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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0081 Original Issue: September 08, 2016 ATA System: 5330 5710 SUBJECT: FUSELAGE - Section 43 - Inspection of the Underwing Longeron Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2016 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 9 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 2 0 E. Compliance .............................................. 2 0 F . A p p r o v a l ............................................... 4 2 G. Manpower .............................................. 4 2 H. Weight and Balance Changes .................................... 4 9 I. Electrical Load Data ......................................... 4 9 J . R e f e r e n c e s .............................................. 4 9
1. Existing Data: ......................................... 4 9
2. Data Supplied with this Service Bulletin: ........................... 4 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 0 K. Publications Affected ........................................ 5 0 L. Interchangeability and Intermixability of Parts ........................... 5 0 M. Software Accomplishment Summary ................................ 5 0
2. MATERIAL INFORMATION ........................................ 5 1 A. Material - Price and Availability ................................... 5 1 B. Industry Support Information .................................... 5 2 C. Parts Necessary for Each Airplane ................................. 5 2 1 . K i t s / P a r t s ............................................ 5 2
2. Parts and Materials Supplied by the Operator ........................ 5 7
3. Parts Modified and Reidentified ................................ 5 8
4. Parts Removed and Not Replaced .............................. 5 8 D. Parts Necessary to Change Spares ................................. 5 8 E. Special Tooling - Price and Availability ............................... 5 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 9 A. GENERAL INFORMATION ..................................... 5 9 B. WORK INSTRUCTIONS ....................................... 6 1 FIGURE 1: DETAILED INSPECTION OF THE LEFT SIDE BUILT-UP UNDERWING LONGERON [Group 1 - 2 , 9 ] .............................................. 7 1 FIGURE 2: DETAILED INSPECTION OF THE RIGHT SIDE BUILT-UP UNDERWING LONGERON [Group 1 - 2 , 9 ] .............................................. 7 4 FIGURE 3: DETAILED INSPECTION OF THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 3 - 8 , 1 0 - 1 2 ] ........................................... 7 7 FIGURE 4: DETAILED INSPECTION OF THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 3 - 8 , 1 0 - 1 2 ] ........................................... 7 9 FIGURE 5: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION O F T H E L E F T S I D E B U I L T - U P L O N G E R O N [ G r o u p 1 - 2 , 9 ] ................. 8 1 FIGURE 6: DETAILED INSPECTION AND HIGH FREQUENCY EDDY CURRENT INSPECTION (HFEC) O F T H E R I G H T S I D E B U I L T - U P L O N G E R O N [ G r o u p 1 - 2 , 9 ] ................ 8 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 7: DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE LEFT SIDE MACHINED LONGERON [Group 3-8, 10-12] ................................ 8 7 FIGURE 8: DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE MACHINED LONGERON [Group 3-8, 10-12] ................................ 8 9 FIGURE 9: REMOVAL OF THE LEFT SIDE UNDERWING LONGERON ................ 9 1 FIGURE 10: INSPECTION OF THE FUSELAGE SKIN AROUND THE LEFT SIDE UNDERWING LONGERON .................................................. 9 4 FIGURE 11: INSPECTION OF THE LOWER WING SKIN AROUND THE LEFT SIDE UNDERWING L O N G E R O N.......................................... 9 6 FIGURE 12: INSPECTION OF THE LOWER WING BODY CHORD, SPAR CHORD AND SPAR WEB AROUND THE LEFT SIDE LONGERON ........................... 9 8 FIGURE 13: INSTALL THE FASTENERS [Group 1, 3, 5] ......................... 1 0 1 FIGURE 14: INSTALL THE FASTENERS [Group 2, 4, 6-12] ....................... 1 0 4 FIGURE 15: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 1, 3] .... 1 0 7 FIGURE 16: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 2, 4, 7] . . . 118 FIGURE 17: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 5] ...... 1 2 9 FIGURE 18: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 6, 8] .... 1 3 9 FIGURE 19: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 9-11] .... 1 4 9 FIGURE 20: INSTALL THE LEFT SIDE MACHINED UNDERWING LONGERON [Group 12] ..... 1 6 1 FIGURE 21: REMOVAL OF THE RIGHT SIDE UNDERWING LONGERON .............. 1 7 1 FIGURE 22: INSPECTION OF THE FUSELAGE SKIN AROUND THE RIGHT SIDE UNDERWING L O N G E R O N .......................................... 1 7 4 FIGURE 23: INSPECTION OF THE LOWER WING SKIN AROUND THE RIGHT SIDE UNDERWING L O N G E R O N .......................................... 1 7 6 FIGURE 24: INSPECTION OF THE LOWER WING BODY CHORD, SPAR CHORD AND SPAR WEB AROUND THE RIGHT SIDE LONGERON ......................... 1 7 8 FIGURE 25: INSTALL THE FASTENERS [Group 1, 3, 5] ......................... 1 8 1 FIGURE 26: INSTALL THE FASTENERS [Group 2, 4, 6-12] ....................... 1 8 4 FIGURE 27: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 1, 3] .... 1 8 7 FIGURE 28: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 2, 4, 7] . . 198 FIGURE 29: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 5] ..... 2 0 9 FIGURE 30: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 6, 8] .... 2 1 9 FIGURE 31: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 9-11] . . . 229 FIGURE 32: INSTALL THE RIGHT SIDE MACHINED UNDERWING LONGERON [Group 12] .... 2 4 1 FIGURE 33: POST REPLACEMENT DETAILED INSPECTION OF THE LEFT SIDE MACHINED UNDERWING L O N G E R O N .......................................... 2 5 1 FIGURE 34: POST REPLACEMENT DETAILED INSPECTION OF THE RIGHT SIDE MACHINED UNDERWING LONGERON ................................. 2 5 3 FIGURE 35: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE LEFT SIDE MACHINED UNDERWING LONGERON .................... 2 5 5 FIGURE 36: POST REPLACEMENT DETAILED INSPECTION AND ULTRASONIC INSPECTION OF THE RIGHT SIDE MACHINED UNDERWING LONGERON ................... 2 5 7 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: INSPECT THE BUILT-UP UNDERWING LONGERON FOR ANY CRACK IN 777-200 AIRPLANES [Group 1-2] . . 259 APPENDIX B: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-200 AIRPLANES [Group 3-6] . . 263 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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APPENDIX C: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 3: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-200LR AND 777F AIRPLANES [Group 7 - 8 ] ............................................... 2 6 7 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 4: INSPECT THE BUILT-UP UNDERWING LONGERON FOR ANY CRACK IN 777-300 AIRPLANES [Group 9] . . . 271 APPENDIX E: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 5: INSPECT THE MACHINED UNDERWING LONGERON FOR ANY CRACK IN 777-300 AIRPLANES [Group 10] . . . 275 APPENDIX F: L OGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 6: INSPECT THE MACHINED UNDERWING LONGERONS FOR ANY CRACK IN 777-300ER AIRPLANES [Group 11-12] ................................................. 2 7 9 APPENDIX G: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 7: POST REPLACEMENT INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200 AIRPLANES [Group 1-6] ................................... 2 8 3 APPENDIX H: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 8: POST REPLACEMENT
INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200 AIRPLANES [Group 1-6] .............................. 2 8 7 APPENDIX I: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 9: POST REPLACEMENT
INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200LR AND 777F AIRPLANES [Group 7-8] ...................... 2 9 1 APPENDIX J: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 10: POST REPLACEMENT
INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-200LR AND 777F AIRPLANES [Group 7-8] ...................... 2 9 5 APPENDIX K: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 11: POST REPLACEMENT INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300 AIRPLANES [Group 9-10] .................................. 2 9 9 APPENDIX L: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 12: POST REPLACEMENT
INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300 AIRPLANES [Group 9-10] ............................. 3 0 3 APPENDIX M: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 13: POST REPLACEMENT
INSPECTIONS ON THE LEFT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300ER AIRPLANES [Group 11-12] ........................... 3 0 7 APPENDIX N: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 14: POST REPLACEMENT
INSPECTIONS ON THE RIGHT SIDE UNDERWING LONGERON FOR ANY CRACK ON 777-300ER AIRPLANES [Group 11-12] ........................... 3 1 1 APPENDIX O: PART DEMAND INTENT .................................. 3 1 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0081Original Issue: September 08, 2016 ATA System: 5330 5710 SUBJECT: FUSELAGE - Section 43 - Inspection of the Underwing Longeron
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin is sent to provide instructions for inspection and replacement of the underwing longeron at Station (STA) 1035. Cracks have been found which led to the underwing longeron becoming severed. The growth of cracks could lead to a crack in the wing lower spar chord. If left uncorrected, cracks could result in fuel leakage into the forward cargo area and consequent increased risk of a fire, or, in a more severe case, could adversely affect the structural integrity of the airplane.
The first underwing longeron crack was discovered in service. An operator had reports of fuel smell in the forward cargo area. The subsequent investigation found a crack in the center wing tank that was attributed to the longeron crack found. All models except some 777-200 models without a center wing tank, are affected by the potential for a fuel leak into the forward cargo area.
Subsequently, three more operators have reported cracks on the left underwing longeron. The cracks have been reported in 777-300ER and 777-200 airplanes. The cracks have been reported as early as 3,784 Flight Cycles and 31,240 Flight Hours. As the cracks grow in the longeron further cracking has been reported and three operators noted the front lower wing spar chord had cracked. The table below gives the flight cycles and flight hours at which operators reported finding airplanes with a crack.
Flight HoursFlight CyclesAirplane 85,44212,835777-200 31,2403,784777-300ER 43,3445,247777-300ER 39,5935,359777-300ER 51,4527,299777-300ER 51,2127,413777-300ER Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Boeing Service Related Problem (SRP) 777-SRP-53-0485 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 53-15002 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION Do a detailed inspection of the underwing longeron. If any crack is found in the underwing longeron, remove and replace the underwing longeron and inspect the front lower wing spar chord and body ring chord. If no crack is found, repeat the detailed inspection.
EFFECTIVITY All 777 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of September 23, 2015. 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX O of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 777-53A0081
ALERT ALERT STA 1035
DO A DETAILED INSPECTION OF THE UNDERWING LONGERON. IF ANY CRACK IS FOUND IN THE UNDERWING
LONGERON, REMOVE AND REPLACE THE UNDERWING
LONGERON AND INSPECT THE FRONT LOWER WING SPAR CHORD AND BODY RING CHORD. IF NO CRACK IS FOUND,
REPEAT THE DETAILED INSPECTION 2503072 Original Issue: September 08, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 777-53A0081 Work - See page 1 for details. 10 of 315
Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0081 Original Issue: September 08, 2016 ATA System: 5330 5710 SUBJECT: FUSELAGE - Section 43 - Inspection of the Underwing Longeron
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to 777-200, 777-200LR, 777-300, 777-300ER, and 777F line number 1 - 9999 in 12 Groups. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1503.
Affected airplanes after Line Number 1503 will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page.
DESCRIPTIONCONFIGURATIONGROUP 777-200 airplanes, line numbers 1 through 400, with built-up longeron without center wing fuel tank.
-1 777-200 airplanes, line numbers 1 through 400, with built-up longeron and center wing fuel tank.
-2 777-200 airplanes, line numbers 401 through 629, with machined longeron and without center wing fuel tank.
-3 777-200 airplanes, line numbers 401 through 629, with machined longeron and center wing fuel tank.
-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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DESCRIPTIONCONFIGURATIONGROUP 777-200 airplanes, line numbers 630 and on, with extra tabs on machined longeron and without center wing fuel tank.
-5 777-200 airplanes, line numbers 630 and on, with extra tabs on machined longeron and center wing fuel tank.
-6 777-200LR, line numbers 401 through 629, with machined longeron.-7 777-200LR and 777F airplanes, line numbers 630 and on, with extra tabs on machined longeron.
-8 777-300 airplanes, line numbers 1 through 400, with built-up longeron.-9 777-300 airplanes, line numbers 401 through 629, with machined longeron.
-10 777-300ER airplanes, line numbers 401 through 629, with machined longeron.
-11 777-300ER airplanes, line numbers 630 and on, with extra tabs on machined longeron.
-12 Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER, 777F GroupVariable Number 1WA001 - WA017 1WA076 - WA080 1WA086 - WA093 1WA101 - WA104 1WA116 - WA119 1WA131 - WA137 1WA171 - WA175 1WA196 - WA198 1WA206 - WA212 1WA221 - WA223 1WA231 - WA232 1WA241 - WA250 1WA261 - WA266 3WA281 - WA282 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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