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Commercial Airplane Group 777 Service Bulletin ALERT Number: 777-78A0070 Date: November 20, 2008 ATA System: 7831 SUBJECT: EXHAUST (GE90) - Thrust Reverser System - GE Scavenge Tube Interference with Thrust Reverser Insulation Blanket Bolt - 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, MD-10, MD-11, MD-80, MD-88, MD-90, 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 1 of 22
2.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 2 of 22 BOEING SERVICE BULLETIN 777-78A0070
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 1 E. Compliance .............................................. 1 1 F . Approval ............................................... 1 1 G. Manpower .............................................. 1 1 H. Weight and Balance Changes .................................... 1 2 I. Electrical Load Data ......................................... 1 2 J. References .............................................. 1 2
1. Existing Data .......................................... 1 2
2. Data supplied with this Service Bulletin ............................ 1 2
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 2 K. Publications Affected ......................................... 1 3 L. Interchangeability and Intermixability of Parts ........................... 1 3
2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 6 C. Parts Necessary For Each Airplane ................................. 1 6
1. Kits/Parts ............................................ 1 6
2. Parts and Materials Supplied by the Operator ........................ 1 6
3. Parts Modified and Reidentified ................................ 1 6
4. Parts Removed and Not Replaced .............................. 1 7 D. Parts Necessary to Change Spares ................................. 1 7 E. Special Tooling - Price and Availability ............................... 1 7 F . Special Tooling Necessary to do this Service Bulletin ....................... 1 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 9 A. GENERAL INFORMATION ..................................... 1 9 B. WORK INSTRUCTIONS ....................................... 1 9 FIGURE 1: THRUST REVERSER - AFT COWL INSULATION BLANKET - FASTENER CHANGE . . . 20 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 3 of 22 BOEING SERVICE BULLETIN 777-78A0070
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 4 of 22 BOEING SERVICE BULLETIN 777-78A0070
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Commercial Airplane Group 777 Service Bulletin ALERT SummaryNumber: 777-78A0070Date: November 20, 2008 ATA System: 7831 SUBJECT: EXHAUST (GE90) - Thrust Reverser System - GE Scavenge Tube Interference with Thrust Reverser Insulation Blanket Bolt - 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 Accomplishment of this service bulletin will prevent interference between an oil scavenge tube on the Turbine Rear Frame (TRF) of the General Electric (GE) engine and an aft cowl insulation blanket bolt. This interference can cause damage to the oil scavenge tube. This damage could result in a puncture in the oil scavenge tube.
A punctured oil scavenge tube would cause oil loss and could cause an in-flight shutdown of the engine.
Boeing determined that there was insufficient clearance between an oil scavenge tube on the GE engine and an aft cowl insulation blanket bolt. This location could experience interference under flight loads. Damage to the oil scavenge tube was confirmed at Boeing on non-delivered airplanes after flight. Several in-service airplanes were also inspected. Many of the airplanes showed damage because of the interference condition.The damage was limited to dents, gouges, or chafing. However, some of the damage that was found was outside of serviceable limits. No oil tube punctures were found or reported.
This service bulletin provides instructions to replace the aft cowl insulation blanket fasteners at one location to gain additional clearance from the oil scavenge tube and remove the possible interference condition.
There are two related vendor service bulletins. GE Service Bulletin 79-0017 provides instructions to inspect the oil scavenge tube for damage and should be done concurrently with this service bulletin. GE Service Bulletin 79-0019 provides instructions to replace the oil scavenge tube with a new tube that will increase clearance with the insulation blanket bolt.
Boeing Service Related Problem (SRP) 777-SRP-72-0032 is related to this service bulletin.
ACTION Open the left thrust reverser. Remove the lower aft cowl insulation blanket. Change the fasteners at one location.
Install the removed insulation blanket. Close the thrust reverser.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 5 of 22
EFFECTIVITY 777-200LR and -300ER Airplanes with GE90-100 engines. 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 180 days or 300 flight cycles after the date on this service bulletin, whichever occurs later.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the changes given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursEngines
2.502.50Each Engine
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.
November 20, 2008 777-78A0070 6 of 22 BOEING SERVICE BULLETIN 777-78A0070
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BOEING SERVICE BULLETIN 777-78A0070
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OPEN THE
LEFT THRUST
REVERSER
CLOSE THE
LEFT THRUST
REVERSER
REMOVE THE
LOWER AFT COWL
INSULATION
BLANKET
CHANGE THE
FASTENERS AT ONE
LOCATION
INSTALL THE
REMOVED
INSULATION
BLANKET FWD 1556029 November 20, 2008 777-78A0070 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 22
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 8 of 22 BOEING SERVICE BULLETIN 777-78A0070
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Commercial Airplane Group 777 Service Bulletin ALERT Number: 777-78A0070 Date: November 20, 2008 ATA System: 7831 SUBJECT: EXHAUST (GE90) - Thrust Reverser System - GE Scavenge Tube Interference with Thrust Reverser Insulation Blanket Bolt - 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.
DESCRIPTIONCONFIGURATIONGROUP 777-200LR and -300ER Airplanes with GE90-100 Engines-1 Airplane Models:
777-200LR, 777-300ER GroupVariable Number 1WD001 - WD002 1WD011 - WD014 1WD031 - WD033 1WD046 - WD048 1WD501 - WD507 1WD521 - WD537 1WD546 - WD552 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 9 of 22
GroupVariable Number 1WD561 - WD571 1WD581 - WD594 1WD606 - WD609 1WD621 - WD632 1WD651 - WD657 1WD671 - WD675 1WD691 - WD701 1WD741 - WD745 1WD761 - WD768 1WD786 - WD787 1WD796 - WD799 1WD826 - WD828 1WD846 1WD871
2. Spares Affected None.
B. Concurrent Requirements The service bulletin listed below must be done before or at the same time as this service bulletin:
DescriptionService BulletinCompany Inspection of GE Engine Oil Scavenge Tube79-0017General Electric (GE) C. Reason Accomplishment of this service bulletin will prevent interference between an oil scavenge tube on the Turbine Rear Frame (TRF) of the General Electric (GE) engine and an aft cowl insulation blanket bolt.
This interference can cause damage to the oil scavenge tube. This damage could result in a puncture in the oil scavenge tube. A punctured oil scavenge tube would cause oil loss and could cause an in-flight shutdown of the engine.
Boeing determined that there was insufficient clearance between an oil scavenge tube on the GE engine and an aft cowl insulation blanket bolt. This location could experience interference under flight loads. Damage to the oil scavenge tube was confirmed at Boeing on non-delivered airplanes after flight. Several in-service airplanes were also inspected. Many of the airplanes showed damage because of the interference condition. The damage was limited to dents, gouges, or chafing. However, some of the damage that was found was outside of serviceable limits. No oil tube punctures were found or reported.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 10 of 22 BOEING SERVICE BULLETIN 777-78A0070
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This service bulletin provides instructions to replace the aft cowl insulation blanket fasteners at one location to gain additional clearance from the oil scavenge tube and remove the possible interference condition.
There are two related vendor service bulletins. GE Service Bulletin 79-0017 provides instructions to inspect the oil scavenge tube for damage and should be done concurrently with this service bulletin.
GE Service Bulletin 79-0019 provides instructions to replace the oil scavenge tube with a new tube that will increase clearance with the insulation blanket bolt.
Boeing Service Related Problem (SRP) 777-SRP-72-0032 is related to this service bulletin.
D. Description Open the left thrust reverser. Remove the lower aft cowl insulation blanket. Change the fasteners at one location. Install the removed insulation blanket. Close the thrust reverser.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones ZoneModel 417777-200LR, 777-300ER 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.
Boeing recommends that the change given in this service bulletin be done within 180 days or 300 flight cycles after the date on this service bulletin, whichever occurs later.
F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA).The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other 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.
G. Manpower The table below shows an estimate of the task hours necessary to do this change for each engine.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Time to adjust to the workplace Time to schedule the work Time to inspect the work Time to cure the materials Time to make the parts Time to find the tools.
Elapsed HoursTask HoursNumber of Persons Task
0.500.501Open Access
1.501.501Figure 1
0.500.501Close Access
2.502.50TOTAL FOR EACH ENGINE H. Weight and Balance Changes None.
I. Electrical Load Data Not changed.
J. References
1. Existing Data
a. Service Related Problem (SRP) 777-SRP-72-0032
b. Boeing Service Letter (SL) 777-SL-78-021
c. Boeing Fleet Team Digest (FTD) Article 777-FTD-79-08001
d. 777 Aircraft Maintenance Manual (AMM) 78-31-00, 78-31-06
e. General Electric (GE) Service Bulletin 79-0017, 79-0019 NOTE: The supplier was told to send copies of the service bulletin to each operator.
2. Data supplied with this Service Bulletin None.
3. Installation Drawings Used in the Preparation of this Service Bulletin TitleDrawing Number Insulation Blanket Instl. - T/R Fan Duct Inner Wall315W1810 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
November 20, 2008 777-78A0070 12 of 22 BOEING SERVICE BULLETIN 777-78A0070