPORT JACKSCREW
FITTING AND HORIZONTAL STABILIZER JACKSCREW FITTING.
REPLACE KARON LINED BUSHINGS IF ANY DISCREPANCIES ARE FOUND.
INSTALL HSTA THAT IS IN A KNOWN
SERVICEABLE CONDITION OR
OVERHAULED IN ACCORDANCE WITH THIS SERVICE BULLETIN. REPEAT
THE DETAILED INSPECTION AND
MEASUREMENT IN ACCORDANCE WITH THIS SERVICE BULLETIN.
LOWER GIMBAL
FWD HORIZONTAL STABILIZER
JACKSCREW FITTING Original Issue: May 20, 2010 777-55A0017
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 55
Commercial Airplanes 777 Service Bulletin ALERT Number: 777-55A0017 Original Issue: May 20, 2010 ATA System: 5518 2741 SUBJECT: STABILIZERS - Horizontal Stabilizer - Horizontal Stabilizer Jackscrew Fitting - Karon Lined Bushing Inspection and 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below is complete for airplanes through line number 893. At least one airplane after line number 893 is also affected by this service bulletin, and these airplanes are in Group(s) 1. These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page.
DESCRIPTIONCONFIGURATIONGROUP 777-200, 777-200LR, 777-300, and 777-300ER airplanes.-1 Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER GroupVariable Number 1WA001 - WA017 1WA076 - WA080 1WA086 - WA093
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GroupVariable Number 1WA101 - WA104 1WA116 - WA119 1WA131 - WA137 1WA171 - WA175 1WA196 - WA198 1WA206 - WA212 1WA221 - WA223 1WA231 - WA232 1WA241 - WA250 1WA261 - WA266 1WA281 - WA283 1WA301 - WA304 1WB001 - WB021 1WB031 - WB046 1WB051 - WB088 1WB101 - WB106 1WB121 - WB125 1WB131 - WB148 1WB151 - WB155 1WB161 - WB177 1WB181 - WB194 1WB201 - WB215 1WB231 - WB247 1WB271 - WB273 1WB276 - WB286 1WB291 - WB302 1WB306 - WB307 1WB311 - WB337 1WB341 - WB342 1WB366 - WB368 1WB371 - WB388 1WB406 1WB411 - WB413
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Original Issue: May 20, 2010 777-55A0017 10 of 55 BOEING SERVICE BULLETIN 777-55A0017
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GroupVariable Number 1WB416 - WB439 1WB446 - WB453 1WB476 1WB481 - WB484 1WB501 - WB512 1WB531 - WB537 1WB551 - WB554 1WB591 - WB597 1WB601 - WB606 1WB611 - WB622 1WB631 - WB638 1WB646 - WB649 1WC051 - WC073 1WC101 - WC104 1WC111 - WC120 1WC221 - WC224 1WC241 - WC243 1WC281 - WC290 1WC301 - WC308 1WC361 - WC364 1WC371 - WC374 1WC381 - WC395 1WC441 1WC446 - WC449 1WC456 - WC459 1WC486 - WC493 1WC506 - WC508 1WC521 - WC522 1WC531 - WC536 1WC546 - WC548 1WC556 1WC566 - WC567 1WC571 - WC574
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GroupVariable Number 1WC581 1WD001 - WD002 1WD011 - WD018 1WD031 - WD036 1WD046 - WD055 1WD066 - WD075 1WD081 - WD088 1WD091 1WD501 - WD513 1WD521 - WD541 1WD546 - WD554 1WD561 - WD573 1WD581 - WD599 1WD606 - WD609 1WD621 - WD632 1WD651 - WD665 1WD671 - WD676 1WD691 - WD709 1WD741 - WD752 1WD761 - WD771 1WD786 - WD788 1WD796 - WD813 1WD826 - WD837 1WD846 - WD861 1WD871 - WD882 1WD911 - WD914 1WD921 - WD922 1WD936 - WD939 1WD946 - WD951 1WD966 - WD969 1WD981 - WD982 1WD986 - WD987 1WE001 - WE004
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Original Issue: May 20, 2010 777-55A0017 12 of 55 BOEING SERVICE BULLETIN 777-55A0017