Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-53A0068

Original Issue: June 12, 2013

ATA System: 5345 5365 2315

SUBJECT: FUSELAGE - Sections 44 and 46 - Crown Skin Panel - Corrosion and Crack on Fuselage

Skin Below SATCOM Antenna Adapter Plate - Inspection

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ECCN: 9E991

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Unpublished Work. All Rights Reserved.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT

BLANK PAGE
Table of Contents

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

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 43

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 45

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 45

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

FIGURE 1: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE

FASTENER COMMON TO BONDING JUMPER AND ADAPTER PLATE [Group 1-2] . . . 53

FIGURE 2: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

[Group 1-2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

FIGURE 3: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

[Group 1-2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

FIGURE 4: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE

FASTENER COMMON TO BONDING JUMPER AND ADAPTER PLATE [Group 2] . . . . 61

FIGURE 5: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

[Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

FIGURE 6: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

[Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
FIGURE 7: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE

FASTENER COMMON TO BONDING JUMPER AND ADAPTER PLATE [Group 3-4; Group 5,

Configuration 3-4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

FIGURE 8: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

[Group 3-4; Group 5, Configuration 3-4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

FIGURE 9: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

[Group 3-4; Group 5, Configuration 3-4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Commercial 

Airplanes 777

Service Bulletin

ALERT

Summary Number: 777-53A0068

Original Issue: June 12, 2013

ATA System: 5345 5365 2315

SUBJECT: FUSELAGE - Sections 44 and 46 - Crown Skin Panel - Corrosion and Crack on Fuselage

Skin Below SATCOM Antenna Adapter Plate - 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 inspect for corrosion and cracks in the crown fuselage skin under 2-bay

and 3-bay satellite communication (SATCOM) antenna adapter plates located in Sections 44 and 46. There

could be fretting and damage to the fuselage skin finish due to a contact between the adapter plate bonding

jumper and fuselage skin. Removal of finish in the fuselage skin results in exposure to corrosion, which can lead

to cracks. Cracks in the fuselage skin that are not found and repaired can propagate to the point where the

fuselage skin structure cannot sustain limit load. When the fuselage skin cannot sustain limit load, this can

results in possible rapid decompression and loss of structural integrity.

One operator reported a 16 inch crack under the 3-bay SATCOM antenna adapter plate in the crown skin of the

fuselage between STA 1601 and STA 1622 (Section 46), and S-1L and S-2L on an airplane that was 14 years

old with approximately 14,000 total flight cycles. This crack was found while doing Maintenance Planning Data

(MPD) inspection, 777 MPD Section 2, 53-598-00, which requires fuselage skin inspection between STA 1434

and STA 1832. As a part of the MPD inspection, removal of antennas and adapter plates are necessary to

access the entire fuselage skin. Subsequent to this crack finding, the same operator inspected 42 other airplanes

that are between 6 and 16 years old and found some local corrosion, but no other cracking.

Boeing has performed metallurgical fracture analysis of the section of the fuselage skin with the 16 inch crack,

which was sent in by the operator. The damaged fuselage skin showed that the braided section of the bonding

jumper cable was contacting the skin. The contact between the bonding jumper and fuselage skin results in

fretting and removal of the fuselage skin finish. The removal of finish results in exposure to corrosion. The

damaged skin panel showed severe exfoliation corrosion in the area where the braided section of the bonding

jumper contacted the skin. The fracture analysis showed that primary crack initiated at the area of the exfoliation

corrosion. The analysis also showed that cracking progressed by intergranular stress corrosion partially through

thickness for 13.5 inches along the interior surface of the skin. Further propagation of the crack through to the

exterior surface occurred by fatigue.

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In addition, Boeing has performed an analysis of SATCOM antenna installations. The installation drawing for

3-bay SATCOM antenna in Section 46 show no clearance between the fuselage skin and the fastener attaching

the SATCOM lug adapter plate to the bonding jumper. Due to the lack of clearance, the fastener may come in

contact with the fuselage skin. Furthermore, the fastener is located between stringers where the fastener can

have a contact with the fuselage due to pillowing out effect when the fuselage is pressurized. The fastener

contact with the fuselage skin results in fretting that causes removal of the fuselage skin finish, which results in

exposure to corrosion.

Boeing has also determined that there are 2-bay and 3-bay SATCOM antennas that are installed at two locations.

The "2-bay" and "3-bay" terminologies are used to describe the length of the antenna in terms of frame bays.

The 2-bay SATCOM antennas are 2 frame bays long and are installed in Section 46. The 3-bay SATCOM

antennas are 3 frame bays long and are installed in Section 44 or Section 46, or both. Airplanes can be delivered

with either 2-bay or 3-bay SATCOM antenna in Section 46 as a primary option. If a SATCOM antenna is installed

in Section 46, additional 3-bay SATCOM antenna in Section 44 can be installed as a dual option. The analysis

showed that both 2-bay and 3-bay SATCOM antennas in Sections 44 and 46 can have similar issues related

to bonding jumper and the fastener contacting the skin that results in fretting and removal of fuselage skin finish.

The fretting and presence of corrosion are factors that can lead to fuselage skin cracking.

This service bulletin gives instructions to inspect for corrosion and cracks in the crown fuselage skin under 2-bay

and 3-bay SATCOM antenna adapter plates located in Sections 44 and 46 of the airplane.

Boeing Service Related Problem (SRP) 777-SRP-53-0418 is related to this service bulletin. A future service

bulletin will be issued to give a terminating action for the continued inspections given in this service bulletin.

NOTE: There has been a production change to the bonding jumper installation for 3-bay SATCOM antennas

in Section 44 at line number 1068 and on, and in Section 46 at line number 1077 and on. There has

not been a production change to the bonding jumper installation for 2-bay SATCOM antennas.

Boeing Fleet Team Digest (FTD) 777 FTD 53-12001 is related to this service bulletin.

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

information.

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 No 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 Material No

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Planning Data Affected Reference

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Group 5, Configuration 1-2, 5:

No action is necessary in accordance with this service bulletin.

Group 1-4; Group 5, Configuration 3-4:

Get internal and external access to SATCOM antenna(s). Do repetitive internal and external detailed and surface

high frequency eddy current (HFEC) inspections of the visible fuselage skin and doubler, if installed. If any

corrosion or crack is found, do a repair in accordance with 777 SRM or contact Boeing for repair instructions

and do the repair. If an indication is found that shows a contact of the fastener attaching the SATCOM lug adapter

plate to the bonding jumper, contact Boeing for repair instructions and do the repair. After the repair, repeat the

inspections in accordance with this service bulletin. Put the airplane back to a serviceable condition.

EFFECTIVITY

777-200, 777-200LR, 777-300, 777-300ER, and 777F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the

list of affected airplane(s).

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.

Group 5, Configuration 1-2, 5:

None. No action is necessary in accordance with this service bulletin.

Group 1-4; Group 5, Configuration 3-4:

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of June 25, 2012. Please refer to Paragraph

2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of

this service bulletin.

MANPOWER

Group 5, Configuration 1-2, 5:

None. No action is necessary in accordance with this service bulletin.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 1:

Airplanes Total Task Hours Elapsed Hours

Group 1: 17.60 13.40

Section 46 - 3-

Bay SATCOM

Antenna - Fuselage Skin Inspection

Group 2:

Airplanes Total Task Hours Elapsed Hours

Group 2: 35.20 26.80

Sections 44 and

46 - 3-Bay SATCOM Antenna -

Fuselage Skin

Inspection

Group 3-4; Group 5, Configuration 3-4:

Airplanes Total Task Hours Elapsed Hours

Group 3-4; 5, 17.60 13.40

Configuration 3-

4:

Section 46 - 2-

Bay SATCOM

Antenna - Fuselage Skin Inspection

MATERIAL INFORMATION

None.

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-53A0068

Original Issue: June 12, 2013

ATA System: 5345 5365 2315

SUBJECT: FUSELAGE - Sections 44 and 46 - Crown Skin Panel - Corrosion and Crack on Fuselage

Skin Below SATCOM Antenna Adapter Plate - 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 for the airplane(s) shown below.

NOTE: This service bulletin is for the airplanes identified in the Group Configuration table. The

effectivity list shown below includes airplanes up to line number 1202. Some airplanes

before line number 1202 may be affected by this service bulletin but not included in the

effectivity list because they are being delivered out of sequence. At least one airplane,

either before or after line number 1202 or both, is affected by this service bulletin and

these airplanes are in Group(s) 5. 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.

GROUP CONFIGURATION DESCRIPTION

Airplanes line number 1 through 1076 with 3-bay SATCOM antenna

in Section 46. These airplanes do not have SATCOM antenna in

Section 44.

1 -

Airplanes line number 1 through 1067 with 3-bay SATCOM antenna

in Sections 44 and 46.

2 -

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GROUP CONFIGURATION DESCRIPTION

Airplanes line number 1 through 1123 with 2-bay SATCOM antenna

in Section 46. These airplanes do not have SATCOM antenna in

Section 44.

3 -

Airplanes line number 1068 through 1123 with 3-bay SATCOM

antenna in Section 44 and 2-bay SATCOM antenna in Section 46.

4 -

Airplanes not delivered at the original issue date of this service bulletin

and the SATCOM antenna configuration is unknown.

5 -

Airplanes with 3-bay SATCOM antenna in Section 46. These airplanes

have a production change to the bonding jumper installation for 3-bay

SATCOM antenna in Section 46. These airplanes do not have

SATCOM antenna in Section 44.

1

Airplanes with 3-bay SATCOM antenna in Sections 44 and 46. These

airplanes have a production change to the bonding jumper installation

for 3-bay SATCOM antenna in Sections 44 and 46.

2

Airplanes with 2-bay SATCOM antenna in Section 46. These airplanes

do not have a production change to the bonding jumper installation

for 2-bay SATCOM antenna in Section 46. These airplanes do not

have SATCOM antenna in Section 44.

3

Airplanes with 3-bay SATCOM antenna in Section 44 and 2-bay

SATCOM antenna in Section 46. These airplanes have a production

change to the bonding jumper installation for 3-bay SATCOM antenna

in Section 44. These airplanes do not have a production change to

the bonding jumper installation for 2-bay SATCOM antenna in Section

46.

4

5 Airplanes with no SATCOM antenna.

Airplane Models:

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

Variable Number Group

WB105 - WB106 1

WB140 - WB148 1

WB151 - WB155 1

WB176 - WB177 1

WB181 - WB194 1

WB201 - WB215 1

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Variable Number Group

WB231 - WB247 1

WB271 - WB273 2

WB276 - WB286 2

WB291 - WB302 2

WB311 - WB337 1

WB341 - WB342 1

WB366 - WB368 1

WB371 - WB388 1

WB406 2

WB416 - WB439 1

WB446 - WB453 1

WB476 2

WB501 - WB512 1

WB611 - WB622 1

WB631 - WB638 1

WB646 - WB649 1

WC051 - WC073 1

WC101 - WC104 1

WC116 - 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

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Variable Number Group

WC546 - WC548 1

WC556 1

WC566 - WC567 1

WC571 - WC574 3

WC581 1

WC586 1

WD001 - WD002 1

WD011 - WD018 2

WD031 - WD036 1

WD046 - WD051 1

WD052 - WD055 3

WD066 - WD075 1

WD081 - WD089 3

WD091 3

WD096 3

WD101 - WD106 3

WD111 3

WD116 - WD117 1

WD121 5

WD501 - WD513 1

WD521 - WD541 1

WD546 - WD554 1

WD561 - WD573 1

WD581 - WD594 1

WD595 - WD599 3

WD606 - WD609 1

WD621 - WD632 1

WD651 - WD665 1

WD671 - WD675 1

WD676 3

WD677 1

WD691 - WD709 1

WD741 - WD752 1

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ALERT ALERT
Variable Number Group

WD761 - WD771 1

WD786 - WD788 1

WD796 - WD819 1

WD820 - WD824 5

WD826 - WD837 1

WD846 - WD850 1

WD851 - WD867 3

WD871 - WD892 3

WD893 - WD894 5

WD911 - WD918 3

WD921 - WD929 3

WD936 - WD939 1

WD940 - WD944 3

WD945 5

WD946 - WD957 3

WD966 - WD970 3

WD981 - WD982 1

WD986 - WD987 1

WD991 - WD992 1

WD994 5

WD996 1

WE001 - WE004 1

WE011 - WE012 1

WE021 - WE026 3

WE031 - WE034 1

WE051 - WE055 3

WE071 - WE072 3

WE073 - WE075 5

WE081 - WE084 3

WE091 - WE093 1

WE095 5

WE126 - WE137 3

WE141 - WE142 3

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BOEING SERVICE BULLETIN 777-53A0068

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Variable Number Group

WE143 - WE144 5

WE151 - WE165 3

WE166 - WE167 5

WE176 - WE177 1

WE186 - WE208 3

WE209 - WE211 5

WE216 - WE217 1

WE218 5

WE226 - WE231 1

WE236 - WE240 1

WE244 5

WE251 - WE253 1

WE261 - WE263 1

WE266 5

WE271 - WE276 3

WE277 - WE278 5

WE291 - WE292 5

WE301 - WE309 3

WE310 - WE311 5

WE331 - WE334 4

WE335 - WE336 5

WE352 - WE356 5

WE376 - WE377 5

WE386 - WE387 5

WE396 5

WE417 - WE420 5

WE426 5

WE436 5

WE441 5

WF001 - WF004 3

WF016 - WF022 3

WF023 5

WF031 - WF038 3

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Variable Number Group

WF039 - WF040 5

WF046 - WF064 3

WF065 - WF066 5

WF075 - WF077 3

WF081 - WF088 3

WF096 - WF101 3

WF106 - WF109 3

WF111 - WF115 3

WF121 - WF124 3

WF131 - WF133 3

WF136 - WF138 3

WF139 5

WF146 - WF147 3

WF151 - WF152 3

WF156 - WF157 5

WF166 5

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

This service bulletin gives instructions to inspect for corrosion and cracks in the crown fuselage skin

under 2-bay and 3-bay satellite communication (SATCOM) antenna adapter plates located in Sections

44 and 46. There could be fretting and damage to the fuselage skin finish due to a contact between

the adapter plate bonding jumper and fuselage skin. Removal of finish in the fuselage skin results in

exposure to corrosion, which can lead to cracks. Cracks in the fuselage skin that are not found and

repaired can propagate to the point where the fuselage skin structure cannot sustain limit load. When

the fuselage skin cannot sustain limit load, this can results in possible rapid decompression and loss

of structural integrity.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
One operator reported a 16 inch crack under the 3-bay SATCOM antenna adapter plate in the crown

skin of the fuselage between STA 1601 and STA 1622 (Section 46), and S-1L and S-2L on an airplane

that was 14 years old with approximately 14,000 total flight cycles. This crack was found while doing

Maintenance Planning Data (MPD) inspection, 777 MPD Section 2, 53-598-00, which requires fuselage

skin inspection between STA 1434 and STA 1832. As a part of the MPD inspection, removal of antennas

and adapter plates are necessary to access the entire fuselage skin. Subsequent to this crack finding,

the same operator inspected 42 other airplanes that are between 6 and 16 years old and found some

local corrosion, but no other cracking.

Boeing has performed metallurgical fracture analysis of the section of the fuselage skin with the 16

inch crack, which was sent in by the operator. The damaged fuselage skin showed that the braided

section of the bonding jumper cable was contacting the skin. The contact between the bonding jumper

and fuselage skin results in fretting and removal of the fuselage skin finish. The removal of finish results

in exposure to corrosion. The damaged skin panel showed severe exfoliation corrosion in the area

where the braided section of the bonding jumper contacted the skin. The fracture analysis showed that

primary crack initiated at the area of the exfoliation corrosion. The analysis also showed that cracking

progressed by intergranular stress corrosion partially through thickness for 13.5 inches along the interior

surface of the skin. Further propagation of the crack through to the exterior surface occurred by fatigue.

In addition, Boeing has performed an analysis of SATCOM antenna installations. The installation

drawing for 3-bay SATCOM antenna in Section 46 show no clearance between the fuselage skin and

the fastener attaching the SATCOM lug adapter plate to the bonding jumper. Due to the lack of clearance,

the fastener may come in contact with the fuselage skin. Furthermore, the fastener is located between

stringers where the fastener can have a contact with the fuselage due to pillowing out effect when the

fuselage is pressurized. The fastener contact with the fuselage skin results in fretting that causes

removal of the fuselage skin finish, which results in exposure to corrosion.

Boeing has also determined that there are 2-bay and 3-bay SATCOM antennas that are installed at

two locations. The "2-bay" and "3-bay" terminologies are used to describe the length of the antenna in

terms of frame bays. The 2-bay SATCOM antennas are 2 frame bays long and are installed in Section

46. The 3-bay SATCOM antennas are 3 frame bays long and are installed in Section 44 or Section 46,

or both. Airplanes can be delivered with either 2-bay or 3-bay SATCOM antenna in Section 46 as a

primary option. If a SATCOM antenna is installed in Section 46, additional 3-bay SATCOM antenna in

Section 44 can be installed as a dual option. The analysis showed that both 2-bay and 3-bay SATCOM

antennas in Sections 44 and 46 can have similar issues related to bonding jumper and the fastener

contacting the skin that results in fretting and removal of fuselage skin finish. The fretting and presence

of corrosion are factors that can lead to fuselage skin cracking.

This service bulletin gives instructions to inspect for corrosion and cracks in the crown fuselage skin

under 2-bay and 3-bay SATCOM antenna adapter plates located in Sections 44 and 46 of the airplane.

Boeing Service Related Problem (SRP) 777-SRP-53-0418 is related to this service bulletin. A future

service bulletin will be issued to give a terminating action for the continued inspections given in this

service bulletin.

NOTE: There has been a production change to the bonding jumper installation for 3-bay SATCOM

antennas in Section 44 at line number 1068 and on, and in Section 46 at line number 1077

and on. There has not been a production change to the bonding jumper installation for 2-bay

SATCOM antennas.

Boeing Fleet Team Digest (FTD) 777 FTD 53-12001 is related to this service bulletin.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
D. Description

Group 5, Configuration 1-2, 5:

No action is necessary in accordance with this service bulletin.

Group 1-4; Group 5, Configuration 3-4:

Get internal and external access to SATCOM antenna(s). Do repetitive internal and external detailed

and surface high frequency eddy current (HFEC) inspections of the visible fuselage skin and doubler,

if installed. If any corrosion or crack is found, do a repair in accordance with 777 SRM or contact Boeing

for repair instructions and do the repair. If an indication is found that shows a contact of the fastener

attaching the SATCOM lug adapter plate to the bonding jumper, contact Boeing for repair instructions

and do the repair. After the repair, repeat the inspections in accordance with this service bulletin. Put

the airplane back to a serviceable condition.

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

Group 1:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777-300, 253, 254

777-300ER

Group 2:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR 243, 244, 253, 254

Group 3:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777- 253, 254

300ER, 777F

Group 4:

Affected Maintenance Zones

Model Zone

777-300ER 253, 254

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 5:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777-300, 253, 254

777-300ER, 777F

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.

Group 5, Configuration 1-2, 5:

None. No action is necessary in accordance with this service bulletin.

Group 5, Configuration 3-4:

Refer to Table 13 for the Compliance Information for Section 46 - 2-Bay SATCOM Antenna.

Group 1-4:

Use the Compliance Information Index tables to find the applicable Fuselage Skin Inspection compliance

table for each affected SATCOM antenna. Refer to the following table for the Compliance Information

Index tables.

Group 1-4:

NOTE: In the compliance table titles, the compliance information in terms of "Days" refers to the time

since the date of issuance of the original certificate of airworthiness or the original export

certificate of airworthiness.

Group 1-4:

Compliance Infor- Group 1 Group 2 Group 3 Group 4

mation Index Table

SATCOM Antenna

Location/Description

Section 46 - 3-Bay SATCOM Table 1 X X - -

Antenna

Section 44 - 3-Bay SATCOM Table 5 - X - -

Antenna

Section 46 - 2-Bay SATCOM Table 9 - - X X

Antenna

Group 1-2:

Table 1: Section 46 - 3-Bay SATCOM Antenna - Compliance Information Index

Condition Questionnaire Action

1. Does the airplane have more than or equal to If Yes, go to Table 2. If No, go to the next question.

14,000 total flight cycles at the time of the original

issue date of this service bulletin?

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 1-2:

Table 1: Section 46 - 3-Bay SATCOM Antenna - Compliance Information Index

Condition Questionnaire Action

2. For the airplane, at the time of the original issue If Yes, go to Table 2. If No, go to the next question.

date of this service bulletin, has the time been more

than or equal to 5,250 days since the date of issuance of the original certificate of airworthiness or

the original export certificate of airworthiness?

3. Does the airplane have more than or equal to If Yes, go to Table 3. If No, go to the next question.

12,000 total flight cycles and less than 14,000 total

flight cycles at the time of the original issue date of

this service bulletin?

4. For the airplane, at the time of the original issue If Yes, go to Table 3. If No, go to Table 4.(a)

date of this service bulletin, has the time been more

than or equal to 4,500 days and less than 5,250 days

since the date of issuance of the original certificate

of airworthiness or the original export certificate of

airworthiness?

(a) At the time of the original issue date of this service bulletin, the airplane has less than 12,000 total flight

cycles and has been less than 4,500 days since the date of issuance of the original certificate of airworthiness or the original export certificate of airworthiness.

Group 1-2:

Table 2: Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with More than or

Equal to 14,000 Total Flight Cycles or 5,250 Days

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 120 days after the original

issue date of this service bulletin.(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 1-2:

Table 2: Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with More than or

Equal to 14,000 Total Flight Cycles or 5,250 Days

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1601

to STA 1622 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 1-2:

Table 3: Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Except for Airplanes Identified

in Table 2; Airplanes with More than or Equal to 12,000 and Less than 14,000 Total Flight Cycles; or

More than or Equal to 4,500 and Less than 5,250 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs First)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 750 flight

cycles or 375

days after the

original issue

date of this service bulletin,

whichever occurs first.(a)

Within 120 days

after reaching

one of the following (whichever

occurs first):

– 14,000 total

flight cycles.

– 5,250 days

from the

date of issuance of

the original

certificate

of airworthiness or the

original export certificate of airworthiness

whichever

occurs first.

(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 1-2:

Table 3: Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Except for Airplanes Identified

in Table 2; Airplanes with More than or Equal to 12,000 and Less than 14,000 Total Flight Cycles; or

More than or Equal to 4,500 and Less than 5,250 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs First)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1601

to STA 1622 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 1-2:

Table 4: Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with Less than

12,000 Total Flight Cycles and 4,500 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 750 flight

cycles or 375

days after the

original issue

date of this service bulletin,

whichever occurs first.(a)

Before 12,000

total flight cycles

or within 4,500

days from the

date of issuance

of the original

certificate of airworthiness or

the original export certificate

of airworthiness,

whichever occurs first.(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

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ALERT ALERT
Group 1-2:

Table 4: Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with Less than

12,000 Total Flight Cycles and 4,500 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1601

to STA 1622 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

Group 2:

Table 5: Section 44 - 3-Bay SATCOM Antenna - Compliance Information Index

Condition Questionnaire Action

1. Does the airplane have more than or equal to If Yes, go to Table 6. If No, go to the next question.

14,000 total flight cycles at the time of the original

issue date of this service bulletin?

2. For the airplane, at the time of the original issue If Yes, go to Table 6. If No, go to the next question.

date of this service bulletin, has the time been more

than or equal to 5,250 days since the date of issuance of the original certificate of airworthiness or

the original export certificate of airworthiness?

3. Does the airplane have more than or equal to If Yes, go to Table 7. If No, go to the next question.

12,000 total flight cycles and less than 14,000 total

flight cycles at the time of the original issue date of

this service bulletin?

4. For the airplane, at the time of the original issue If Yes, go to Table 7. If No, go to Table 8.(a)

date of this service bulletin, has the time been more

than or equal to 4,500 days and less than 5,250 days

since the date of issuance of the original certificate

of airworthiness or the original export certificate of

airworthiness?

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ALERT ALERT
Group 2:

Table 5: Section 44 - 3-Bay SATCOM Antenna - Compliance Information Index

Condition Questionnaire Action

(a) At the time of the original issue date of this service bulletin, the airplane has less than 12,000 total flight

cycles and has been less than 4,500 days since the date of issuance of the original certificate of airworthiness or the original export certificate of airworthiness.

Group 2:

Table 6: Section 44 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with More than or

Equal to 14,000 Total Flight Cycles or 5,250 Days

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 120 days after the original

issue date of this service bulletin.(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

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ALERT ALERT
Group 2:

Table 6: Section 44 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with More than or

Equal to 14,000 Total Flight Cycles or 5,250 Days

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1077

to STA 1098 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

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Original Issue: June 12, 2013

777-53A0068

28 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 2:

Table 7: Section 44 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Except for Airplanes Identified

in Table 6; Airplanes with More than or Equal to 12,000 and Less than 14,000 Total Flight Cycles; or

More than or Equal to 4,500 and Less than 5,250 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs First)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 750 flight

cycles or 375

days after the

original issue

date of this service bulletin,

whichever occurs first.(a)

Within 120 days

after reaching

one of the following (whichever

occurs first):

– 14,000 total

flight cycles.

– 5,250 days

from the

date of issuance of

the original

certificate

of airworthiness or the

original export certificate of airworthiness

whichever

occurs first.

(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

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777-53A0068

29 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 2:

Table 7: Section 44 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Except for Airplanes Identified

in Table 6; Airplanes with More than or Equal to 12,000 and Less than 14,000 Total Flight Cycles; or

More than or Equal to 4,500 and Less than 5,250 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs First)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1077

to STA 1098 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

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777-53A0068

30 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 2:

Table 8: Section 44 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with Less than

12,000 Total Flight Cycles and 4,500 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 750 flight

cycles or 375

days after the

original issue

date of this service bulletin,

whichever occurs first.(a)

Before 12,000

total flight cycles

or within 4,500

days from the

date of issuance

of the original

certificate of airworthiness or

the original export certificate

of airworthiness,

whichever occurs first.(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 2:

Table 8: Section 44 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with Less than

12,000 Total Flight Cycles and 4,500 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1077

to STA 1098 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

Group 3-4:

Table 9: Section 46 - 2-Bay SATCOM Antenna - Compliance Information Index

Condition Questionnaire Action

1. Does the airplane have more than or equal to If Yes, go to Table 10. If No, go to the next question.

14,000 total flight cycles at the time of the original

issue date of this service bulletin?

2. For the airplane, at the time of the original issue If Yes, go to Table 10. If No, go to the next question.

date of this service bulletin, has the time been more

than or equal to 5,250 days since the date of issuance of the original certificate of airworthiness or

the original export certificate of airworthiness?

3. Does the airplane have more than or equal to If Yes, go to Table 11. If No, go to the next question.

12,000 total flight cycles and less than 14,000 total

flight cycles at the time of the original issue date of

this service bulletin?

4. For the airplane, at the time of the original issue If Yes, go to Table 11. If No, go to Table 12.(a)

date of this service bulletin, has the time been more

than or equal to 4,500 days and less than 5,250 days

since the date of issuance of the original certificate

of airworthiness or the original export certificate of

airworthiness?

Export Controlled ECCN: 9E991 - BOEING

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 3-4:

Table 9: Section 46 - 2-Bay SATCOM Antenna - Compliance Information Index

Condition Questionnaire Action

(a) At the time of the original issue date of this service bulletin, the airplane has less than 12,000 total flight

cycles and has been less than 4,500 days since the date of issuance of the original certificate of airworthiness or the original export certificate of airworthiness.

Group 3-4:

Table 10: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with More than

or Equal to 14,000 Total Flight Cycles or 5,250 Days

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 120 days after the original

issue date of this service bulletin.(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 3-4:

Table 10: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with More than

or Equal to 14,000 Total Flight Cycles or 5,250 Days

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1601

to STA 1622 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: June 12, 2013

777-53A0068

34 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 3-4:

Table 11: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Except for Airplanes Identified

in Table 10; Airplanes with More than or Equal to 12,000 and Less than 14,000 Total Flight Cycles; or

More than or Equal to 4,500 and Less than 5,250 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs First)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 750 flight

cycles or 375

days after the

original issue

date of this service bulletin,

whichever occurs first.(a)

Within 120 days

after reaching

one of the following (whichever

occurs first):

– 14,000 total

flight cycles.

– 5,250 days

from the

date of issuance of

the original

certificate

of airworthiness or the

original export certificate of airworthiness

whichever

occurs first.

(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: June 12, 2013

777-53A0068

35 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 3-4:

Table 11: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Except for Airplanes Identified

in Table 10; Airplanes with More than or Equal to 12,000 and Less than 14,000 Total Flight Cycles; or

More than or Equal to 4,500 and Less than 5,250 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs First)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1601

to STA 1622 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

36 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 3-4:

Table 12: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with Less than

12,000 Total Flight Cycles and 4,500 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.(a)

Within 750 flight

cycles or 375

days after the

original issue

date of this service bulletin,

whichever occurs first.(a)

Before 12,000

total flight cycles

or within 4,500

days from the

date of issuance

of the original

certificate of airworthiness or

the original export certificate

of airworthiness,

whichever occurs first.(a)

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.(a)

All airplanes.

Do a 777 SRM repair in Before further flight. (b)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: June 12, 2013

777-53A0068

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 3-4:

Table 12: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes with Less than

12,000 Total Flight Cycles and 4,500 Days

Repeat Interval

(Not to Exceed)

Compliance Time

(Whichever Occurs Later)

Condition Action

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) Previous accomplishment of internal or external detailed inspection of the fuselage skin from STA 1601

to STA 1622 and from S-1L to S-1R meets the requirements of the initial internal and external detailed

and surface HFEC inspection of the visible fuselage skin in accordance with Paragraph 3.B., Work Instructions, Part 2.

Refer to 777 MPD Section 2, 53-598-00, Boeing Multi-Operator Message (MOM-MOM-12-0466-01B),

and 777 FTD 53-12001 for additional information related to this service bulletin issue.

(b) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

Group 5, Configuration 3-4:

Table 13: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes Not Yet Delivered

at the Original Issue Date of this Service Bulletin

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

1,500 flight cycles

or 750 days,

whichever occurs

first.

Before 12,000 total flight cycles or

within 4,500 days from the date of

issuance of the original certificate

of airworthiness or the original export certificate of airworthiness,

whichever occurs first.

Do internal and external

detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

All airplanes.

Do a 777 SRM repair in Before further flight. (a)

accordance with Paragraph 3.B., Work Instructions, Part 2, or contact

Boeing for repair instructions and do the repair.

Any corrosion found

or

Any crack found.

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: June 12, 2013

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BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
Group 5, Configuration 3-4:

Table 13: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection - Airplanes Not Yet Delivered

at the Original Issue Date of this Service Bulletin

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Contact Boeing for repair Before further flight. -

instructions and do the

repair.

Any indication found that

shows a contact of the fastener attaching the SATCOM lug adapter plate to

the bonding jumper given

in Paragraph 3.B., Work

Instructions, Part 2.

and

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler, if installed, in

accordance with Paragraph 3.B., Work Instructions, Part 2.

Any blend repair accomplished within Allowable

Damage 1 limits in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

1,500 flight cycles

or 750 days,

whichever occurs

first.

Within 1,500 flight cycles or 750

days after the repair, whichever

occurs first.

Repeat internal and external detailed and surface

HFEC inspections of the

visible fuselage skin and

doubler in accordance

with Paragraph 3.B.,

Work Instructions, Part 2.

Any fuselage skin repair

doubler installed in accordance with 777 SRM 53-

00-01 given in Paragraph

3.B., Work Instructions,

Part 2.

(a) For airplanes on which any blend repair is accomplished within allowable damage 1 limits in accordance

with 777 SRM 53-00-01 and for airplanes on which any fuselage skin repair doubler is installed in accordance 777 SRM 53-00-01 given in Paragraph 3.B., Work Instructions, Part 2, refer to the applicable rows

in this table for additional inspections.

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 777-53A0068

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.

G. Manpower

The tables below show an estimate of the task hours necessary to do this inspection for each airplane.

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.

Group 5, Configuration 1-2, 5:

None. No action is necessary in accordance with this service bulletin.

Group 1:

Table 1: Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection

Task Number of Persons Task Hours Elapsed Hours

Open Access - Inter- 1 2.00 2.00

nal

Open Access - Exter- 2 4.20 2.10

nal

FIGURE 1 1 0.20 0.20

FIGURE 2 1 3.00 3.00

FIGURE 3 1 2.00 2.00

Close Access - Inter- 1 2.00 2.00

nal

Close Access - Exter- 2 4.20 2.10

nal

TOTAL FOR EACH AIRPLANE 17.60 13.40

Group 2:

Table 2: Sections 44 and 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection

Task Number of Persons Task Hours Elapsed Hours

Section 44 - 3-Bay SATCOM Antenna

Open Access - Inter- 1 2.00 2.00

nal

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Group 2:

Table 2: Sections 44 and 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection

Task Number of Persons Task Hours Elapsed Hours

Open Access - Exter- 2 4.20 2.10

nal

FIGURE 4 1 0.20 0.20

FIGURE 5 1 3.00 3.00

FIGURE 6 1 2.00 2.00

Close Access - Inter- 1 2.00 2.00

nal

Close Access - Exter- 2 4.20 2.10

nal

Section 46 - 3-Bay SATCOM Antenna

Open Access - Inter- 1 2.00 2.00

nal

Open Access - Exter- 2 4.20 2.10

nal

FIGURE 1 1 0.20 0.20

FIGURE 2 1 3.00 3.00

FIGURE 3 1 2.00 2.00

Close Access - Inter- 1 2.00 2.00

nal

Close Access - Exter- 2 4.20 2.10

nal

TOTAL FOR EACH AIRPLANE 35.20 26.80

Group 3-4; Group 5, Configuration 3-4:

Table 3: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection

Task Number of Persons Task Hours Elapsed Hours

Open Access - Inter- 1 2.00 2.00

nal

Open Access - Exter- 2 4.20 2.10

nal

FIGURE 7 1 0.20 0.20

FIGURE 8 1 3.00 3.00

FIGURE 9 1 2.00 2.00

Close Access - Inter- 1 2.00 2.00

nal

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Group 3-4; Group 5, Configuration 3-4:

Table 3: Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection

Task Number of Persons Task Hours Elapsed Hours

Close Access - Exter- 2 4.20 2.10

nal

TOTAL FOR EACH AIRPLANE 17.60 13.40

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

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

b. Boeing Service Related Problem (SRP) 777-SRP-53-0418

c. Service Bulletin Index D624W001

d. Standard Overhaul Practices Manual (SOPM) 20-50-19

e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19, 20-20-10

f. 777 Aircraft Maintenance Manual (AMM) 23-15-08, 23-15-23, 25-80-00, 53-61-51

g. 777 Fleet Team Digest (FTD) 53-12001

h. 777 Maintenance Planning Data (MPD) Section 2, 53-598-00

i. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01

j. 777-200 Structural Repair Manual (SRM) 51-10-02, 53-00-01

k. 777-300 Structural Repair Manual (SRM) 51-10-02, 53-00-01

l. 777F Structural Repair Manual (SRM) 51-10-02, 53-00-01

2. Data Supplied with this Service Bulletin:

None.

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

Drawing Number Title

144W0026 SUPPORT INSTL - SATCOM, HIGH GAIN TOP MOUNT

146W0027 SUPPORT INSTL - SATCOM, HIGH GAIN TOP MOUNT

The table above lists applicable drawings used to prepare this service bulletin. The drawings are

not necessary to make the specified changes, and are not supplied with this service bulletin. The

drawings may not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

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 but no new DTIs are necessary.

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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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

None.

B. Industry Support Information

Boeing warranty remedies are available for 777 airplanes in warranty as of June 25, 2012. For inspection

labor task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Warranty & Product Assurance Contracts. If the condition described in this service bulletin is found

during the inspection for airplanes in warranty as of that date and additional task hours are required,

send a warranty claim to Boeing Warranty & Product Assurance Contracts. Please refer to this service

bulletin number and reference the airplane variable number(s) in your purchase order. The warranty

remedies will expire eight years from the original issue date of 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 limits to tighten nuts and bolts are in SRM Chapter 51

4. Use the approved fastener and process material substitutions in accordance with

SRM Chapter 51.

5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,

and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.

6. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

7. 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.

8. 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.

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9. 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.

10. 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.

11. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

12. Shaded areas in Figures are to separate the non-critical and non-authoritative

information from the critical and authoritative information.

13. The satellite communication (SATCOM) antenna is also referred to as Top Mount

High Gain Antenna (TMHGA). For this service bulletin, "SATCOM antenna" is used

to refer to the antenna.

B. WORK INSTRUCTIONS

Group 5, Configuration 1-2, 5:

No action is necessary in accordance with this service bulletin. These airplanes either have a production

change to the bonding jumper installation for 3-bay SATCOM antenna or do not have any SATCOM

antennas installed.

Group 1-4; Group 5, Configuration 3-4:

Part 1 - Access

1. Group 1-2:

Section 46 - 3-Bay SATCOM Antenna - Internal Access:

a. Open the circuit breaker to the SATCOM antenna and remove interior furnishings. Refer to

777 AMM 23-15-08 as an accepted procedure.

b. Remove insulation blankets. Refer to 777 AMM 25-80-00 as an accepted procedure.

2. Group 2:

Section 44 - 3-Bay SATCOM Antenna - Internal Access:

a. Open the circuit breaker to the SATCOM antenna and remove interior furnishings. Refer to

777 AMM 23-15-08 as an accepted procedure.

b. Remove insulation blankets. Refer to 777 AMM 25-80-00 as an accepted procedure.

3. Group 3-4; Group 5, Configuration 3-4:

Section 46 - 2-Bay SATCOM Antenna - Internal Access:

a. Open the circuit breaker to the SATCOM antenna and remove interior furnishings. Refer to

777 AMM 23-15-08 as an accepted procedure.

b. Remove insulation blankets. Refer to 777 AMM 25-80-00 as an accepted procedure.

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4. Group 1-2:

Section 46 - 3-Bay SATCOM Antenna - External Access:

a. Remove the SATCOM antenna. Refer to 777 AMM 23-15-23 as an accepted procedure.

b. Remove the adapter plate. Refer to 777 AMM 53-61-51 as an accepted procedure. During

the removal of the adapter plate, locate and mark the location of the fastener common to the

adapter plate and bonding jumper on the fuselage skin or doubler, if installed, in accordance

with FIGURE 1.

5. Group 2:

Section 44 - 3-Bay SATCOM Antenna - External Access:

a. Remove the SATCOM antenna. Refer to 777 AMM 23-15-23 as an accepted procedure.

b. Remove the adapter plate. Refer to 777 AMM 53-61-51 as an accepted procedure. During

the removal of the adapter plate, locate and mark the location of the fastener common to the

adapter plate and bonding jumper on the fuselage skin or doubler, if installed, in accordance

with FIGURE 4.

6. Group 3-4; Group 5, Configuration 3-4:

Section 46 - 2-Bay SATCOM Antenna - External Access:

a. Remove the SATCOM antenna. Refer to 777 AMM 23-15-23 as an accepted procedure.

b. Remove the adapter plate. Refer to 777 AMM 53-61-51 as an accepted procedure. During

the removal of the adapter plate, locate and mark the location of the fastener common to the

adapter plate and bonding jumper on the fuselage skin or doubler, if installed, in accordance

with FIGURE 7.

Group 1-4; Group 5, Configuration 3-4:

Part 2 - Inspection

1. Group 1-2:

Section 46 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection:

Do internal detailed and surface high frequency eddy current (HFEC) inspections of the visible

fuselage skin in accordance with FIGURE 2. If a fuselage skin repair doubler is installed, do detailed

and surface HFEC inspections of the visible doubler in the specified inspection area in accordance

with the figure.

Do external detailed and surface HFEC inspections of the visible fuselage skin in accordance with

FIGURE 3. If a fuselage skin repair doubler is installed, do detailed and surface HFEC inspections

of the visible doubler in the specified inspection area in accordance with the figure.

NOTE: Previous accomplishment of internal or external detailed inspection of the fuselage skin

from STA 1601 to STA 1622 and from S-1L to S-1R meets the intent of the initial internal

and external detailed and surface HFEC inspection of the visible fuselage skin.

a. If any corrosion is found, do a repair in accordance with 777-200 SRM 53-00-01 or 777-300

SRM 53-00-01; or contact Boeing for repair instructions and do the repair. General corrosion

damage removal procedure and inspection is specified in 777-200 SRM 51-10-02 or 777-300

SRM 51-10-02.

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(1) If a blend repair was accomplished within Allowable Damage 1 limits in accordance with

777-200 SRM 53-00-01 or 777-300 SRM 53-00-01, repeat the internal and external

detailed and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

(2) If external repair doubler is necessary in accordance with 777 SRM, contact Boeing for

repair instructions and do the repair to make sure that there is sufficient clearance between

the fuselage skin or doubler, and fastener attaching the SATCOM lug adapter plate to

the bonding jumper.

If a fuselage skin repair doubler was installed, repeat the internal and external detailed

and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

b. If any crack is found, do a repair in accordance with 777-200 SRM 53-00-01 or 777-300 SRM

53-00-01; or contact Boeing for repair instructions and do the repair.

(1) If external repair doubler is necessary in accordance with 777 SRM, contact Boeing for

repair instructions and do the repair to make sure that there is sufficient clearance between

the fuselage skin or doubler, and fastener attaching the SATCOM lug adapter plate to

the bonding jumper.

(2) If a fuselage skin repair doubler was installed, repeat the internal and external detailed

and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

c. If any indication is found that shows a contact of the fastener attaching the SATCOM lug

adapter plate to the bonding jumper, contact Boeing for repair instructions and do the repair.

Indications of the fastener contact include imprint, gouge, rubbing, and scratch. After the

repair, repeat the internal and external detailed and surface HFEC inspections at the time

given in Paragraph 1.E., Compliance.

2. Group 2:

Section 44 - 3-Bay SATCOM Antenna - Fuselage Skin Inspection:

Do internal detailed and surface HFEC inspections of the visible fuselage skin in accordance with

FIGURE 5. If a fuselage skin repair doubler is installed, do detailed and surface HFEC inspections

of the visible doubler in the specified inspection area in accordance with the figure.

Do external detailed and surface HFEC inspections of the visible fuselage skin in accordance with

FIGURE 6. If a fuselage skin repair doubler is installed, do detailed and surface HFEC inspections

of the visible doubler in the specified inspection area in accordance with the figure.

NOTE: Previous accomplishment of internal or external detailed inspection of the fuselage skin

from STA 1077 to STA 1098 and from S-1L to S-1R meets the intent of the initial internal

and external detailed and surface HFEC inspection of the visible fuselage skin.

a. If any corrosion is found, do a repair in accordance with 777-200 SRM 53-00-01 or 777-300

SRM 53-00-01; or contact Boeing for repair instructions and do the repair. General corrosion

damage removal procedure and inspection is specified in 777-200 SRM 51-10-02 or 777-300

SRM 51-10-02.

(1) If a blend repair was accomplished within Allowable Damage 1 limits in accordance with

777-200 SRM 53-00-01 or 777-300 SRM 53-00-01, repeat the internal and external

detailed and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

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(2) If external repair doubler is necessary in accordance with 777 SRM, contact Boeing for

repair instructions and do the repair to make sure that there is sufficient clearance between

the fuselage skin or doubler, and fastener attaching the SATCOM lug adapter plate to

the bonding jumper.

If a fuselage skin repair doubler was installed, repeat the internal and external detailed

and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

b. If any crack is found, do a repair in accordance with 777-200 SRM 53-00-01 or 777-300 SRM

53-00-01; or contact Boeing for repair instructions and do the repair.

(1) If external repair doubler is necessary in accordance with 777 SRM, contact Boeing for

repair instructions and do the repair to make sure that there is sufficient clearance between

the fuselage skin or doubler, and fastener attaching the SATCOM lug adapter plate to

the bonding jumper.

(2) If a fuselage skin repair doubler was installed, repeat the internal and external detailed

and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

c. If any indication is found that shows a contact of the fastener attaching the SATCOM lug

adapter plate to the bonding jumper, contact Boeing for repair instructions and do the repair.

Indications of the fastener contact include imprint, gouge, rubbing, and scratch. After the

repair, repeat the internal and external detailed and surface HFEC inspections at the time

given in Paragraph 1.E., Compliance.

3. Group 3-4; Group 5, Configuration 3-4:

Section 46 - 2-Bay SATCOM Antenna - Fuselage Skin Inspection:

Do internal detailed and surface HFEC inspections of the visible fuselage skin in accordance with

FIGURE 8. If a fuselage skin repair doubler is installed, do detailed and surface HFEC inspections

of the visible doubler in the specified inspection area in accordance with the figure.

Do external detailed and surface HFEC inspections of the visible fuselage skin in accordance with

FIGURE 9. If a fuselage skin repair doubler is installed, do detailed and surface HFEC inspections

of the visible doubler in the specified inspection area in accordance with the figure.

NOTE: Previous accomplishment of internal or external detailed inspection of the fuselage skin

from STA 1601 to STA 1622 and from S-1L to S-1R meets the intent of the initial internal

and external detailed and surface HFEC inspection of the visible fuselage skin.

a. If any corrosion is found, do a repair in accordance with 777-200 SRM 53-00-01, 777-300

SRM 53-00-01, or 777F SRM 53-00-01; or contact Boeing for repair instructions and do the

repair. General corrosion damage removal procedure and inspection is specified in 777-200

SRM 51-10-02, 777-300 SRM 51-10-02, or 777F SRM 51-10-02.

(1) If a blend repair was accomplished within Allowable Damage 1 limits in accordance with

777-200 SRM 53-00-01, 777-300 SRM 53-00-01, or 777F SRM 53-00-01, repeat the

internal and external detailed and surface HFEC inspections at the time given in Paragraph

1.E., Compliance.

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(2) If external repair doubler is necessary in accordance with 777 SRM, contact Boeing for

repair instructions and do the repair to make sure that there is sufficient clearance between

the fuselage skin or doubler, and fastener attaching the SATCOM lug adapter plate to

the bonding jumper.

If a fuselage skin repair doubler was installed, repeat the internal and external detailed

and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

b. If any crack is found, do a repair in accordance with 777-200 SRM 53-00-01, 777-300 SRM

53-00-01, or 777F SRM 53-00-01; or contact Boeing for repair instructions and do the repair.

(1) If external repair doubler is necessary in accordance with 777 SRM, contact Boeing for

repair instructions and do the repair to make sure that there is sufficient clearance between

the fuselage skin or doubler, and fastener attaching the SATCOM lug adapter plate to

the bonding jumper.

(2) If a fuselage skin repair doubler was installed, repeat the internal and external detailed

and surface HFEC inspections at the time given in Paragraph 1.E., Compliance.

c. If any indication is found that shows a contact of the fastener attaching the SATCOM lug

adapter plate to the bonding jumper, contact Boeing for repair instructions and do the repair.

Indications of the fastener contact include imprint, gouge, rubbing, and scratch. After the

repair, repeat the internal and external detailed and surface HFEC inspections at the time

given in Paragraph 1.E., Compliance.

Group 1-4; Group 5, Configuration 3-4:

Part 3 - Restoration

1. Internal Restoration

a. Install insulation blankets. Refer to 777 AMM 25-80-00 as an accepted procedure.

b. Install interior furnishings. Refer to 777 AMM 23-15-08 as an accepted procedure.

2. External Restoration

a. Install the adapter plate. Refer to 777 AMM 53-61-51 as an accepted procedure for installing

the adapter plate. Refer to SWPM 20-20-10 as an accepted procedure for installing the bonding

jumper.

After the installation of the fastener attaching the adapter plate to the bonding jumper,

encapsulate the fastener, washer, nut, and periphery of the bonding jumper with BMS 5-95.

Refer to SOPM 20-50-19 as an accepted procedure. Make sure there is no contact between

the sealant of the cap sealed fastener and fuselage skin or doubler, if installed. Use of a

boroscope or feeler gauge is an acceptable method to ensure there is no contact.

3. Install the SATCOM antenna. Refer to 777 AMM 23-15-23 as an accepted procedure. Close the

circuit breaker to the SATCOM antenna. Refer to AMM 23-15-08 or 23-15-23 as an accepted

procedure.

4. Put the airplane back to a serviceable condition.

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This Figure applies only to: Group 1-2.

FIGURE 1: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE FASTENER

COMMON TO BONDING JUMPER AND ADAPTER PLATE

(SHEET 1 OF 2)

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Locate

(a) Directly under the fastener common to the adapter plate and bonding jumper, locate and mark the location

of the fastener on the fuselage skin or doubler, if installed, within 0.25 inch using a felt tip marker. The

location of the mark will be used to identify the inspection area in FIGURE 3.

FIGURE 1: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE FASTENER

COMMON TO BONDING JUMPER AND ADAPTER PLATE

(SHEET 2 OF 2)

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This Figure applies only to: Group 1-2.

FIGURE 2: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 1 OF 3)

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FIGURE 2: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 2 OF 3)

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Inspect

FUSELAGE - - (b)

SKIN/DOUBLER

2 Inspect

(a) Do a detailed inspection of the visible fuselage skin for cracks. Do the inspection in the area between

STA 1567.5 and STA 1643, and S-2L and S-2R.

If a fuselage skin repair doubler is installed, do a detailed inspection of the visible doubler in the specified

inspection area.

(b) Do a surface HFEC inspection of the visible fuselage skin for cracks in accordance with 777 NDT Manual

Part 6, 51-00-01.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the visible doubler in the

specified inspection area.

FIGURE 2: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT
This Figure applies only to: Group 1-2.

FIGURE 3: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 1 OF 3)

Export Controlled ECCN: 9E991 - BOEING

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777-53A0068

58 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
FIGURE 3: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 2 OF 3)

Export Controlled ECCN: 9E991 - BOEING

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Original Issue: June 12, 2013

777-53A0068

59 of 76

BOEING SERVICE BULLETIN 777-53A0068

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Inspect

FUSELAGE - - (b)

SKIN/DOUBLER

2 Inspect

FUSELAGE - - (c)

SKIN/DOUBLER

3 Inspect

(a) Do a detailed inspection of the visible fuselage skin for corrosion and cracks, and for any indication that

shows a contact of the fastener attaching the SATCOM lug adapter plate to the bonding jumper. Do the

inspection in the area between STA 1567.5 and STA 1643, and S-2L and S-2R. Indications of the fastener

contact include imprint, gouge, rubbing, and scratch.

If a fuselage skin repair doubler is installed, do a detailed inspection of the visible doubler in the specified

inspection area.

(b) Do a surface HFEC inspection of the visible fuselage skin for cracks in accordance with 777 NDT Manual

Part 6, 51-00-01. The marked location on the fuselage was accomplished in FIGURE 1.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the visible doubler in the

specified inspection area.

(c) Do a surface HFEC inspection of the fuselage skin around the edge of the bonding jumper for cracks in

accordance with 777 NDT Manual Part 6, 51-00-01.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the doubler in the specified

inspection area.

FIGURE 3: SECTION 46 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 3 OF 3)

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Original Issue: June 12, 2013

777-53A0068

60 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 4: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE FASTENER

COMMON TO BONDING JUMPER AND ADAPTER PLATE

(SHEET 1 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

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Original Issue: June 12, 2013

777-53A0068

61 of 76

BOEING SERVICE BULLETIN 777-53A0068

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Locate

(a) Directly under the fastener common to the adapter plate and bonding jumper, locate and mark the location

of the fastener on the fuselage skin or doubler, if installed, within 0.25 inch using a felt tip marker. The

location of the mark will be used to identify the inspection area in FIGURE 6.

FIGURE 4: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE FASTENER

COMMON TO BONDING JUMPER AND ADAPTER PLATE

(SHEET 2 OF 2)

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PROPRIETARY - Copyright © Unpublished

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Original Issue: June 12, 2013

777-53A0068

62 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 5: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 1 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

63 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
FIGURE 5: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 2 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

64 of 76

BOEING SERVICE BULLETIN 777-53A0068

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Inspect

FUSELAGE - - (b)

SKIN/DOUBLER

2 Inspect

(a) Do a detailed inspection of the visible fuselage skin for cracks. Do the inspection in the area between

STA 1035 and STA 1119, and S-2L and S-2R.

If a fuselage skin repair doubler is installed, do a detailed inspection of the visible doubler in the specified

inspection area.

(b) Do a surface HFEC inspection of the visible fuselage skin for cracks in accordance with 777 NDT Manual

Part 6, 51-00-01.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the visible doubler in the

specified inspection area.

FIGURE 5: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 3 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

65 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 6: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 1 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

66 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
FIGURE 6: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 2 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

67 of 76

BOEING SERVICE BULLETIN 777-53A0068

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Inspect

FUSELAGE - - (b)

SKIN/DOUBLER

2 Inspect

FUSELAGE - - (c)

SKIN/DOUBLER

3 Inspect

(a) Do a detailed inspection of the visible fuselage skin for corrosion and cracks, and for any indication that

shows a contact of the fastener attaching the SATCOM lug adapter plate to the bonding jumper. Do the

inspection in the area between STA 1567.5 and STA 1643, and S-2L and S-2R. Indications of the fastener

contact include imprint, gouge, rubbing, and scratch.

If a fuselage skin repair doubler is installed, do a detailed inspection of the visible doubler in the specified

inspection area.

(b) Do a surface HFEC inspection of the visible fuselage skin for cracks in accordance with 777 NDT Manual

Part 6, 51-00-01. The marked location on the fuselage was accomplished in FIGURE 4.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the visible doubler in the

specified inspection area.

(c) Do a surface HFEC inspection of the fuselage skin around the edge of the bonding jumper for cracks in

accordance with 777 NDT Manual Part 6, 51-00-01.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the doubler in the specified

inspection area.

FIGURE 6: SECTION 44 - 3-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 3 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

68 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
This Figure applies only to: Group 3-4; Group 5, Configuration 3-4.

FIGURE 7: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE FASTENER

COMMON TO BONDING JUMPER AND ADAPTER PLATE

(SHEET 1 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

69 of 76

BOEING SERVICE BULLETIN 777-53A0068

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Locate

(a) Directly under the fastener common to the adapter plate and bonding jumper, locate and mark the location

of the fastener on the fuselage skin or doubler, if installed, within 0.25 inch using a felt tip marker. The

location of the mark will be used to identify the inspection area in FIGURE 9.

FIGURE 7: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - MARK AND LOCATE FASTENER

COMMON TO BONDING JUMPER AND ADAPTER PLATE

(SHEET 2 OF 2)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

70 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
This Figure applies only to: Group 3-4; Group 5, Configuration 3-4.

FIGURE 8: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 1 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

71 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
FIGURE 8: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 2 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

72 of 76

BOEING SERVICE BULLETIN 777-53A0068

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Inspect

FUSELAGE - - (b)

SKIN/DOUBLER

2 Inspect

(a) Do a detailed inspection of the visible fuselage skin for cracks. Do the inspection in the area between

STA 1580 and STA 1643, and S-2L and S-2R.

If a fuselage skin repair doubler is installed, do a detailed inspection of the visible doubler in the specified

inspection area.

(b) Do a surface HFEC inspection of the visible fuselage skin for cracks in accordance with 777 NDT Manual

Part 6, 51-00-01.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the visible doubler in the

specified inspection area.

FIGURE 8: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - INTERNAL INSPECTION

(SHEET 3 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

73 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
This Figure applies only to: Group 3-4; Group 5, Configuration 3-4.

FIGURE 9: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 1 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

74 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT
FIGURE 9: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 2 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

75 of 76

BOEING SERVICE BULLETIN 777-53A0068

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

Step Task Name Identification Qty More Data

FUSELAGE - - (a)

SKIN/DOUBLER

1 Inspect

FUSELAGE - - (b)

SKIN/DOUBLER

2 Inspect

FUSELAGE - - (c)

SKIN/DOUBLER

3 Inspect

(a) Do a detailed inspection of the visible fuselage skin for corrosion and cracks, and for any indication that

shows a contact of the fastener attaching the SATCOM lug adapter plate to the bonding jumper. Do the

inspection in the area between STA 1580 and STA 1643, and S-2L and S-2R. Indications of the fastener

contact include imprint, gouge, rubbing, and scratch.

If a fuselage skin repair doubler is installed, do a detailed inspection of the visible doubler in the specified

inspection area.

(b) Do a surface HFEC inspection of the visible fuselage skin for cracks in accordance with 777 NDT Manual

Part 6, 51-00-01. The marked location on the fuselage was accomplished in FIGURE 7.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the visible doubler in the

specified inspection area.

(c) Do a surface HFEC inspection of the fuselage skin around the edge of the bonding jumper for cracks in

accordance with 777 NDT Manual Part 6, 51-00-01.

If a fuselage skin repair doubler is installed, do a surface HFEC inspection of the doubler in the specified

inspection area.

FIGURE 9: SECTION 46 - 2-BAY SATCOM ANTENNA - FUSELAGE SKIN - EXTERNAL INSPECTION

(SHEET 3 OF 3)

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 12, 2013

777-53A0068

76 of 76

BOEING SERVICE BULLETIN 777-53A0068

ALERT ALERT