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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-78A0094 Original Issue: July 29, 2014 ATA System: 7830 SUBJECT: EXHAUST (Trent 800 Engines) - Thrust Reverser System - Thrust Reverser Inner Wall Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2014 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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: July 29, 2014 777-78A0094 1 of 144
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2014 777-78A0094 2 of 144 BOEING SERVICE BULLETIN 777-78A0094
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Table of Contents
Summary5
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 3 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 1 8 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 1 9 I. Electrical Load Data ......................................... 2 0 J. References .............................................. 2 0
1. Existing Data: ......................................... 2 0
2. Data Supplied with this Service Bulletin: ........................... 2 0
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 1 K. Publications Affected ........................................ 2 1 L. Interchangeability and Intermixability of Parts ........................... 2 2 M. Software Accomplishment Summary ................................ 2 2
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 7
1. Kits/Parts ............................................ 2 7
2. Parts and Materials Supplied by the Operator ........................ 3 1
3. Parts Modified and Reidentified ................................ 3 2
4. Parts Removed and Not Replaced .............................. 3 2 D. Parts Necessary to Change Spares ................................. 3 2 E. Special Tooling - Price and Availability ............................... 3 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 6 FIGURE 1: LEFT TR HALF SPLICE PLATE FASTENER HOLE DETAILED INSPECTION ...... 6 5 FIGURE 2: RIGHT TR HALF SPLICE PLATE FASTENER HOLE DETAILED INSPECTION ...... 6 9 FIGURE 3: LEFT SIDE HINGE BEAM AND LATCH BEAM NUTPLATE INSTALLATION ....... 7 3 FIGURE 4: RIGHT SIDE HINGE BEAM AND LATCH BEAM NUTPLATE INSTALLATION ....... 7 9 FIGURE 5: LEFT TR HALF INNER WALL FORWARD EDGE INSPECTION AND TRIMMING .... 8 5 FIGURE 6: RIGHT TR HALF INNER WALL FORWARD EDGE INSPECTION AND TRIMMING .... 8 9 FIGURE 7: LEFT TR HALF SPLICE PLATE FASTENER INSTALLATION ............... 9 3 FIGURE 8: RIGHT TR HALF SPLICE PLATE FASTENER INSTALLATION ............... 9 7 FIGURE 9: LEFT SIDE INNER WALL CHANGED CLICK BOND LOCATIONS ............ 1 0 1 FIGURE 10: RIGHT SIDE INNER WALL CHANGED CLICK BOND LOCATIONS ........... 1 0 8 APPENDIX A: ALLOWABLE REPAIR LIMITS ................................ 1 1 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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APPENDIX B: TOOLING DIMENSIONS ................................... 1 2 1 APPENDIX C: NUTPLATE RETAINER FABRICATION ........................... 1 3 3 APPENDIX D: LEFT SIDE INNER WALL FLOWCHART .......................... 1 3 4 APPENDIX E: RIGHT SIDE INNER WALL FLOWCHART ......................... 1 3 7 APPENDIX F: HOLES AND DRILLING - CONDITIONS, PROCEDURES, DEFINITIONS AND TOOLS . 141 APPENDIX G: THRUST REVERSER INNER WALL SURFACE COLOR INSPECTION IP8.2 ZONE . . 143 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-78A0094Original Issue: July 29, 2014 ATA System: 7830 SUBJECT: EXHAUST (Trent 800 Engines) - Thrust Reverser System - Thrust Reverser Inner Wall 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 will ensure that the Thrust Reversers (TRs) on Rolls-Royce Trent 800 engines have inner walls which contain no residual thermal damage. Later events have revealed that inner walls which have operated without thermal protection system (TPS) and IP8 related improvements may contain residual thermal damage.
Some thermal damage is not detectable via current inspection methods or repairs conducted prior to Boeing Service Letter 777-SL-78-026 or SRM 54-32-01, Repair #6 may not have removed all of the existing thermal damage. Residual thermal degradation could cause structural pieces of the inner wall to separate from the TR in flight. A separated piece of the TR could cause damage to other airplane areas, or cause injury to persons on the ground. A separated TR piece at departure could cause a runway excursion because of thrust asymmetry from forward thrust on a Refused Take Off (RTO).
Eighteen 777 Rolls-Royce TR events related to thermal damage of the TR inner wall have occurred since 2003.
The events have included Air Turn Backs (ATB), In Flight Shut Downs (IFSD), TR inner wall panel collapses, engine fire loop messages, and TR inner wall panel sections and parts departing the airplane. No hull loss or personal injury has occurred from these events.
This service bulletin provides instructions to perform maintenance records checks and detailed inspections of the TR inner wall to determine if the TR inner wall should be replaced. This service bulletin also provides instructions for replacement of the TR inner wall. This service bulletin also provides instructions to update the airplane scheduled maintenance program to incorporate 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02.
Boeing Service Related Problem (SRP) 777-SRP-78-0076 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2014 777-78A0094 5 of 144
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedYesSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required Service History ReportYear of Event // Cycles // Hours Engine 2 Left Hand (LH) TR half. Shorted fire loop fault messages (intermittent) received during descent. Extensive delamination found during ground inspection.
2003 // 5,871 // 17,982 Engine 1 LH TR half. Extensive delamination found during ground inspection during planned engine change.
2004 // 4,600 // 13,100 Engine 2 LH TR half. Damage seen on arrival. Large portion of inner wall missing.
Debris on runway. Nozzle outer sleeve not found.
2004 // 6,160 // 15,472 Engine 1 LH TR half. Panel collapsed during takeoff. Parts liberated. Air Turn Back (ATB) performed. Nozzle outer sleeve landed on vehicle.
2004 // 6,600 // 16,600 Engine 2 Right Hand (RH) TR half. Exhaust Gas Temperature (EGT) fluctuation during climb out and fire loop fault messages. Flight continued. Damage found during ground inspection.
2006 // 2,450 // 13,124 Engine 1 RH TR half. Panel collapsed during takeoff. Parts liberated. ATB performed.
2006 // 5,782 // 37,687 Engine 2 RH TR half. Engine fire warning after takeoff. In Flight Shut Down (IFSD) and ATB performed. Extensive delamination found during ground inspection.
2007 // 7,627 // 26,963 Engine 2 RH TR half. Intermittent status message "LOOP 1 ENG R" and "OVERHEAT CIRCUIT R", but no warning messages. Damage seen on arrival.
Large portion of inner wall missing. Debris on takeoff runway.
2007 // 9,770 // 34,895 Engine 1 RH TR. During climb, status messages "ENG EEC R", "TRIM AIR PRSOV R+L", "OVERHEAT CIRCUIT L1", and "FIRE LOOP ENG L". ATB performed. Inner wall panel collapse and damage found during ground inspection.
2008 // 3,865 // 28,213 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Service History ReportYear of Event // Cycles // Hours Engine 2 RH TR half. Fire detection advisory message at take off, flight continued.
Damage found during ground inspection.
2009 // 5,616 // 37,245 Engine 2 LH TR half. Indication on take off. Thud heard 5 hrs into flights. PDA, nozzle inner and outer walls liberated.
2010 // 4,702 // 35,471 Crew notified that debris had been collected from the departing runway. Flight diverted. PDA (nozzle intact).
2010 // 7,719 // 38,952 Engine 2, LH TR half. Nozzle outer sleeve recovered from departing airport.2011 // 12,308 // 58,335 Engine 1, LH TR half. Flight diverted. Inner wall collapsed. Aft cowl intact. Nozzle outer sleeve severely damaged but not liberated.
2011 // 8,751 // 40,482 Engine 2, LH TR half. Inner wall collapse during climbout - flight returned to departure airport. PDA - aft cowl & portions of inner wall.
2012 // 7,838 // 50,004 Engine 2, RH TR half. Inner wall collapse during takeoff roll - flight returned to departure airport. PDA - Debris including aft cowl recovered on runway.
2013 // 11,927 // 40,317 Engine 2, RH TR half. Flight continued to destination. PDA - portions of inner wall.2013 // 8,597 // 51,844 Engine 1, RH TR half. Flight returned to departure airport. PDA - aft portions of the TR inner wall.
2013 // 7,241 // 58,668 ACTION (PRR 62402-R) All Airplanes
1. Install a serviceable left and right Thrust Reverser (TR) half on left and right engines.
NOTE: A serviceable TR half is defined as one that has met all the requirements of Paragraph 3.B., Work Instructions, Work Packages 3 (left TR half) or 4 (right TR half) of this service bulletin.
2. Update airplane scheduled maintenance program to incorporate 777 Airworthiness Limitation (AWL) 78-AWL-01 and 78-AWL-02 from the most current published 777 MPD Section 9.
For each TR half
1. Group 1, Configuration 1-2:
Do a maintenance records check for replacement of the Inner Wall (IW) concurrently with or after incorporation of Boeing Service Bulletin (SB) 777-78-0071 or 777-78-0082.
2. Group 1, Configuration 3:
Install the Thermal Protection System (TPS).
3. Group 1, Configuration 4:
Modify the aft cowl and install the TPS.
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Original Issue: July 29, 2014 777-78A0094 7 of 144 BOEING SERVICE BULLETIN 777-78A0094
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4. Group 1, Configuration 1-2:
Do a maintenance records check for incorporation of Boeing SB 777-75A0002 and Rolls-Royce SB RB.211-75-G765 on engines the TR half has operated on.
5. Group 1, Configuration 1-2:
Do a maintenance records check for installation of IW part number 315W5100-63 or 315W5100-64.
EFFECTIVITY 777-200 and 777-300 Airplanes with Rolls-Royce Model RB211 Trent 800 engines. Refer to Paragraph
1.A.1.,Airplanes, for the list of affected airplanes.
Refer to Paragraph 1.A.2., Spares Affected for the list of affected components.
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 December 8, 2004. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Elapsed HoursTotal Task HoursEngines
14.00 (a)26.00 (a)Left Thrust Reverser
14.00 (a)26.00 (a)Right Thrust Reverser
(a) Time given for the inner wall replacement must be added to total shown if inner wall is to be replaced.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2014 777-78A0094 8 of 144 BOEING SERVICE BULLETIN 777-78A0094
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BOEING SERVICE BULLETIN 777-78A0094
ALERT ALERT
ALL AIRPLANES
- UPDATE AIRPLANE SCHEDULED MAINTENANCE PROGRAM TO INCORPORATE 777 AIRWORTHINESS LIMITATION (AWL) 78-AWL-01
- INSTALL A SERVICEABLE LEFT AND RIGHT THRUST REVERSEF (TR) HALF ON LEFT AND RIGHT ENGINE NOTE: A SERVICEABLE TR HALF IS DEFINED AS ONE THAT HAS MET ALL THE REQUIREMENTS OF PARAGRAPH 3.B., WORK INSTRUCTIONS, WORK PACKAGES 3 (LEFT TR HALF) OR 4 (RIGHT TR HALF) OF THIS SERVICE BULLETIN.
FOR EACH TR HALF GROUP 1, CONFIGURATION 1-2:
-DO A MAINTENANCE RECORDS CHECK FOR REPLACEMENT OF
THE INNER WALL (IW) CONCURRENTLY WITH OR AFTER INCORPORATIONOF BOEING SERVICE BULLETIN (SB) 777-78-0071 OR 777-78-0082 GROUP 1, CONFIGURATION 3:
-INSTALL THE THERMAL PROTECTION SYSTEM (TPS).
GROUP 1, CONFIGURATION 4:
-MODIFY THE AFT COWL AND INSTALL THE TPS.
GROUP 1, CONFIGURATION 1-2;
-DO A MAINTENANCE RECORDS CHECK FOR INCORPORATION OF BOEING SB 777-75A0002 AND ROLLS-ROYCE SB RB.211-75-G765 ON ENGINES THE TR HALF HAS OPERATED ON.
GROUP 1, CONFIGURATION 1-2:
-DO A MAINTENANCE RECORDS CHECK FOR INSTALLATION OF IW PART NUMBER 315W5100-63 OR 315W5100-64.
THRUST REVERSER INNER WALL THRUST REVERSER INNER WALL (LEFT SIDE SHOWN) (RIGHT SIDE SHOWN) 2260405 Original Issue: July 29, 2014 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 144
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-78A0094 Original Issue: July 29, 2014 ATA System: 7830 SUBJECT: EXHAUST (Trent 800 Engines) - Thrust Reverser System - Thrust Reverser Inner Wall 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 Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is applicable to 777-200/300 Airplanes with Rolls-Royce Trent 800 engines, line numbers 1-796 in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below. Refer to PRR 62402-R for data about this change.
NOTE: The airplanes shown in the effectivity below had the configuration of Thrust Reverser (TR) described in this service bulletin at delivery or by the incorporation of Boeing service bulletin 777-78-0071 or 777-78-0082. Installation of spare TRs since delivery or the incorporation of Boeing service bulletin 777-78-0071 or 777-78-0082, could put these configurations of TR on airplanes not shown in the effectivity below. Or, rotation of parts between airplanes could put these configurations of TR on airplanes with a different group relationship to that shown in the effectivity below. Check maintenance records to make sure the work in accordance with this service bulletin is accomplished on applicable TRs.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2014 777-78A0094 11 of 144
DESCRIPTIONCONFIGURATIONGROUP 777-200 and 777-300 airplanes with Rolls-Royce engines-1 Thrust reversers that installed TPS by incorporation of Boeing Service Bulletin 777-78-0071 1 Thrust reversers that installed TPS and modified the aft cowl by incorporation of Boeing Service Bulletin 777-78-0082 2 Thrust reversers with inner wall part number 315W5101-(all dash number after -1) for the left TR and part number 315W5102-(all dash numbers after -1) for the right TR that have not installed TPS by incorporation of Boeing Service Bulletin 777-78-0071.
3 Thrust reversers with inner wall part number 315W5101-1 for the left TR and part number 315W5102-1 for the right TR that have not installed TPS and have not modified the aft cowl by incorporation of Boeing Service Bulletin 777-78-0082.
4 Airplane Models:
777-200, 777-300 GroupVariable Number 1WA001 1WA086 - WA093 1WA101 - WA104 1WA196 - WA198 1WB031 - WB046 1WB101 - WB106 1WB161 - WB177 1WB181 - WB194 1WB201 - WB215 1WB231 - WB247 1WB416 - WB439 1WB446 - WB453 1WB501 - WB512 1WB601 - WB606 1WB611 - WB622 1WB631 - WB638 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 29, 2014 777-78A0094 12 of 144 BOEING SERVICE BULLETIN 777-78A0094