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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-57A0069 Original Issue: November 05, 2009 ATA System: 5725 SUBJECT: WINGS - Outer Wing - Skins - Lower Wing Skin at Fuel Tank Access Door Cutout Keyway - Inspection and Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009 777-57A0069 1 of 30
6.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 1 B. Concurrent Requirements ...................................... 1 1 C. Reason ................................................ 1 1 D. Description .............................................. 1 2 E. Compliance .............................................. 1 2 F. Approval ............................................... 1 4 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 5 J. References .............................................. 1 5
1. Existing Data .......................................... 1 5
2. Data supplied with this Service Bulletin ............................ 1 5
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 5 K. Publications Affected ........................................ 1 5 L. Interchangeability and Intermixability of Parts ........................... 1 6
2. MATERIAL INFORMATION ........................................ 1 7 A. Material - Price and Availability ................................... 1 7 B. Industry Support Information .................................... 1 7 C. Parts Necessary For Each Airplane ................................. 1 7
1. Kits/Parts ............................................ 1 7
2. Parts and Materials Supplied by the Operator ........................ 1 7
3. Parts Modified and Reidentified ................................ 1 7
4. Parts Removed and Not Replaced .............................. 1 7 D. Parts Necessary to Change Spares ................................. 1 7 E. Special Tooling - Price and Availability ............................... 1 8 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 9 A. GENERAL INFORMATION ..................................... 1 9 B. WORK INSTRUCTIONS ....................................... 1 9 FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION ......... 2 1 FIGURE 2: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION ........ 2 3 FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE . . . 25 FIGURE 4: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE . . 28
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009 777-57A0069 3 of 30 BOEING SERVICE BULLETIN 777-57A0069
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-57A0069Original Issue: November 05, 2009 ATA System: 5725 SUBJECT: WINGS - Outer Wing - Skins - Lower Wing Skin at Fuel Tank Access Door Cutout Keyway - Inspection and Change
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 The inspection and change in this service bulletin will detect and help prevent cracks in the lower wing skins.
Cracks in the lower wing skin, if left undetected could result in the catastrophic structural failure of the wings.
Three operators have reported finding seven cracks, ranging from 0.02 to 0.380 inches in length, emanating from the keyway of the wing lower skin access panel cutout between wing rib numbers 8 and 9. See service history table in Paragraph 1.C., Reason. The keyway is found on 777-200LR and 777-300ER airplanes at this location as the access door has a fuel measuring stick installed. The keyway is used to ensure that the fuel measuring stick is oriented properly in the access door cutout. The crack is believed to be the result of fatigue due to the position of the keyway. After the crack initiates, if it grows unchecked, it could result in the loss of the lower wing skin load path. The loss of the lower wing skin load path could result in the catastrophic structural failure of the wing.
Inspection of the keyway will detect cracks in the keyway before the cracks can grow to the point the lower wing skin load path is lost. Changing the profile of the keyway will improve the fatigue characteristics of the keyway which will help prevent cracks in the future. The change in the profile of the keyway can also be used to repair cracks up to 0.050 inch in length.
If any crack is found that is greater than 0.45 inch in length, skin panel replacement may be required. Skin panel replacement would require significant manpower and extended downtime.
Boeing Service Related Problem (SRP) 777-SRP-57-0222 is related to this service bulletin.
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Original Issue: November 05, 2009 777-57A0069 5 of 30
ACTION Drain and purge the main fuel tanks. Remove the access panel between rib numbers 8 (Wing Station (W.S.)
387) and rib 9 (W.S. 414.5). Do a High Frequency Eddy Current (HFEC) inspection of the keyway in the access door cutout for cracks. If no crack is found or any crack found is 0.050 inch in length or less, change the profile of the keyway to obtain a larger radius and remove the crack, if present. If any crack greater than 0.050 inch is found, contact The Boeing Company for repair instructions and do the repair. Install the access panel.
EFFECTIVITY 777-200LR and 777-300ER Airplanes. Refer to Paragraph 1.A., Effectivity 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.
See Paragraph 1.E., Compliance for compliance information.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of May 1, 2008. Please refer to Paragraph
2.B., Industry Support Information.
MANPOWER Elapsed HoursTotal Task Hours
12.5032.00
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009 777-57A0069 6 of 30 BOEING SERVICE BULLETIN 777-57A0069
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BOEING SERVICE BULLETIN 777-57A0069
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LEFT WING SHOWN, RIGHT WING OPPOSITE
ACCESS DOOR CUTOUT KEYWAY
CLAMP RING PART 1:
DO A HIGH FREQUENCY EDDY CURRENT
INSPECTION OF THE ESS DOOR
CUTOUT KEYWAY FOR CRACKS \ PART 2:
CHANGE PROFILE OF THE ACCESS DOOR
CUTOUT KEYWAY TO OBTAIN LARGER
RADIUS AND REMOVE CRACKS IF PRESENT.
FWD 1662485 Original Issue: November 05, 2009 777-57A0069 Copyright © Unpublished Work - See page 1 for details. BOEING PROPRIETARY - 7 of 30
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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-57A0069 Original Issue: November 05, 2009 ATA System: 5725 SUBJECT: WINGS - Outer Wing - Skins - Lower Wing Skin at Fuel Tank Access Door Cutout Keyway - Inspection and Change
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below.
Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 777-200LR and 777-300ER Airplanes line numbers 466 through 713, except line numbers 488, 511, 521, 527, 529, 535, 536, 539, 540, 542, 549, 551, 556, 557, 560, 568, 569, 571, 576, 577, 578, 582, 585, 590, 594, 598, 619, 622, 628, 641, 673, and 701.
-1 Airplanes which the access door cutout keyway was not changed to the dimension in Figure 3 or Figure 4 of this service bulletin or were not High Frequency Eddy Current (HFEC) inspected prior to being changed.
1 Airplanes which the access door cutout keyway was High Frequency Eddy Current (HFEC) inspected and changed to the dimension shown in Figure 3 or Figure 4 this service bulletin.
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Original Issue: November 05, 2009 777-57A0069 9 of 30
DESCRIPTIONCONFIGURATIONGROUP 777-300ER Airplanes line numbers 423, 429, 488, 511, 521, 527, 529, 535, 536, 539, 540, 542, 549, 551, 556, 557, 560, 568, 569, 571, 576, 577, 578, 582, 585, 590, 594, 598, 619, 622, 628, 641, 673, and 701. These airplanes had the access door cutout keyway High Frequency Eddy Current (HFEC) inspected and were changed to the dimension shown in Figure 3 or Figure 4 this service bulletin or were repaired prior to the release of the original issue of this service bulletin.
-2 Airplane Models:
777-200LR, 777-300ER GroupVariable Number 1WD001 - WD002 1WD011 - WD015 1WD031 - WD036 1WD046 - WD049 1WD066 - WD067 2WD501 - WD505 1WD506 - WD507 1WD521 - WD537 1WD546 - WD552 2WD561 - WD565 1WD566 - WD572 1WD581 - WD583 2WD584 - WD591 1WD592 - WD594 2WD606 - WD609 1WD621 - WD622 2WD623 - WD632 1WD651 - WD659 1WD671 - WD675 1WD691 - WD700 2WD701 - WD702 1WD703 - WD705
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Original Issue: November 05, 2009 777-57A0069 10 of 30 BOEING SERVICE BULLETIN 777-57A0069
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GroupVariable Number 1WD741 - WD747 1WD761 - WD770 1WD786 - WD788 1WD796 - WD802 1WD826 - WD829 1WD846 - WD848 1WD871 - WD872 1WD911 - WD912
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason The inspection and change in this service bulletin will detect and help prevent cracks in the lower wing skins. Cracks in the lower wing skin, if left undetected could result in could result in the catastrophic structural failure of the wings.
Three operators have reported finding seven cracks, ranging from 0.02 to 0.380 inches in length, emanating from the keyway of the wing lower skin access panel cutout between wing rib numbers 8 and 9. See service history table below. The keyway is found on 777-200LR and 777-300ER airplanes at this location as the access door has a fuel measuring stick installed. The keyway is used to ensure that the fuel measuring stick is oriented properly in the access door cutout. The crack is believed to be the result of fatigue due to the position of the keyway. After the crack initiates, if it grows unchecked, it could result in the loss of the lower wing skin load path. The loss of the lower wing skin load path could result in the catastrophic structural failure of the wing.
Service History Crack Length - Inches (Approximate) Flight-Hours (Approximate) Flight-Cycles (Approximate)Report
0.12612,60012501
0.02015,45015002
0.06711,75015503
0.02615,00017004
0.07813,20021005
0.25015,15026006
0.38015,05031007
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Original Issue: November 05, 2009 777-57A0069 11 of 30 BOEING SERVICE BULLETIN 777-57A0069
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Inspection of the keyway will detect cracks in the keyway before the cracks can grow to the point the lower wing skin load path is lost. Changing the profile of the keyway will improve the fatigue characteristics of the keyway which will help prevent cracks in the future. The change in the profile of the keyway can also be used to repair cracks up to 0.050 inch in length.
If any crack is found that is greater than 0.45 inch in length, skin panel replacement may be required.
Skin panel replacement would require significant manpower and extended downtime.
Boeing Service Related Problem (SRP) 777-SRP-57-0222 is related to this service bulletin.
D. Description Drain and purge the main fuel tanks. Remove the access panel between rib number 8 (Wing Station (W.S.) 387) and rib 9 (W.S. 414.5). Do a High Frequency Eddy Current (HFEC) inspections of the keyway in the access door cutout for cracks. If no crack is found or any crack found is 0.050 inch in length or less, change the profile of the keyway to obtain a larger radius and remove the crack, if present. If any crack greater than 0.050 inch is found, contact The Boeing Company for repair instructions and do the repair. Install the access panel.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 533, 633777-200LR, 777-300ER Group 2:
Affected Maintenance Zones ZoneModel 533, 633777-300ER E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Accomplish Part 1 - Fuel Access Door Cutout Keyway Inspection and Part 2 - Fuel Access Door Cutout Keyway Change, as required in Tables 1 below in accordance with Paragraph 3., Accomplishment Instructions.
NOTE: If allowed by Table 1 below, operators should consider accomplishment of this service bulletin within 750 days after the original issue date on the service bulletin to prevent cracks that would require significant manpower and extended downtime to repair.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009 777-57A0069 12 of 30 BOEING SERVICE BULLETIN 777-57A0069