Boeing ASB 777-78A0066: U.S. DOT/FAA - Boeing Service Bulletin, text

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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-78A0066 Original Issue: June 05, 2008 Revision 2: April 08, 2010 ATA System: 7831 SUBJECT: EXHAUST (GE90 Engine) - Thrust Reverser System - Latch Beam Firewall - Install Insulation Blanket 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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: June 05, 2008 777-78A0066Revision 2: April 08, 2010 1 of 46

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Original Issue: June 05, 2008 777-78A0066Revision 2: April 08, 2010 2 of 46 BOEING SERVICE BULLETIN 777-78A0066

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

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

2. Data supplied with this Service Bulletin: ........................... 1 7

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 7 K. Publications Affected ........................................ 1 7 L. Interchangeability and Intermixability of Parts ........................... 1 7

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 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 2

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 3 FIGURE 1: THRUST REVERSER - LATCH BEAM - REMOVE AFT INSULATION BLANKET AND INSULATION FOAM [Group 1] ................................ 2 5 FIGURE 2: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION [Group 1 ] ................................................ 2 7 FIGURE 3: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION [Group 1 ] ................................................ 3 1 FIGURE 4: THRUST REVERSER - LATCH BEAM - REMOVE INSULATION FOAM [Group 2] .... 3 5 FIGURE 5: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION [Group 2 ] ................................................ 3 7 FIGURE 6: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION [Group 2] ............................................ 4 1 Appendix A: COMPOSITE STUD - ADHESIVE BONDED INSTALLATION ................ 4 5

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Commercial Airplanes 777 Service Bulletin ALERT Revision Transmittal SheetNumber: 777-78A0066Original Issue: June 05, 2008 Revision 2: April 08, 2010 ATA System: 7831 SUBJECT: EXHAUST (GE90 Engine) - Thrust Reverser System - Latch Beam Firewall - Install Insulation Blanket This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD, is related to this service bulletin.

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 add airplanes that were inadvertantly omitted in the original issue of this service bulletin, to change information in the compliance section, and to add an optional instruction to mark the thrust reverser identifcation plate.

The following sections have been changed:

1. Paragraph 1.A.1., Airplanes - Airplanes with variable numbers WB372-WB388 were added to Group 1.

2. In the Compliance section and Paragraph 1.E., 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," has been changed to, "Federal Aviation Administration Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD is related to this service bulletin."

3. In Paragraph 3.B, Work Instructions, Step 8 - "OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number to show the change was done. Refer to SOPM 20-50-10 as an accepted procedure," was added.

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

Original Issue: June 05, 2008 777-78A0066Revision 2: April 08, 2010 5 of 46

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REVISION HISTORY June 05, 2008Original Issue:

March 12, 2009Revision 1:

April 08, 2010Revision 2:

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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-78A0066Original Issue: June 05, 2008 Revision 2: April 08, 2010 ATA System: 7831 SUBJECT: EXHAUST (GE90 Engine) - Thrust Reverser System - Latch Beam Firewall - Install Insulation Blanket

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 This service bulletin tells the operator to add a thermal insulation blankets, and attachments, to the rear section of the latch beam of each Thrust Reverser (T/R) half. This change will make sure that a fire can not breach the bolt-on aluminum plate at the rear of the latch beam and move into the transcowl cavity. A fire that is not contained could move to other cowl or strut areas. This could cause weakened structural pieces of the T/R to separate in flight, with the result of a damaged airplane or injury to persons on the ground.

An operator performed an In Flight Shut Down (IFSD) because of an engine fire indication. An air turn back and satisfactory landing was completed without incident. An under cowl engine fire was put out on the ground. The cause was determined to be an uncontained failure of the starter in the engine core compartment, which progressed into the latch beam cavity fuelled by oil supplied by a damaged Integrated Drive Generator (IDG) oil line. The fire breached the bolt-on aluminum plate on the rear of the latch beam fire wall and moved inside the translating sleeve. This caused damage to inner and outer walls of the T/R translating sleeve. Installation of a thermal insulation blanket over the bolt-on aluminum plate area at the rear of the latch beam will protect this area of the firewall so that it is not breached by a fire. This retrofit is not necessary on T/Rs after airplane line 413, because of a design change. The design change to the T/R, integrated the bolt on the aluminum plate area into the main latch beam casting and incorporated thermal insulation blankets across the area.

Boeing Service Related Problem (SRP) 777-SRP-78-0059 is related to this service bulletin.

ACTION (PRR 62777-57RS) Open a T/R and accomplish the work below:

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Group 1:

1. Remove and keep the existing latch beam insulation blanket.

2. Remove insulation foam on the aft fire wall.

3. Install bonded studs on fire wall.

4. Install new thermal insulation blanket on fire wall.

5. Install removed latch beam insulation blanket.

6. Apply sealant around new thermal insulation blanket.

7. Repeat the work for the opposite T/R. Close the T/R when the work is complete.

NOTE: Service Bulletin 777-24-0058 which installs a check valve in the IDG oil supply should also be done. The bulletin addresses the potential event of failure of the oil supply line, stopping the flow of oil which can help feed a fire in the area of the IDG.

Group 2:

1. Remove insulation foam on the aft fire wall.

2. Install bonded studs on fire wall.

3. Install new thermal insulation blanket on fire wall.

4. Install new latch beam insulation blanket.

5. Apply sealant around new thermal insulation blanket.

6. Repeat the work for the opposite T/R. Close the T/R when the work is complete.

EFFECTIVITY 777-200 Airplanes with GE-90 engines. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD is related to this service bulletin.

Boeing recommends that the change, given in this service bulletin be done within 1, 825 days or 4, 500 flight cycles after the original issue date of this service bulletin, whichever occurs first.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

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MANPOWER Group 1:

EACH ENGINE Elapsed HoursTotal Task Hours

7.507.50 Group 2:

EACH ENGINE Elapsed HoursTotal Task Hours

7.257.25

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

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BOEING SERVICE BULLETIN 777-78A0066

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RIGHT LATCH BEAM SEE

LEFT LATCH BEAM SEE NO. 5 LATCH NO. 4 LATCH NO. 3 LATCH NO. 2 LATCH

REMOVE INSULATION FOAM. INSTALL

BONDED STUDS,

NEW INSULATION

BLANKET AND SEALANT.

GROUP 2 AIRPLANES:

INSTALL NEW INSULATION LATCH ACCESS DOOR FWD < BLANKET

RIGHT LATCH BEAM SHOWN

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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 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. Refer to PRR 62777-57RS for data about this change.

DESCRIPTIONCONFIGURATIONGROUP All 777-200 airplanes with GE90 engines through line number 413 with a forward insulation blanket.

-1 All 777-200 airplanes with GE90 engines through line number 413 without a forward insulation blanket.

-2 Airplane Models:

777-200 GroupVariable Number 2WA076 - WA080 2WA116 - WA119 2WB001 - WB009

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GroupVariable Number 1WB010 - WB021 2WB121 - WB122 1WB123 - WB125 1WB271 - WB273 1WB276 - WB286 1WB291 - WB302 1WB306 - WB307 2WB311 - WB313 1WB314 - WB337 1WB341 - WB342 1WB371 - WB388 1WB406 1WB411 - WB413 1WB476 1WC241 1WC281

2. Spares Affected Spare Thrust Reversers (T/R) are affected. Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for parts necessary to change spares.

B. Concurrent Requirements None.

C. Reason This service bulletin tells the operator to add a thermal insulation blankets, and attachments, to the rear section of the latch beam of each Thrust Reverser (T/R) half. This change will make sure that a fire can not breach the bolt-on aluminum plate at the rear of the latch beam and move into the transcowl cavity. A fire that is not contained could move to other cowl or strut areas. This could cause weakened structural pieces of the T/R to separate in flight, with the result of a damaged airplane or injury to persons on the ground..

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