Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-53A0078

Original Issue: December 05, 2014

ATA System: 5383

SUBJECT: FUSELAGE - Section 48 - Station 2150 - Aft Pressure Bulkhead Web Lap Splice

Inspection

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ECCN: 9E991

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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 19

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 21

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

FIGURE 1: AFT PRESSURE BULKHEAD RADIAL WEB LAP SPLICES INSPECTIONS . . . . . . . . 26

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Summary Number: 777-53A0078

Original Issue: December 05, 2014

ATA System: 5383

SUBJECT: FUSELAGE - Section 48 - Station 2150 - Aft Pressure Bulkhead Web Lap Splice

Inspection

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 gives instructions to provide a through the thickness examination of the aft web of the radial

lap splices using Medium Frequency Eddy Current (MFEC) for fatigue cracks, and to install repairs if any crack

is found. If these inspections and repairs are not done, fatigue cracks can develop in the bulkhead webs. If this

Wide Spread Fatigue cracking is not found and repaired, the cracks can rapidly coalesce and can result in

possible rapid decompression and loss of structural integrity

Widespread Fatigue Damage (WFD) analysis of the 777, as required by 14 CFR 26.21(b), has resulted in the

conclusion that existing MPD Section 9, Airworthiness Limitation Instruction (ALI) inspection program is not

sufficient to preclude the occurrence of WFD in the aft webs of the aft pressure bulkhead lap splices as the

airplane ages. The pressure bulkhead lap splices have multiple adjacent identical details which have the potential

for Multi-Site Damage (MD) and the potential for WFD. 14 CFR 26.21 requires evaluation of such designs for

the potential for WFD and implementation of the appropriate Service Actions to ensure that WFD is precluded

before the Limit of Validity (LOV). The aft pressure bulkhead web lap splices affected by this service bulletin

have been determined to be structure that is susceptible to WFD. Boeing has not received any reports of cracks

in the pressure bulkhead lap splices. Fatigue cracking was found in the pressure bulkhead aft webs of the radial

lap splices common to the full scale fatigue test article.

Accomplishment of the inspections and repairs in this service bulletin will ensure that the aft web of the aft

pressure bulkhead web lap splices are free of detectable cracks and maintain the structural integrity of the aft

pressure bulkhead.

Boeing Service Related Problem (SRP) 777-SRP-53-0463 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

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Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected Yes Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required No Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Get access to the aft side of the aft pressure bulkhead.

Do the Medium Frequency Eddy Current (MFEC) inspections around fasteners in the aft webs at the aft pressure

bulkhead radial lap splices.

If cracks are found, repair in accordance with the 777 Structural Repair Manual (SRM) or contact Boeing for

repair instructions and do the repair.

EFFECTIVITY

All 777-200, 777-200LR, 777 -300, 777 -300ER and 777F Airplane(s), Refer to Paragraph 1.A.1., Airplanes, for

the list of affected airplane(s).

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-07-06 is related to this service bulletin.

The effective date of AD 2012-07-06 is May 15, 2012.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection(s) and/or repair procedures given in this service

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

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MATERIAL INFORMATION

None.

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BOEING SERVICE BULLETIN 777-53A0078

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-53A0078

Original Issue: December 05, 2014

ATA System: 5383

SUBJECT: FUSELAGE - Section 48 - Station 2150 - Aft Pressure Bulkhead Web Lap Splice

Inspection

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 all 777-200, 777-200LR, 777-300, 777- 300ER and 777F

airplanes in 1 Group. The Variable Numbers and Group Information for the applicable airplanes

is given below.

NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1356.

Affected airplanes after Line Number 1356 will be added to the service bulletin's

MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet

Profile Page.

GROUP CONFIGURATION DESCRIPTION

1 - All 777 airplanes

Airplane Models:

777-200, 777-200LR, 777-300, 777-300ER, 777F

Variable Number Group

WA001 - WA017 1

WA076 - WA080 1

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Variable Number Group

WA086 - WA093 1

WA101 - WA104 1

WA116 - WA119 1

WA131 - WA137 1

WA171 - WA175 1

WA196 - WA198 1

WA206 - WA212 1

WA221 - WA223 1

WA231 - WA232 1

WA241 - WA250 1

WA261 - WA266 1

WA281 - WA283 1

WA301 - WA304 1

WB001 - WB021 1

WB031 - WB046 1

WB051 - WB088 1

WB101 - WB106 1

WB121 - WB125 1

WB131 - WB148 1

WB151 - WB155 1

WB161 - WB177 1

WB181 - WB194 1

WB201 - WB215 1

WB231 - WB247 1

WB271 - WB273 1

WB276 - WB286 1

WB291 - WB302 1

WB306 - WB307 1

WB311 - WB337 1

WB341 - WB342 1

WB366 - WB368 1

WB371 - WB388 1

WB406 1

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Variable Number Group

WB411 - WB413 1

WB416 - WB439 1

WB446 - WB453 1

WB476 1

WB481 - WB484 1

WB501 - WB512 1

WB531 - WB537 1

WB551 - WB554 1

WB591 - WB597 1

WB601 - WB606 1

WB611 - WB622 1

WB631 - WB638 1

WB646 - WB649 1

WC051 - WC073 1

WC101 - WC104 1

WC111 - WC120 1

WC221 - WC224 1

WC241 - WC243 1

WC281 - WC290 1

WC301 - WC308 1

WC361 - WC364 1

WC371 - WC374 1

WC381 - WC395 1

WC441 1

WC446 - WC449 1

WC456 - WC459 1

WC486 - WC493 1

WC506 - WC508 1

WC521 - WC522 1

WC531 - WC536 1

WC546 - WC548 1

WC556 1

WC566 - WC567 1

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Variable Number Group

WC571 - WC574 1

WC581 1

WC586 - WC587 1

WC591 - WC595 1

WD001 - WD002 1

WD011 - WD018 1

WD031 - WD036 1

WD046 - WD055 1

WD066 - WD075 1

WD081 - WD089 1

WD091 1

WD096 1

WD101 - WD106 1

WD111 - WD112 1

WD116 - WD117 1

WD121 - WD122 1

WD501 - WD513 1

WD521 - WD541 1

WD546 - WD554 1

WD561 - WD573 1

WD581 - WD599 1

WD606 - WD609 1

WD621 - WD632 1

WD651 - WD665 1

WD671 - WD677 1

WD691 - WD709 1

WD741 - WD752 1

WD761 - WD771 1

WD786 - WD788 1

WD796 - WD837 1

WD846 - WD867 1

WD871 - WD899 1

WD911 - WD918 1

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Variable Number Group

WD921 - WD933 1

WD936 - WD957 1

WD966 - WD970 1

WD981 - WD982 1

WD986 - WD987 1

WD991 - WD994 1

WD996 1

WE001 - WE007 1

WE011 - WE012 1

WE021 - WE026 1

WE031 - WE037 1

WE051 - WE057 1

WE071 - WE078 1

WE081 - WE084 1

WE091 - WE095 1

WE126 - WE148 1

WE151 - WE170 1

WE176 - WE178 1

WE186 - WE219 1

WE226 - WE231 1

WE236 - WE253 1

WE261 - WE267 1

WE271 - WE278 1

WE291 - WE297 1

WE301 - WE317 1

WE331 - WE343 1

WE351 - WE356 1

WE376 - WE377 1

WE381 1

WE386 - WE387 1

WE391 - WE392 1

WE396 - WE401 1

WE416 - WE420 1

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Variable Number Group

WE426 - WE428 1

WE436 - WE439 1

WE441 - WE445 1

WE451 - WE458 1

WE471 - WE474 1

WE486 - WE491 1

WE501 - WE504 1

WE511 - WE513 1

WE526 - WE528 1

WE536 - WE540 1

WE556 - WE563 1

WE566 - WE567 1

WE591 1

WE601 - WE605 1

WE626 1

WE631 1

WF001 - WF004 1

WF016 - WF027 1

WF031 - WF043 1

WF046 - WF067 1

WF075 - WF077 1

WF081 - WF088 1

WF096 - WF101 1

WF106 - WF109 1

WF111 - WF118 1

WF121 - WF124 1

WF131 - WF133 1

WF136 - WF140 1

WF146 - WF147 1

WF151 - WF152 1

WF156 - WF160 1

WF166 - WF173 1

WF176 - WF178 1

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Variable Number Group

WF181 - WF182 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions to provide a through the thickness examination of the aft web

of the radial lap splices using Medium Frequency Eddy Current (MFEC) for fatigue cracks, and to install

repairs if any crack is found. If these inspections and repairs are not done, fatigue cracks can develop

in the bulkhead webs. If this Wide Spread Fatigue cracking is not found and repaired, the cracks can

rapidly coalesce and can result in possible rapid decompression and loss of structural integrity

Widespread Fatigue Damage (WFD) analysis of the 777, as required by 14 CFR 26.21(b), has resulted

in the conclusion that existing MPD Section 9, Airworthiness Limitation Instruction (ALI) inspection

program is not sufficient to preclude the occurrence of WFD in the aft webs of the aft pressure bulkhead

lap splices as the airplane ages. The pressure bulkhead lap splices have multiple adjacent identical

details which have the potential for Multi-Site Damage (MSD) and the potential for WFD. 14 CFR 26.21

requires evaluation of such designs for the potential for WFD and implementation of the appropriate

Service Actions to ensure that WFD is precluded before the Limit of Validity (LOV). The aft pressure

bulkhead web lap splices affected by this service bulletin have been determined to be structure that is

susceptible to WFD. Boeing has not received any reports of cracks in the pressure bulkhead lap splices.

Fatigue cracking was found in the pressure bulkhead aft webs of the radial lap splices common to the

full scale fatigue test article.

Accomplishment of the inspections and repairs in this service bulletin will ensure that the aft web of

the aft pressure bulkhead web lap splices are free of detectable cracks and maintain the structural

integrity of the aft pressure bulkhead.

Boeing Service Related Problem (SRP) 777-SRP-53-0463 is related to this service bulletin.

D. Description

Get access to the aft side of the aft pressure bulkhead.

Do the Medium Frequency Eddy Current (MFEC) inspections around fasteners in the aft webs at the

aft pressure bulkhead radial lap splices.

If cracks are found, repair in accordance with the 777 Structural Repair Manual (SRM) or contact Boeing

for repair instructions and do the repair.

The work in this service bulletin is done in the maintenance zone(s) given below.

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Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777-300, 311, 312

777-300ER, 777F

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-07-06 is related to this service

bulletin. The effective date of AD 2012-07-06 is May 15, 2012.

Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When

more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION

numbers for that CONDITION number or OPTION number.

Table 1 - Aft Pressure Bulkhead Web Lap Splice MFEC Inspections

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later )

Condition Action

Within 4,000 -

flight cycle or

750 days after

the original issue date of this

service bulletin.

whichever occurs first.

Before 38,000

total flight cycles.

Do PART 1: AFT PRESSURE BULKHEAD RADIAL LAP SPLICE MEDIUM FREQUENCY EDDY

CURRENT INSPECTION

for any crack.

(a)

All airplanes

Within 8,400 flight cycles of the 8,400 flight cycles

previous inspection.

Repeat PART 1: AFT

PRESSURE BULKHEAD

RADIAL LAP SPLICE

MEDIUM FREQUENCY

EDDY CURRENT INSPECTION for any crack.

CONDITION 1: NO

CRACK FOUND

(a)

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Table 1 - Aft Pressure Bulkhead Web Lap Splice MFEC Inspections

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later )

Condition Action

OPTION 1 (ACTION 1): Before further flight -

Repair in accordance with

the Structural Repair

Manual (SRM).

CONDITION 2: ANY

CRACK FOUND

Within 8,400 flight cycles of the 8,400 flight cycles

previous inspection.

OPTION 1 (ACTION 2):

Repeat PART 1: AFT

PRESSURE BULKHEAD

RADIAL LAP SPLICE

MEDIUM FREQUENCY

EDDY CURRENT INSPECTION for any crack

in unrepaired areas.

(a)

OPTION 2 (ACTION 1): Before further flight -

Contact Boeing for repair

instructions and do the

repair.

Within 8,400 flight cycles of the 8,400 flight cycles

previous inspection.

OPTION 2 (ACTION 2):

Repeat PART 1: AFT

PRESSURE BULKHEAD

RADIAL LAP SPLICE

MEDIUM FREQUENCY

EDDY CURRENT INSPECTION for any crack

in unrepaired areas.

(a)

(a) It is not necessary to do inspections in accordance with this service bulletin in areas where existing repairs

approved by the Boeing ODA via FAA form 8100-9 cover the affected aft web inspection areas. Continue

to do inspections of these repairs in accordance with existing Damage Tolerance Inspection instructions,

including those provided in the 777 Structural Repair Manual Section 53-80 and in Boeing Service Bulletin

777-53A0039.

NOTE: Once initiated, the Service Bulletin inspections will satisfy the High Frequency Eddy Current

(HFEC) inspections of the aft webs currently required by Structural Significant Item in 777

MPD 53-80-I13A Section 9. The aft web detail identified as HFEC direction 1, from the aft

side in the DTR check form.

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.

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BOEING SERVICE BULLETIN 777-53A0078

ALERT ALERT
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.

The Manager of the FAA Seattle Aircraft Certification Office approves incorporation of the inspections

per this service bulletin (SB) along with the corresponding compliance times specified in Paragraph

1.E. "Compliance" of SB 777-53A0078, Original Issue, as an Alternative Method of Compliance (AMOC)

to the inspections defined in the Damage Tolerance Rating Check Form Document D622W001-DTR

for the corresponding locations of Structural Significant Item 53-80-I13A and in Subsection B,

Airworthiness Limitations-Structural Inspections of Section 9 of the Maintenance Planning Document

D622W001-9, required by paragraphs (g) and (h) of AD 2012-07-06. When this SB specifies contacting

Boeing for repair instructions, the repair instructions must be approved by the FAA in accordance with

paragraph (j) of AD 2012-07-06. This AMOC only applies to the areas inspected in accordance with

this SB. All provisions of AD 2012-07-06 that are not specifically referenced in this paragraph remain

fully applicable and must be complied with accordingly.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each aft

pressure bulkhead. 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:

• 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.

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 1 2 7.50 3.75

Close Access 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 8.50 4.75

NOTE: Additional time will be required for repair if any crack is found.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

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J. References

1. Existing Data:

a. Boeing Service Bulletin 777-53A0039

b. Boeing Service Letter 777-SL-51-013

c. Boeing Service Related Problem (SRP) 777-SRP-53-0463

d. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2012-07-06

e. Service Bulletin Index D624W001

f. 777 Illustrated Tool and Equipment Manual (ITEM) 53-80-03

g. 777 Maintenance Planning Data (MPD), D622W001-9, Section 9, Subsection B, and

D622W001-DTR

h. 777 Non-Destructive Testing (NDT) Manual Part 6, 53-80-06

i. 777-200 Structural Repair Manual (SRM) 53-80-08

j. 777-300 Structural Repair Manual (SRM) 53-80-08

k. 777F Structural Repair Manual (SRM) 53-80-08

2. Data Supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

None.

K. Publications Affected

1. Publications:

Publication Chapter-Section

777 Structural Repair Manual 53-80-08 Repair 2

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected

are contained in Paragraph 1.E., Compliance of this service bulletin.

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L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary

Not affected.

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2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are not available for the inspection(s) and/or repair procedures given in this

service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts

None.

2. Parts and Materials Supplied by the Operator

None.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BLANK PAGE
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque Values:

— Values for structural fasteners are given in 777 Structural Repair Manual,

Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 777

Aircraft Maintenance Manual (AMM).

— Values for electrical maintenance tasks are included in Chapter 20 of

Standard Wiring Practices Manual (SWPM).

— Values for engine maintenance tasks are included in Chapter 70 of 777

Aircraft Maintenance Manual (AMM).

— Non-standard torque values for maintenance tasks are included in the

applicable installation step.

4. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

5. Boeing Service Letter 777-SL-51-013, Damage Reporting and Repair Plan/Design

Guidelines, is an acceptable procedure to request information from Boeing for

additional structural repair instructions. The Service Letter describes what information

must be provided to Boeing before a structural repair can be provided.

6. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

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7. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

8. Use of colors in Figures is based on guidance from the ATA e-Business Program

(ATA) iSpec 2200.

9. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

10. Some steps in the Work Instructions are identified as Required for Compliance (RC).

If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps

identified as RC must be done to comply with the AD. Alternative procedures for

steps not identified with RC can be used if the RC steps can still be done as specified,

and the airplane can be put back in a serviceable condition. An Alternative Method

of Compliance (AMOC) is not necessary for deviations to steps that are not identified

as RC.

B. WORK INSTRUCTIONS

1. Open Service Access Door 311BL for access to the aft side of the aft pressure bulkhead.

NOTE: Boeing recommends that an appropriate maintenance platform be installed for safe access

to the aft surface of the pressure bulkhead. Refer to Platform Assembly J53003-() in 777

ITEM 53-80-03 as an accepted platform.

2. RC - Do PART 1: AFT PRESSURE BULKHEAD RADIAL LAP SPLICE MEDIUM FREQUENCY

EDDY CURRENT INSPECTION for any crack.

3. RC - CONDITION 1: NO CRACK FOUND

a. Repeat PART 1: AFT PRESSURE BULKHEAD RADIAL LAP SPLICE MEDIUM FREQUENCY

EDDY CURRENT INSPECTION for any crack.

4. RC - CONDITION 2: ANY CRACK FOUND

a. OPTION 1:

(1) OPTION 1 (ACTION 1): Repair in accordance with 777-200 SRM 53-80-08 Repair 2,

777-300 SRM 53-80-08 Repair 2, or 777F SRM 53-80-08 Repair 2.

(2) OPTION 1 (ACTION 2): Repeat PART 1: AFT PRESSURE BULKHEAD RADIAL LAP

SPLICE MEDIUM FREQUENCY EDDY CURRENT INSPECTION for any crack in

unrepaired areas.

b. OPTION 2:

(1) OPTION 2 (ACTION 1): Contact Boeing for repair instructions if the repair exceeds the

applicability of 777-200 SRM 53-80-08 Repair 2, 777-300 SRM 53-80-08 Repair 2, or

777F SRM 53-80-08 Repair 2, and do the repair in accordance with the instructions from

Boeing.

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(2) OPTION 2 (ACTION 2): Repeat PART 1: AFT PRESSURE BULKHEAD RADIAL LAP

SPLICE MEDIUM FREQUENCY EDDY CURRENT INSPECTION for any crack in

unrepaired areas.

5. Put the airplane back into a serviceable condition. Do the inspection again at the time given in

Paragraph 1.E., Compliance.

PART 1: AFT PRESSURE BULKHEAD RADIAL LAP SPLICE MEDIUM FREQUENCY EDDY

CURRENT INSPECTION

1. Do Medium Frequency Eddy Current (MFEC) inspections of the aft webs in the aft pressure

bulkhead radial lap splices for any crack in accordance with Figure 1.

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FIGURE 1: AFT PRESSURE BULKHEAD RADIAL WEB LAP SPLICES INSPECTIONS

(SHEET 1 OF 5)

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FIGURE 1: AFT PRESSURE BULKHEAD RADIAL WEB LAP SPLICES INSPECTIONS

(SHEET 2 OF 5)

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FIGURE 1: AFT PRESSURE BULKHEAD RADIAL WEB LAP SPLICES INSPECTIONS

(SHEET 3 OF 5)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this figure.

FIGURE 1: AFT PRESSURE BULKHEAD RADIAL WEB LAP SPLICES INSPECTIONS

(SHEET 4 OF 5)

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Step Task Name Identification Qty More Data

RADIAL WEB LAP - 12 (a) (b) (c) (d)

SPLICES

1 Inspect

(a) It is not necessary to do the inspection at locations covered by tear straps, failsafe straps, doublers, aft

cover pan or the Y-ring pressure chord/failsafe chord.

(b) Do Medium Frequency Eddy Current (MFEC) for any crack in accordance with 777 NDT Manual Part 6,

53-80-06.

(c) It is not necessary to do inspections in accordance with this service bulletin in area where existing repairs

cover the affected aft web inspection areas. Continue to do inspections of these repairs in accordance

with existing Damage Tolerance Inspection instructions, including those provided in the 777 Structural

Repair Manual and in Boeing Service Bulletin 777-53A0039.

(d) On airplanes line number 423 and on, two bays common to Radial Web Lap Splice RS-16R contain HiLocs, not rivets. Refer to View A-A.

FIGURE 1: AFT PRESSURE BULKHEAD RADIAL WEB LAP SPLICES INSPECTIONS

(SHEET 5 OF 5)

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