# Boeing Alert Service Bulletin 777-57A0069: No revision named

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- Title as filed: U.S. DOT/FAA - Boeing Service Bulletin
- Pages: 30
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## Text

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### Page 1

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Unpublished Work - All Rights Reserved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.
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Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
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
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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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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.
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BOEING SERVICE BULLETIN 777-57A0069
ALERT  ALERT
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
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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.
2
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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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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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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.
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Group 1, Configuration 1:
Table 1: Fuel Access Door Cutout Keyway Inspection and Change
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 500
flight cycles af-
ter the original
issue date on
the service bul-
letin.
Before 3500 total
flight cycles since
the date of is-
suance of the origi-
nal certificate of
airworthiness or
the original export
certificate of airwor-
thiness.
Do a High Frequency Ed-
dy Current (HFEC) inspec-
tion of the access door
cutout keyway between
wing rib numbers 8 and 9
on the left and right wing
in accordance with Part 1
- Fuel Access Door Cutout
Keyway Inspection.
All Airplanes
--Before further
flight.
Change access door
cutout keyway between
wing rib numbers 8 and 9
on the left and right wing
in accordance with Part 2
- Fuel Access Door Cutout
Keyway Change.
Condition 1 -
No crack found
or
Any crack found is
0.050 inch or less
in length
--Before further
flight.
Contact The Boeing Com-
pany for repair instructions
and do the repair.
Condition 2 -
Any crack found
that is greater than
0.050 inch in
length.
Group 1, Configuration 2; Group 2:
Table 2: Fuel Access Door Cutout Keyway Inspection and Change
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs
Later)
ActionCondition
--No action is required. These
airplanes do not require an insur-
ance cut.
Airplanes on which no crack
was found in the cutout
keyway when the cutout
keyway was changed.
-Within 1125 days af-
ter the original issue
date on the service
bulletin.
Do a High Frequency Eddy
Current (HFEC) inspection of
the changed area in accordance
with Part 1 - Fuel Access Door
Cutout Keyway Inspection.
Airplanes on which a crack
was found in the cutout
keyway when the cutout
keyway was changed.
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Group 1, Configuration 2; Group 2:
Table 2: Fuel Access Door Cutout Keyway Inspection and Change
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs
Later)
ActionCondition
-Before further flightDo an insurance cut of the key-
way cutout in accordance with
Part 2 - Fuel Access Door
Cutout Keyway Change.
Condition 3 -
No crack found during Part
1 - Fuel Access Door
Cutout Keyway Inspection
-Before further flightContact The Boeing Company
for repair instructions and do the
repair.
Condition 4 -
Any crack found during Part
1 - Fuel Access Door
Cutout Keyway Inspection.
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.
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 table below shows an estimate of the task hours necessary to do this inspection and change 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.
Elapsed
Hours
Task
Hours
Number of
Persons
Task
4.7519.004Open Access
Inspect
1.001.001......Left wing - FIGURE 1
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Elapsed
Hours
Task
Hours
Number of
Persons
Task
1.001.001......Right wing - FIGURE 2
Change Keyway Profile
2.002.001......Left wing - FIGURE 3
2.002.001......Right wing - FIGURE 4
1.7574Close Access
12.5032.00TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data
a. Boeing Service Related Problem (SRP) 777-SRP-57-0222
b. Component Maintenance Manual (CMM) 20-10-03, 20-43-03
c. 777 Aircraft Maintenance Manual (AMM) 06-44-00, 28-11-00, 28-26-00
d. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01
2. Data supplied with this Service Bulletin
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin
None.
K. Publications Affected
1. Publications:
None.
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated 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 does not affect FCS, therefore DTIs are not necessary.
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L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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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 May 1, 2008. For inspection
task hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing
Commercial Airplanes Group - Warranties. 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 Commercial Airplanes Group - Warranties. Please refer to this service
bulletin number and reference the airplane variable numbers in your purchase order.
C. Parts Necessary For Each Airplane
1. Kits/Parts
None.
2. Parts and Materials Supplied by the Operator
The following parts or materials are necessary to do the change in this service bulletin. Parts and
materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine
operator supply to make sure all necessary parts and materials are available.
NotesNameQTYPart Number / Specifica-
tion
(b)Chemical Conversion Coating2 Oz.ALODINE 600
(a)Primer - Fuel Tank4 Oz.BMS 10-20, TYPE II
(a) See the Qualified Products List at the end of the Boeing Material Specification
(BMS) for supplier data.
(b) Refer to CMM 20-43-03 for supplier data.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
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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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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. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s)
give the recommended sequence of steps. The sequence of steps to do this service
bulletin can be changed.
2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
3. Obey all of the warnings and cautions given in the specified manual sections.
4. 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
5. Use the approved process material substitutions in accordance with the applicable
777 SRM, Chapter 51.
6. 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.
B. WORK INSTRUCTIONS
1. Defuel left and right main tanks. Refer to 777 AMM 28-26-00 as an accepted procedure.
2. Purge the left and right main tank and prepare for entry. Refer to 777 AMM 28-11-00 as an accepted
procedure.
3. Remove access panel 533AB (left wing) and 633AB (right wing). Refer to 777 AMM 06-44-00 and
777 AMM 28-11-00 as accepted procedures.
4. Do a High Frequency Eddy Current (HFEC) inspection of the left and right wing fuel access cutouts
between wing rib numbers 8 (Wing Station (W.S.).387) and 9 (W.S. 414.5) for cracks at the keyway
in accordance with Part 1 - Fuel Access Door Cutout Keyway Inspection.
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777-57A0069
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### Page 20

a. Group 1, Configuration 1:
Condition 1 - If no crack is found or any crack found is 0.050 inch or less in length, do Part 2
- Fuel Access Door Cutout Keyway Change at the time in Table 1 in Paragraph 1.E.,
Compliance.
b. Group 1, Configuration 1:
Condition 2 - If any crack found that is greater than 0.050 inch in length, contact the Boeing
Company for repair instructions and do the repair at the time in Table 1 in Paragraph 1.E.,
Compliance.
c. Group 1, Configuration 2; Group 2:
Condition 3 - If no crack is found during Part 1 - Fuel Access Door Cutout Keyway Inspection,
do an insurance cut of the keyway cutout in accordance with Part 2 - Fuel Access Door Cutout
Keyway Change at the time in Table 1 in Paragraph 1.E., Compliance.
d. Group 1, Configuration 2; Group 2:
Condition 4 - If any crack is found during Part 1 - Fuel Access Door Cutout Keyway Inspection,
contact The Boeing Company for repair instructions and do the repair at the time in Table 1
in Paragraph 1.E., Compliance.
5. Install access panel 533AB (left wing) and 633AB (right wing). Refer to 777 AMM 06-44-00 and
777 AMM 28-11-00 as accepted procedures.
6. Put the airplane back to a serviceable condition.
Part 1 - Fuel Access Door Cutout Keyway Inspection
1. Do a High Frequency Eddy Current inspection of the left wing access door cutout keyway for cracks
in accordance with FIGURE 1.
2. Do a High Frequency Eddy Current inspection of the right wing access door cutout keyway for
cracks in accordance with FIGURE 2.
Part 2 - Fuel Access Door Cutout Keyway Change
1. Change the profile of the left wing access door cutout keyway between wing rib numbers 8 (Wing
Station (W.S.) 387) and 9 (W.S. 414.5) in accordance with FIGURE 3.
2. Change the profile of the right wing access door cutout keyway between wing rib numbers 8 (Wing
Station (W.S.) 387) and 9 (W.S. 414.5) in accordance with FIGURE 4.
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009
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### Page 21 (OCR)

BOEING SERVICE BULLETIN 777-57A0069
ALERT  ALERT
200
ACCESS DOOR
CUTOUT
KEYWAY
CLAMP RING
1653095
FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION
(SHEET 1 OF 2)
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Copyright © Unpublished Work - See page 1 for details.  21 of 30

### Page 22

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a High Frequency Eddy Current
(HFEC) inspection of the indicated area
for cracks in accordance with 777 NDT
Part 6, 51-00-01, Procedure 1 or Proce-
dure 2.
--Access hole cutout
keyway
Inspect1
FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009
777-57A0069
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### Page 23 (OCR)

BOEING SERVICE BULLETIN 777-57A0069
ALERT  ALERT
5000oc
T000
ACCESS DOOR
CUTOUT
KEYWAY
CLAMP RING
1662380
FIGURE 2: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION
(SHEET 1 OF 2)
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Copyright © Unpublished Work - See page 1 for details.  23 of 30

### Page 24

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a High Frequency Eddy Current
(HFEC) inspection of the indicated area
for cracks in accordance with 777 NDT
Part 6, 51-00-01, Procedure 1 or Proce-
dure 2.
--Access hole cutout
keyway
Inspect1
FIGURE 2: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009
777-57A0069
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### Page 25 (OCR)

BOEING SERVICE BULLETIN 777-57A0069
ALERT  ALERT
200
OR B
ACCESS DOOR
CUTOUT
KEYWAY
CLAMP RING
1662391
FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE
(SHEET 1 OF 3)
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### Page 26 (OCR)

BOEING SERVICE BULLETIN 777-57A0069
ALERT  ALERT
3.0 R ( 1)
13.0 R
EDGE OF CLAMP
RING MILLSTEP
3.0 R
FWD
NO CRACK
FOUNL
TYPICAL CRACK
3.0R ( 1)
13.0 R
3) CUT  INSURANCE  EDGE OF CLAMP
0.050  0.025  RING MILLSTEP
MAXIMUM 0.020
3.0 R
FWD
ANY CRACK
FOUND
1662450
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE
(SHEET 2 OF 3)
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### Page 27

NOTE: Material of the wing panel is 2324 T-39 aluminum.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Machine the wing panel to obtain a 3.0
inch diameter radius at the keyway as
shown. Blend new radius into the exist-
ing cutout with a 3.0 inch return radius.
--Access hole cutout
keyway
Change1
If no crack is present align radius with
edge of existing keyway.
If, crack is present, move the radius up
to a maximum of 0.050 inch from the
keyway as required to remove the crack.
Maintain a 63 microinch or better surface
finish.
Do a High Frequency Eddy Current
(HFEC) inspection of the machined ar-
eas for cracks in accordance with 777
NDT Part 6, 51-00-01, Procedure 1 or
Procedure 2. If a crack is found, continue
to machine the radius up to a maximum
of 0.050 inch from the existing keyway
edge until crack is not found. If a crack
is found after the radius has been ma-
chined to the maximum of 0.050 inch
from the edge of the keyway, contact
The Boeing Company for additional in-
structions and do the repair.
--Access hole cutout
keyway
Inspect2
Insurance cut.--Access hole cutout
keyway
Change3
Machine an additional 0.020 to 0.025
inch from the keyway edge.
Maintain a 63 microinch or better surface
finish.
Break sharp edges.--Access hole cutout
keyway
Change4
Intensity: 0.004A to 0.012A.--Access hole cutout
keyway
Shot Peen5
Coverage: 2.0.
Shot peen machined edges. Refer to
SOPM 20-10-03 as an accepted proce-
dure.
Touch-up machined areas. Refer to
SOPM 20-43-03 as an accepted proce-
dure.
-ALODINE 600Chemical Conversion
Coating
Apply6
One coat to machined areas. Apply only
to machined edges, do not apply to sur-
face where the gasket seats.
-BMS 10-20, TYPE
II
Primer - Fuel TankApply
FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE
(SHEET 3 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009
777-57A0069
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### Page 28 (OCR)

BOEING SERVICE BULLETIN 777-57A0069
ALERT  ALERT
ACCESS DOOR
OR  CUTOUT
KEYWAY
CLAMP RING
1662458
FIGURE 4: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE
(SHEET 1 OF 3)
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### Page 29 (OCR)

BOEING SERVICE BULLETIN 777-57A0069
ALERT  ALERT
3.0 R 1
O 3.0 R
EDGE OF CLAMP
RING MILLSTEP
3.0 R (1)  2450 -
NO CRACK
FWD  FOUND
TYPICAL CRACK
3.0 R (1)
O 3.0 R
3 INSURANCE  CUT  EDGE OF CLAMP
1) 0.03  MAXIMUN  0.025  0.020  RING MILLSTEP
3.0 R 1  246€
FWD
ANY CRACK
FOUND
1662460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for one side of the airplane.
FIGURE 4: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE
(SHEET 2 OF 3)
Original Issue: November 05, 2009
BOEING PROPRIETARY -  777-57A0069
Copyright © Unpublished Work - See page 1 for details.  29 of 30

### Page 30

NOTE: Material of the wing panel is 2324 T-39 aluminum.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Machine the wing panel to obtain a 3.0
inch diameter radius at the keyway as
shown. Blend new radius into the exist-
ing cutout with a 3.0 inch return radius.
--Access hole cutout
keyway
Change1
If no crack is present align radius with
edge of existing keyway.
If, crack is present, move the radius up
to a maximum of 0.050 inch from the
keyway as required to remove the crack.
Maintain a 63 microinch or better surface
finish.
Do a High Frequency Eddy Current
(HFEC) inspection of the machined ar-
eas for cracks in accordance with 777
NDT Part 6, 51-00-01, Procedure 1 or
Procedure 2. If a crack is found, continue
to machine the radius up to a maximum
of 0.050 inch from the existing keyway
edge until crack is not found. If a crack
is found after the radius has been ma-
chined to the maximum of 0.050 inch
from the edge of the keyway, contact
The Boeing Company for additional in-
structions and do the repair.
--Access hole cutout
keyway
Inspect2
Insurance cut.--Access hole cutout
keyway
Change3
Machine an additional 0.020 to 0.025
inch from the keyway edge.
Maintain a 63 microinch or better surface
finish.
Break sharp edges.--Access hole cutout
keyway
Change4
Intensity: 0.004A to 0.012A.--Access hole cutout
keyway
Shot Peen5
Coverage: 2.0.
Shot peen machined edges. Refer to
SOPM 20-10-03 as an accepted proce-
dure.
Touch-up machined areas. Refer to
SOPM 20-43-03 as an accepted proce-
dure.
-ALODINE 600Chemical Conversion
Coating
Apply6
One coat to machined areas. Apply only
to machined edges, do not apply to sur-
face where the gasket seats.
-BMS 10-20, TYPE
II
Primer - Fuel TankApply
FIGURE 4: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE
(SHEET 3 OF 3)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2009
777-57A0069
30 of 30
BOEING SERVICE BULLETIN 777-57A0069
ALERTALERT

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