# Boeing Alert Service Bulletin 777-57A0087: Revision 1

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- Document: [Boeing Alert Service Bulletin 777-57A0087](https://openairdocs.org/service-documents/boeing/777-57a0087.md)
- Title as filed: U.S. DOT/FAA - Boeing Service Bulletin
- Pages: 68
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## Text

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### Page 1

Commercial 
Airplanes
777
Service Bulletin
ALERT
Number: 777-57A0087
Original Issue: November 11, 2010
ATA System: 5710
SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - Inspection
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 © 2010 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Unpublished Work - All Rights Reserved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 3
B. Concurrent Requirements ...................................... 1 3
C. Reason ................................................ 1 4
D. Description .............................................. 1 4
E. Compliance .............................................. 1 5
F. Approval ............................................... 1 6
G. Manpower .............................................. 1 6
H. Weight and Balance Changes .................................... 1 7
I. Electrical Load Data ......................................... 1 7
J. References .............................................. 1 7
1. Existing Data .......................................... 1 7
2. Data supplied with this Service Bulletin ............................ 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 8
K. Publications Affected ........................................ 1 8
L. Interchangeability and Intermixability of Parts ........................... 1 8
2. MATERIAL INFORMATION ........................................ 1 9
A. Material - Price and Availability ................................... 1 9
B. Industry Support Information .................................... 1 9
C. Parts Necessary For Each Airplane ................................. 1 9
1. Kits/Parts ............................................ 1 9
2. Parts and Materials Supplied by the Operator ........................ 1 9
3. Parts Modified and Reidentified ................................ 1 9
4. Parts Removed and Not Replaced .............................. 1 9
D. Parts Necessary to Change Spares ................................. 1 9
E. Special Tooling - Price and Availability ............................... 1 9
F. Special Tooling Necessary to do this Service Bulletin ....................... 1 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1
A. GENERAL INFORMATION ..................................... 2 1
B. WORK INSTRUCTIONS ....................................... 2 2
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 1] ............... 2 5
FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 1] ............... 3 0
FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 1] ............... 3 5
FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 2] ............... 4 0
FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 2] ............... 4 5
FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 2] ............... 5 0
APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB .............. 5 5
APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT
TO UPPER AND LOWER CHORD .............................. 5 9
APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL
STIFFENER .......................................... 6 4
APPENDIX D: SCOPE OF WORK ....................................... 6 8
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Commercial 
Airplanes
777
Service Bulletin
ALERT
SummaryNumber: 777-57A0087Original Issue: November 11, 2010
ATA System: 5710
SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - 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
Accomplishment of the inspections in this service bulletin will detect cracks in the Wing Center Section (WCS)
spanwise beams before the beam can not carry design load. Inability of the wing center section spanwise beam
to carry design loads could result in the loss of the wing center section load path. Loss of the wing center section
load path could result in the catastrophic loss of the outer wings.
There are three spanwise beams in the WCS. The beams are numbered from 1 to 3 starting from the aft beam.
These beams are used to stabilize the WCS and are considered primary structure. Two operators have reported
finding a crack in the WCS spanwise beam on two airplanes. In the first report, a 1.5 inch crack was found on
the web pocket of spanwise beam no. 3 at Right Buttock Line (RBL) 85.20. The airplane had approximately
5,600 flight cycles and approximately 34,500 flight hours. In the second report, a crack was found on the web
pocket of spanwise beam no. 3 at Right Buttock Line (RBL) 96.00. The airplane had approximately 8,500 flight
cycles and approximately 27,200 flight hours. Both were 777-200 airplanes with wet center sections. Other
airplane models and airplanes with dry center sections are included due to similar design. Metallurgical testing
of one of the cracked webs shows that the cracks were the result of fatigue from reverse bending (diagonal
tension buckling). If cracking at multiple locations occurs in multiple spanwise beams, the WCS spanwise beams
may not be able to carry design loads. This could result in the loss of the WCS load path. Loss of the WCS load
path could result in the catastrophic loss of the outer wings.
Inspection of the WCS spanwise beams web pockets will detect cracks before the WCS spanwise beams can
not carry design loads.
Boeing Service Related Problem (SRP) 777-SRP-57-0238 is related to this service bulletin.
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ACTION (PRR 62777-72S)
Drain center tank (airplanes with wet center sections). Purge and prepare center tank for entry (airplanes with
wet center sections). Remove the keel beam access door, the center section access door and the WCS spanwise
beam baffle doors. Do a detailed inspection (DET) and High Frequency Eddy Current (HFEC) Inspection of
selected web bays of Spanwise Beams numbers 1, 2, and 3 for cracks. Install the WCS spanwise beam baffle
doors, center section access door, and the keel beam access door.
EFFECTIVITY
777-200, -200LR, -300, -300ER, and 777F 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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection,and/or repair procedures given in this service
bulletin.
MANPOWER
Elapsed HoursTotal Task HoursAirplanes
19.5037.00Group 1 Airplanes
25.0050.00Group 2 airplanes
MATERIAL INFORMATION
None.
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BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
DETAILED INSPECTION
(DET)
DO A DET OF THE
FORWARD AND AFT
SIDE OF SELECTED
SPANWISE BEAM WEB
POCKETS FOR CRACKS
HIGH FREQUENCY EDDY
CURRENT INSPECTION
(HFEC)
DO AN HFEC INSPECTION
OF SELECTED WEB POCKET
FWD  RADII FOR CRACKS
SPANWISE BEAM
(3 LOCATIONS),
WING
CENTER
SECTION
ACCESS DOOR
139AZ
ACCESS PANEL  139AL  1998826
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Commercial 
Airplanes
777
Service Bulletin
ALERT
Number: 777-57A0087
Original Issue: November 11, 2010
ATA System: 5710
SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - 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
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent
production airplanes. Refer to PRR 62777-72S for data about this change.
Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line
Number, and Serial Number data.
NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below
is complete for airplanes through line number 919. At least one airplane after line number
919 is also affected by this service bulletin, and these airplanes are in Group(s) 1,2. 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.
DESCRIPTIONCONFIGURATIONGROUP
777-200 Airplanes with dry center section, line numbers 1 through
933.
-1
777-200 Airplanes with wet center sections (777-200ER), -200LR,
-300, -300ER, and 777F Airplanes line numbers 41 through 933.
-2
Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER, 777F
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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
1WA281 - WA283
1WA301 - WA304
2WB001 - WB021
2WB031 - WB046
2WB051 - WB088
2WB101 - WB106
2WB121 - WB125
2WB131 - WB148
2WB151 - WB155
2WB161 - WB177
2WB181 - WB194
2WB201 - WB215
2WB231 - WB247
2WB271 - WB273
2WB276 - WB286
2WB291 - WB302
2WB306 - WB307
2WB311 - WB337
2WB341 - WB342
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GroupVariable Number
2WB366 - WB368
2WB371 - WB388
2WB406
2WB411 - WB413
2WB416 - WB439
2WB446 - WB453
2WB476
2WB481 - WB484
2WB501 - WB512
2WB531 - WB537
2WB551 - WB554
2WB591 - WB597
2WB601 - WB606
2WB611 - WB622
2WB631 - WB638
2WB646 - WB649
2WC051 - WC073
2WC101 - WC104
2WC111 - WC120
2WC221 - WC224
2WC241 - WC243
2WC281 - WC290
2WC301 - WC308
2WC361 - WC364
2WC371 - WC374
2WC381 - WC395
2WC441
2WC446 - WC449
2WC456 - WC459
2WC486 - WC493
2WC506 - WC508
2WC521 - WC522
2WC531 - WC536
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GroupVariable Number
2WC546 - WC548
2WC556
2WC566 - WC567
2WC571 - WC574
2WC581
2WD001 - WD002
2WD011 - WD018
2WD031 - WD036
2WD046 - WD055
2WD066 - WD075
2WD081 - WD088
2WD091
2WD096
2WD101 - WD103
2WD501 - WD513
2WD521 - WD541
2WD546 - WD554
2WD561 - WD573
2WD581 - WD599
2WD606 - WD609
2WD621 - WD632
2WD651 - WD665
2WD671 - WD676
2WD691 - WD709
2WD741 - WD752
2WD761 - WD771
2WD786 - WD788
2WD796 - WD813
2WD826 - WD837
2WD846 - WD861
2WD871 - WD883
2WD911 - WD915
2WD921 - WD922
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GroupVariable Number
2WD936 - WD939
2WD946 - WD951
2WD966 - WD970
2WD981 - WD982
2WD986 - WD987
2WD996
2WE001 - WE004
2WE011 - WE012
2WE021 - WE025
2WE031
2WE051 - WE052
2WE071
2WE081 - WE082
2WE126 - WE133
2WF001 - WF004
2WF016 - WF020
2WF031 - WF032
2WF046 - WF054
2WF076 - WF077
2WF081 - WF088
2WF096 - WF099
2WF106 - WF107
2WF111 - WF112
2WF121
2. Spares Affected
None.
B. Concurrent Requirements
None.
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C. Reason
Accomplishment of the inspections in this service bulletin will detect cracks in the Wing Center Section
(WCS) spanwise beams before the beam can not carry design load. Inability of the wing center section
spanwise beam to carry design loads could result in the loss of the wing center section load path. Loss
of the wing center section load path could result in the catastrophic loss of the outer wings.
There are three spanwise beams in the WCS. The beams are numbered from 1 to 3 starting from the
aft beam. These beams are used to stabilize the WCS and are considered primary structure. Two
operators have reported finding a crack in the WCS spanwise beam on two airplanes. In the first report,
a 1.5 inch crack was found on the web pocket of spanwise beam no. 3 at Right Buttock Line (RBL)
85.20. The airplane had approximately 5,600 flight cycles and approximately 34,500 flight hours. In
the second report, a crack was found on the web pocket of spanwise beam no. 3 at Right Buttock Line
(RBL) 96.00. The airplane had approximately 8,500 flight cycles and approximately 27,200 flight hours.
Both were 777-200 Airplanes with wet center sections. Other airplane models and airplanes with dry
center sections are included due to similar design. Metallurgical testing of one of the cracked webs
shows that the cracks were the result of fatigue from reverse bending (diagonal tension buckling). If
cracking at multiple locations occurs in multiple spanwise beams, the WCS spanwise beams may not
be able to carry design loads. This could result in the loss of the WCS load path. Loss of the WCS load
path could result in the catastrophic loss of the outer wings.
Inspection of the WCS spanwise beams web pockets will detect cracks before the WCS spanwise
beams can not carry design loads.
Boeing Service Related Problem (SRP) 777-SRP-57-0238 is related to this service bulletin.
D. Description
Drain center tank (airplanes with wet center sections). Purge and prepare center tank for entry (airplanes
with wet center sections). Remove the keel beam access door, the center section access door and the
WCS spanwise beam baffle doors. Do a detailed inspection (DET) and High Frequency Eddy Current
(HFEC) Inspection of selected web bays of Spanwise Beams numbers 1, 2, and 3 for cracks. Install
the WCS spanwise beam baffle doors, center section access door, and the keel beam access door.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
133, 134777-200
Group 2:
Affected Maintenance Zones
ZoneModel
133, 134777-200, 777-200LR, 777-300,
777-300ER, 777F
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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.
Do the actions below in accordance with paragraph 3. Accomplishment Instructions.
Accomplish the actions and evaluate the conditions in Table 1 separately for each spanwise beam and
affected bay in each spanwise beam.
TABLE 1: PART 1 - INSPECTION
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
-Within 6,000
flight cycles or
1,125 days,
whichever oc-
curs first, after
the original issue
date of this ser-
vice bulletin.
Before 8,000
total flight cy-
cles.
Do a Detailed Inspection (DET) and a High
Frequency Eddy Current Inspection (HFEC)
of the Wing Center Section (WCS) Spanwise
Beam web pockets for cracks in accordance
with Part 1 - Inspection.
All Airplanes
8,000 flight
cycles.
--Repeat DET and a HFEC inspection of the
WCS Spanwise Beam web pockets for
cracks in accordance with Part 1 - Inspec-
tion.
No crack is found.
---Do 1) or 2)1) Any crack, 1.5
inch or less, is
found; and 2) no
crack is found in
a repair (if repair
is installed).
Before further
flight.
1) Repair in accordance with Appendix
A, B, or C.
or
Before further
flight.
2) Contact The Boeing Company for re-
pair instructions and do the repair.
and
8,000 flight
cycles.
--Repeat DET and a HFEC inspection of the
WCS Spanwise Beam web pockets for
cracks in accordance with Part 1 - Inspec-
tion.
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TABLE 1: PART 1 - INSPECTION
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time (Whichever
Occurs Later)
ActionCondition
--Before further
flight.
Contact The Boeing Company for repair in-
structions and do the repair.
1) Any crack,
greater than 1.5
inch, is found; or
2) Any crack is
found in a repair
(if repair is in-
stalled).
and
8,000 flight
cycles.
--Repeat DET and a HFEC inspection of the
WCS Spanwise Beam web pockets for
cracks in accordance with Part 1 - Inspec-
tion.
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 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 1:
Elapsed HoursTask HoursNumber of Per-
sons
Task
1.001.001Open Access
Inspect
7.2514.502...Spanwise Beam No. 1 - FIGURE 1
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Group 1:
Elapsed HoursTask HoursNumber of Per-
sons
Task
4.759.502...Spanwise Beam No. 2 - FIGURE 2
5.5011.002...Spanwise Beam No. 3 - FIGURE 3
1.001.001Close Access
19.5037.00TOTAL FOR EACH AIRPLANE
Group 2:
Elapsed HoursTask HoursNumber of PersonsTask
1.004.004Defuel Center Tank
3.006.002Purge and Prepare Center Tank for En-
try
1.001.001Open Access
Inspect
7.2514.502...Spanwise Beam No. 1 - FIGURE 4
4.759.502...Spanwise Beam No. 2 - FIGURE 5
5.5011.002...Spanwise Beam No. 3 - FIGURE 6
1.503.002Close Access
1.001.001Test
25.0050.00TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
J. References
1. Existing Data
a. Engineering Change Memo PRR 62777-72S
b. Boeing Service Letter 777-SL-51-013
c. Boeing Service Related Problem (SRP) 777-777-57-0238
d. Standard Overhaul Practices Manual (SOPM) 20-43-03
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e. 777 Aircraft Maintenance Manual (AMM) 06-41-00, 28-11-00, 28-11-02, 28-11-04, 28-26-00,
51-21-10
f. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01
g. 777-200 Structural Repair Manual (SRM) 51-40-05, 51-70-13
h. 777-300 Structural Repair Manual (SRM) 51-40-05, 51-70-13
i. 777F Structural Repair Manual (SRM) 51-40-05, 51-70-13
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 the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected
are contained in Paragraph 1.E., Compliance of this service bulletin.
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 not available for the inspection, and/or repair procedures given in this
service bulletin.
C. Parts Necessary For Each Airplane
1. Kits/Parts
None.
2. Parts and Materials Supplied by the Operator
None.
3. Parts Modified and Reidentified
None.
4. Parts Removed and Not Replaced
None.
D. Parts Necessary to Change Spares
None.
E. Special Tooling - Price and Availability
None.
F. Special Tooling Necessary to do this Service Bulletin
No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance
and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine
operator tool supply to make sure all necessary tools are available.
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### Page 21

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
– 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 are in 777 Structural Repair Manual
(SRM) 51
– Torque limits to tighten nuts and bolts are in 777 SRM 51
5. Use the approved fastener and process material substitutions in accordance with
777 SRM 51. Alternate fasteners are listed in 777 SRM 51 and Boeing Drawing
012W6100.
6. If the length of any fastener specified in this service bulletin does not meet the
installation standards in 777 SRM 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards in 777
SRM 51 may be used.
7. A Detailed Inspection (DET) 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 access procedures may be required.
8. 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.
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9. 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.
10. 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. Refer to
777-200 SRM 51-70-13, 777-300 SRM 51-70-13, or 777F SRM 51-70-13 for typical
web repairs and for guidance when submitting repairs to The Boeing Company.
11. Accomplish the actions and evaluate the conditions separately for each spanwise
beam and affected bay in each spanwise beam.
12. See APPENDIX A for Repair - Crack (1.5 inch maximum) in Center of Web.
13. See APPENDIX B for Repair - Crack (1.5 inch maximum) at Top or Bottom Fillet
Radius Adjacent to Upper or Lower Chord.
14. See APPENDIX C for Repair - Crack (1.5 inch maximum) at Side Fillet Radius
Adjacent to Vertical Stiffener.
15. Refer to APPENDIX D for Scope of Work.
B. WORK INSTRUCTIONS
1. Do a DET and High Frequency Eddy Current Inspection (HFEC) of the Wing Center Section (WCS)
Spanwise Beams Numbers 1, 2, and 3 web pockets for cracks in accordance with Part 1 - Inspection
within the threshold in Paragraph 1.E., Compliance.
a. No crack is found - Repeat Part - 1 Inspection at the interval in Paragraph 1.E., Compliance.
b. 1) Any crack, 1.5 inch or less, is found; and 2) no crack is found in a repair (if repair is installed).
(1) Repair in accordance with one of the methods below within the threshold in Paragraph
1.E., Compliance.
(a) APPENDIX A, APPENDIX B, or APPENDIX C; or
(b) Contact the Boeing Company for repair instructions.
(2) Repeat DET and HFEC inspection of the WCS Spanwise Beams Numbers 1, 2, and 3
in accordance with Part - 1 Inspection at the interval in Paragraph 1.E., Compliance.
c. 1) Any crack, greater than 1.5 inch, is found; or 2) Any crack is found in a repair (if repair is
installed).
(1) Contact the Boeing Company for repair instructions and do the repair within the threshold
in Paragraph 1.E., Compliance.
(2) Repeat DET and HFEC inspection of the WCS Spanwise Beams Numbers 1, 2, and 3
in accordance with Part - 1 Inspection at the interval in Paragraph 1.E., Compliance.
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Part 1 - Inspection
1. Access
a. Group 2:
Defuel center tank. Refer to 777 AMM 28-26-00 as an accepted procedure.
b. Group 2:
Purge and prepare to enter center tank. Refer to 777 AMM 28-11-00 as an accepted procedure.
c. Remove the forward keel beam access panel 139AL. Refer to 777 AMM 06-41-00 for location
of these panels.
d. Remove the wing center section access door 139AZ. Refer to as 777 AMM 28-11-02 an
accepted procedure.
e. Remove the wing center section spanwise beam baffle doors 133AZ, 133BZ, 133CZ. Refer
to 777 AMM 28-11-04 as an accepted procedure.
2. Inspection
a. Do DET and HFEC inspections of WCS Spanwise Beams Number 1 in accordance with the
figure below:
Figure
Group 2 AirplanesGroup 1 Airplanes
FIGURE 4FIGURE 1
b. Do DET and HFEC inspections of WCS Spanwise Beams Number 2 in accordance with the
figure below:
Figure
Group 2 AirplanesGroup 1 Airplanes
FIGURE 5FIGURE 2
c. Do DET and HFEC inspections of WCS Spanwise Beams Number 3 in accordance with the
figure below:
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Figure
Group 2 AirplanesGroup 1 Airplanes
FIGURE 6FIGURE 3
3. Restoration
a. Install the wing center section spanwise beam baffle doors 133AZ, 133BZ, 133CZ. Refer to
777 AMM 28-11-04 as an accepted procedure.
b. Install the wing center section access door 139AZ. Refer to as 777 AMM 28-11-02 an accepted
procedure.
c. Install the forward keel beam access panel 139AL. Refer to 777 AMM 06-41-00 for location
of these panels.
4. Put the airplane back to a serviceable condition.
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BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
This Figure applies only to: Group 1.
FWD
SPANWISE BEAM
(3 LOCATIONS),
WING
CENTER
SECTION
ACCESS DOOR
139AZ
ACCESS PANEL  CTO00
139AL
ACCESS
DOOR 139AZ
SPANWISE BEAM
NUMBER 3
SPANWISE BEAM
NUMBER 2
• •
SPANWISE BEAM
NUMBER 1
OPENING
(3 LOCATIONS)
A-A  1998841
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 1 OF 5)
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### Page 26 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
LBL  SEE B-B  ‚SEE C-C  „SEE B-B SEE C-C  BL O
122.45
C
4  9
TYPICAL
CRACKS
INBD
# = WEB BAY NUMBER
BL O  SEE C-C SEE B-B SEE C-C  SEE B-B  RBL
122.45
10  11  12  13  14  15  16  17  18
# = WEB BAY NUMBER
INBD
AFT SIDE SPANWISE BEAM NUMBER 1, VIEW LOOKING FORWARD
(STIFFENERS NOT SHOWN, WEB ONLY)
1996786
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 2 OF 5)
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### Page 27 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
TANGENT LINE
0.50
TYPICAL
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  FASTENER
ROW  (TYPICAL)  ROW
B-B
W
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX -  • 1.00 MAX
CENTERLINE  CENTERLINE
ROW  FASTENER  (TYPICAL)  FASTENER  ROW  1996787
C-C
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 3 OF 5)
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### Page 28

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 each airplane.
NOTE: It is not necessary to remove any clips, brackets, doublers, or other parts from the beam. It
is not necessary to remove repairs performed in accordance with Appendix A, B, and C of
this Service Bulletin. These inspections only require inspection of what is visible and accessible.
1.
2. Group 1 - WCS Spanwise Beam No. 1 Inspection can be used as a guide to accomplishing
and recording the inspections.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a DET of the visible portions of the
indicated web pockets, including the
radius, from the aft side of the beam.
If repair is installed, do a DET of the
repair for cracks.
18-Web / Web PocketInspect1
Do a HFEC inspection of the accessi-
ble areas of the indicated web pockets
adjacent to the radii in accordance with
777 NDT Part 6, 51-00-01.
8-Web / Web PocketInspect2
Do a DET of the visible portions of the
indicated web pockets between the
upper and lower chords from the for-
ward side of the beam. Use the fasten-
er lines of the stiffeners installed on
the aft side to locate the bay. If repair
is installed, do a DET of the repair for
cracks.
18-Web / Web PocketInspect3
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 4 OF 5)
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### Page 29

GROUP 1 - WCS SPANWISE BEAM NUMBER 1 - INSPECTION
Date:Airplane:
DET
(FWD Side)
Step 3
HFEC
(Web Pocket Radius)
Step 2
DET
(Aft Side)
Step 1
Web Pocket
Thickness
(inches)Web Pocket
Left Side of Airplane
0.0651
0.0652
Not Applicable0.0653
Not Applicable0.0604
0.0555
0.0556
Not Applicable0.0507
Not Applicable0.0508
Not Applicable0.0509
Right Side of Airplane
Not Applicable0.05010
Not Applicable0.05011
Not Applicable0.05012
0.05513
0.05514
Not Applicable0.06015
Not Applicable0.06516
0.06517
0.06518
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 5 OF 5)
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BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
This Figure applies only to: Group 1.
FWD
SPANWISE BEAM
(3 LOCATIONS),
WING
CENTER
SECTION
ACCESS DOOR
139AZ
ACCESS PANEL
139AL
ACCESS
DOOR 139AZ
SPANWISE BEAM
NUMBER 3
SPANWISE BEAM
NUMBER 2
SPANWISE BEAM
NUMBER 1
• OPENING
(3 LOCATIONS)
A-A  1999310
FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 1 OF 5)
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
122.45  LBL  SEE C-C  SEE B-B SEE B-B  BL O
TYPICAL
CRACKS
6
TYPICAL
CRACKS
# = WEB BAY NUMBER
SEE B-B SEE B-B SEE C-C  RBL
122.45
9  10  12
# = WEB BAY NUMBER
AFT SIDE SPANWISE BEAM NUMBER 2, VIEW LOOKING FORWARD  INBD
(STIFFENERS NOT SHOWN, WEB ONLY)
1999331
FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 2 OF 5)
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### Page 32 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
TANGENT LINE
0.50
TYPICAL
D
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  FASTENER
ROW  (TYPICAL)  ROW
B-B
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX -  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  ROW  (TYPICAL)  FASTENER  ROW  1999335
C-C
FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 3 OF 5)
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### Page 33

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 each airplane.
NOTE: It is not necessary to remove any clips, brackets, doublers, or other parts from the beam. It
is not necessary to remove repairs performed in accordance with Appendix A, B, and C of
this Service Bulletin. These inspections only require inspection of what is visible and accessible.
1.
2. Group 1 - WCS Spanwise Beam No. 2 Inspection can be used as a guide to accomplishing
and recording the inspections.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a DET of the visible portions of the
indicated web pockets, including the
radius, from the aft side of the beam.
If repair is installed, do a DET of the
repair for cracks.
12-Web / Web PocketInspect1
Do a HFEC inspection of the accessi-
ble areas of the indicated web pockets
adjacent to the radii in accordance with
777 NDT Part 6, 51-00-01.
8-Web / Web PocketInspect2
Do a DET of the visible portions of the
indicated web pockets between the
upper and lower chords from the for-
ward side of the beam. Use the fasten-
er lines of the stiffeners installed on
the aft side to locate the bay. If repair
is installed, do a DET of the repair for
cracks.
12-Web / Web PocketInspect3
FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 4 OF 5)
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GROUP 1 - WCS SPANWISE BEAM NUMBER 2 - INSPECTION
Date:Airplane:
DET
(FWD Side)
Step 3
HFEC
(Web Pocket Radius)
Step 2
DET
(Aft Side)
Step 1
Web Pocket
Thickness
(inches)Web Pocket
Left Side of Airplane
Not Applicable0.0601
Not Applicable0.0602
0.0553
0.0504
0.0505
0.0506
Right Side of Airplane
0.0507
0.0508
0.0509
0.05510
Not Applicable0.06011
Not Applicable0.06012
FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 5 OF 5)
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### Page 35 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
This Figure applies only to: Group 1.
FWD
SPANWISE BEAM
(3 LOCATIONS),
WING
CENTER
SECTION
ACCESS DOOR
139AZ
ACCESS PANEL  CTO00
139AL
ACCESS
DOOR 139AZ
SPANWISE BEAM
NUMBER 3
SPANWISE BEAM
NUMBER 2
• •
SPANWISE BEAM
NUMBER 1
OPENING
(3 LOCATIONS)
W  A-A  1999337
FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 1 OF 5)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
LBL  SEE B-BSEE B-B  SEE C
122.45
2
TYPICAL
CRACKS
# = WEB BAY NUMBER
SEE B-B  SEE B-B  RBL
122.45
10  11  12  13  14
# = WEB BAY NUMBER
AFT SIDE SPANWISE BEAM NUMBER 3, VIEW LOOKING FORWARD  INBD
(STIFFENERS NOT SHOWN, WEB ONLY)
FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 2 OF 5)
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### Page 37 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
TANGENT LINE
0.50
TYPICAL
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  FASTENER
ROW  (TYPICAL)  ROW
B-B
W
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX -  • 1.00 MAX
CENTERLINE  CENTERLINE
ROW  FASTENER  (TYPICAL)  FASTENER  ROW  1999385
C-C
FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 3 OF 5)
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### Page 38

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 each airplane.
NOTE: It is not necessary to remove any clips, brackets, doublers, or other parts from the beam. It
is not necessary to remove repairs performed in accordance with Appendix A, B, and C of
this Service Bulletin. These inspections only require inspection of what is visible and accessible.
1.
2. Group 1 - WCS Spanwise Beam No. 3 Inspection can be used as a guide to accomplishing
and recording the inspections.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a DET of the visible portions of the
indicated web pockets, including the
radius, from the aft side of the beam.
If repair is installed, do a DET of the
repair for cracks.
14-Web / Web PocketInspect1
Do a HFEC inspection of the accessi-
ble areas of the indicated web pockets
adjacent to the radii in accordance with
777 NDT Part 6, 51-00-01.
8-Web / Web PocketInspect2
Do a DET of the visible portions of the
indicated web pockets between the
upper and lower chords from the for-
ward side of the beam. Use the fasten-
er lines of the stiffeners installed on
the aft side to locate the bay. If repair
is installed, do a DET of the repair for
cracks.
14-Web / Web PocketInspect3
FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 4 OF 5)
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### Page 39

GROUP 1 - WCS SPANWISE BEAM NUMBER 3 - INSPECTION
Date:Airplane:
DET
(FWD Side)
Step 3
HFEC
(Web Pocket Radius)
Step 2
DET
(Aft Side)
Step 1
Web Pocket
Thickness
(inches)Web Pocket
Left Side of Airplane
0.0501
0.0502
0.0503
0.0504
Not Applicable0.0505
Not Applicable0.0506
Not Applicable0.0507
Right Side of Airplane
Not Applicable0.0508
Not Applicable0.0509
Not Applicable0.05010
0.05011
0.05012
0.05013
0.05014
FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 5 OF 5)
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### Page 40 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
This Figure applies only to: Group 2.
FWD
SPANWISE BEAM
(3 LOCATIONS),
WING
CENTER
SECTION
ACCESS DOOR
139AZ
ACCESS PANEL
139AL
ACCESS
DOOR 139AZ
SPANWISE BEAM
NUMBER 3
SPANWISE BEAM
NUMBER 2
SPANWISE BEAM
NUMBER 1
• OPENING
(3 LOCATIONS)
A-A  1999454
FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 1 OF 5)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
LBL  SEE B-B  _SEE C-C  SEE B-B  SEE C-C  BLO
122.45
БА
B
4  6B  8  9
6C
TYPICAL
CRACKS
INBD
# = WEB BAY NUMBER
BL O  SEE C-C SEE B-B  SEE C-C  SEE B-B  RBL
122.45
18A
•
11  12  13B  14  15  16  17  18B
13C
18C
# = WEB BAY NUMBER
INBD
AFT SIDE SPANWISE BEAM NUMBER 1, VIEW LOOKING FORWARD
(STIFFENERS NOT SHOWN, WEB ONLY)
FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 2 OF 5)
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### Page 42 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
TANGENT LINE
0.50
TYPICAL
D
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  FASTENER
ROW  (TYPICAL)  ROW
B-B
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX -  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  ROW  (TYPICAL)  FASTENER  ROW  1999483
C-C
FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 3 OF 5)
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### Page 43

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 each airplane.
NOTE: It is not necessary to remove any clips, brackets, doublers, or other parts from the beam. It
is not necessary to remove repairs performed in accordance with Appendix A, B, and C of
this Service Bulletin. These inspections only require inspection of what is visible and accessible.
1.
2. Group 2 - WCS Spanwise Beam No. 1 Inspection can be used as a guide to accomplishing
and recording the inspections.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a DET of the visible portions of the
indicated web pockets, including the
radius, from the aft side of the beam.
If repair is installed, do a DET of the
repair for cracks.
26-Web / Web PocketInspect1
Do a HFEC inspection of the accessi-
ble areas of the indicated web pockets
adjacent to the radii in accordance with
777 NDT Part 6, 51-00-01.
16-Web / Web PocketInspect2
Do a DET of the visible portions of the
indicated web pockets between the
upper and lower chords from the for-
ward side of the beam. Use the fasten-
er lines of the stiffeners installed on
the aft side to locate the bay. If repair
is installed, do a DET of the repair for
cracks.
26-Web / Web PocketInspect3
FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 4 OF 5)
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BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 44

GROUP 2 - WCS SPANWISE BEAM NUMBER 1 - INSPECTION
Date:Airplane:
DET
(FWD Side)
Step 3
HFEC
(Web Pocket Radius)
Step 2
DET
(AFT Side)
Step 1
Web Pocket
Thickness
(inches)Web Pocket
Left Side of Airplane
0.0651A
0.0651B
0.0651C
0.0652
Not Applicable0.0653
Not Applicable0.0604
0.0555
0.0556A
0.0556B
0.0556C
Not Applicable0.0507
Not Applicable0.0508
Not Applicable0.0509
Right Side of Airplane
Not Applicable0.05010
Not Applicable0.05011
Not Applicable0.05012
0.05513A
0.05513B
0.05513C
0.05514
Not Applicable0.06015
Not Applicable0.06516
0.06517
0.06518A
0.06518B
0.06518C
FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION
(SHEET 5 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 11, 2010
777-57A0087
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BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 45 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
This Figure applies only to: Group 2.
FWD
SPANWISE BEAM
(3 LOCATIONS),
WING
CENTER
SECTION
ACCESS DOOR
139AZ
ACCESS PANEL  CTO00
139AL
ACCESS
DOOR 139AZ
SPANWISE BEAM
NUMBER 3
SPANWISE BEAM
NUMBER 2
• •
SPANWISE BEAM
NUMBER 1
OPENING
(3 LOCATIONS)
W  A-A  1999486
FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 1 OF 5)
Original Issue: November 11, 2010
777-57A0087
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  45 of 68

### Page 46 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
122.45  LBL  ‚SEE C-C  SEE B-B SEE B-B  BLO
TYPICAL
CRACKS  1B  4  6B
6C
INBD
# = WEB BAY NUMBER
BL 0  SEE B-B.  SEE B-B SEE C-C  RBL
122.45
I2A
7A
7B  9  10  11  12B
7C
# = WEB BAY NUMBER
AFT SIDE SPANWISE BEAM NUMBER 2, VIEW LOOKING FORWARD  INBD
(STIFFENERS NOT SHOWN, WEB ONLY)
FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 2 OF 5)
Original Issue: November 11, 2010
777-57A0087
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  46 of 68

### Page 47 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
TANGENT LINE
0.50
TYPICAL
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  FASTENER
ROW  (TYPICAL)  ROW
B-B
W
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX -  • 1.00 MAX
CENTERLINE  CENTERLINE
ROW  FASTENER  (TYPICAL)  FASTENER  ROW  1999540
C-C
FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 3 OF 5)
Original Issue: November 11, 2010
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### Page 48

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 each airplane.
NOTE: It is not necessary to remove any clips, brackets, doublers, or other parts from the beam. It
is not necessary to remove repairs performed in accordance with Appendix A, B, and C of
this Service Bulletin. These inspections only require inspection of what is visible and accessible.
1.
2. Group 2 - WCS Spanwise Beam No. 2 Inspection can be used as a guide to accomplishing
and recording the inspections.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a DET of the visible portions of the
indicated web pockets, including the
radius, from the aft side of the beam.
If repair is installed, do a DET of the
repair for cracks.
20-Web / Web PocketInspect1
Do a HFEC inspection of the accessi-
ble areas of the indicated web pockets
adjacent to the radii in accordance with
777 NDT Part 6, 51-00-01.
12-Web / Web PocketInspect2
Do a DET of the visible portions of the
indicated web pockets between the
upper and lower chords from the for-
ward side of the beam. Use the fasten-
er lines of the stiffeners installed on
the aft side to locate the bay. If repair
is installed, do a DET of the repair for
cracks.
20-Web / Web PocketInspect3
FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 4 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 11, 2010
777-57A0087
48 of 68
BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 49

GROUP 2 - WCS SPANWISE BEAM NUMBER 2 - INSPECTION
Date:Airplane:
DET
(FWD Side)
Step 3
HFEC
(Web Pocket Radius)
Step 2
DET
(Aft Side)
Step 1
Web Pocket
Thickness
(inches)Web Pocket
Left Side of Airplane
Not Applicable0.0651A
Not Applicable0.0651B
Not Applicable0.0651C
Not Applicable0.0652
0.0603
0.0604
0.0605
0.0606A
0.0606B
0.0606C
Right Side of Airplane
0.0607A
0.0607B
0.0607C
0.0608
0.0609
0.06010
Not Applicable0.06511
Not Applicable0.06512A
Not Applicable0.06512B
Not Applicable0.06512C
FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION
(SHEET 5 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 11, 2010
777-57A0087
49 of 68
BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 50 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
This Figure applies only to: Group 2.
FWD
SPANWISE BEAM
(3 LOCATIONS),
WING
CENTER
SECTION
ACCESS DOOR
139AZ
ACCESS PANEL
139AL
ACCESS
DOOR 139AZ
SPANWISE BEAM
NUMBER 3
SPANWISE BEAM
NUMBER 2
SPANWISE BEAM
NUMBER 1
OPENING
(3 LOCATIONS)
A-A  1999541
FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 1 OF 5)
Original Issue: November 11, 2010
BOEING PROPRIETARY -  777-57A0087
Copyright © Unpublished Work - See page 1 for details.  50 of 68

### Page 51 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
LBL  SEE B-B  SEE B-B  SEE C-C
122.45
2B  4  7B
TYPICAL
CRACKS
# = WEB BAY NUMBER
SEE B-B  SEE B-B  RBL
122.45
8A
8B  9  10  11  12  13B  14
8C
# = WEB BAY NUMBER
AFT SIDE SPANWISE BEAM NUMBER 3, VIEW LOOKING FORWARD  INBD
(STIFFENERS NOT SHOWN, WEB ONLY)
FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 2 OF 5)
Original Issue: November 11, 2010
777-57A0087
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  51 of 68

### Page 52 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
TANGENT LINE
0.50
TYPICAL
D
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX  - 1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  FASTENER
ROW  (TYPICAL)  ROW
B-B
R 0.50
(TYPICAL ALL FILLETS)
1.00 MAX -  1.00 MAX
CENTERLINE  CENTERLINE
FASTENER  ROW  (TYPICAL)  FASTENER  ROW  1999543
C-C
FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 3 OF 5)
Original Issue: November 11, 2010
BOEING PROPRIETARY -  777-57A0087
Copyright © Unpublished Work - See page 1 for details.  52 of 68

### Page 53

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 each airplane.
NOTE: It is not necessary to remove any clips, brackets, doublers, or other parts from the beam. It
is not necessary to remove repairs performed in accordance with Appendix A, B, and C of
this Service Bulletin. These inspections only require inspection of what is visible and accessible.
1.
2. Group 2 - WCS Spanwise Beam No. 3 Inspection can be used as a guide to accomplishing
and recording the inspections.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
Do a DET of the visible portions of the
indicated web pockets, including the
radius, from the aft side of the beam.
If repair is installed, do a DET of the
repair for cracks.
22-Web / Web PocketInspect1
Do a HFEC inspection of the accessi-
ble areas of the indicated web pockets
adjacent to the radii in accordance with
777 NDT Part 6, 51-00-01.
12-Web / Web PocketInspect2
Do a DET of the visible portions of the
indicated web pockets between the
upper and lower chords from the for-
ward side of the beam. Use the fasten-
er lines of the stiffeners installed on
the aft side to locate the bay. If repair
is installed, do a DET of the repair for
cracks.
22-Web / Web PocketInspect3
FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 4 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 11, 2010
777-57A0087
53 of 68
BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 54

GROUP 2 - WCS SPANWISE BEAM NUMBER 3 - INSPECTION
Date:Airplane:
DET
(FWD Side)
Step 3
HFEC
(Web Pocket Radius)
Step 2
DET
(Aft Side)
Step 1
Web Pocket
Thickness
(inches)Web Pocket
Left Side of Airplane
0.0601
0.0602A
0.0602B
0.0602C
0.0603
0.0604
Not Applicable0.0555
Not Applicable0.0556
Not Applicable0.0557A
Not Applicable0.0557B
Not Applicable0.0557C
Right Side of Airplane
Not Applicable0.0558A
Not Applicable0.0558B
Not Applicable0.0558C
Not Applicable0.0559
Not Applicable0.05510
0.06011
0.06012
0.06013A
0.06013B
0.06013C
0.06014
FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION
(SHEET 5 OF 5)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 11, 2010
777-57A0087
54 of 68
BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 55 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
- EXISTING WEB
→ A
- CUTOUT
• FIELD
FASTENER 1
(TYPICAL)
• REPAIR DOUBLER
REPAIR
STIFFENERS
EXISTING
EXISTING FASTENER  2000451
LOCATION
APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB
(SHEET 1 OF 4)
Original Issue: November 11, 2010
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### Page 56 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
REPAIR  TYPICAL
STIFFENER  CUTOUT  CRACK
REPAIR
DOUBLER
REPAIR
EXISTING FASTENER  LOCATION  A-A  STIFFENER  2000452
APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB
(SHEET 2 OF 4)
Original Issue: November 11, 2010
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Copyright © Unpublished Work - See page 1 for details.  56 of 68

### Page 57

NOTE: Cutout cracked area.1.
– Cutout cracked area,1.94 inch maximum diameter, 0.94 inch minimum, before insurance
cut. Cutout does not need be round. 0.50 minimum radius on all corners
– Do a HFEC inspection around the edge of the cutout for cracks in accordance with 777
NDT Part 6, 51-00-01. If cracks are found, continue to oversize cutout up to maximum
before insurance cut hole size. If crack still exists contact The Boeing Company for
additional instructions.
– Make an insurance cut, increase cutout size by 1/16 (0.0625) inch minimum on the
diameter or 1/32 (0.03125) inch minimum from the edge on oblong cutouts. Maximum
hole size after insurance cut is 2.0 inch, 1.00 minimum. Maintain minimum 63 Microinch
Ra finish on all edges. Break all sharp edges. Oblong cutout can be maximum 2.00 inch
in length with a minimum width of 1.00 inch.
– Apply Chemical Conversion Coating, ALODINE 600 to trimmed edges. Refer to SOPM
20-43-03 as an accepted procedure.
– Apply Primer, Fuel Tank, BMS 10-20, TYPE II to trimmed edges. Refer to 777 AMM
51-21-10 as an accepted procedure.
2. Design repair.
– Use two rows of fasteners around the cutout. Spacing for field fasteners is 4D to 6D,
where D is the diameter of the hole. For 1/64 and 1/32 inch oversize fasteners, use the
hole size of the standard size fastener for spacing calculation. Use existing fastener in
the stiffeners on each side of the web bay and the upper and lower chord at the top and
bottom of each web bay as a guide in locating fastener holes.
– Adjust size of repair doubler and the location of the field fasteners as required to to
maintain 2.0 e/D edge margin from edge of the repair doubler and edge of repair cutout
in web, where e is the distance from the center of the hole to the edge of the part and D
is the diameter of the hole.
– Adjust location of field fasteners in the area of the trimmed out area to maintain minimum
edge margin and meet spacing requirements between fasteners.
– At the existing stiffener locations, install oversize (1/64 minimum, 1/32 maximum) shear
hi-loks. Refer to Table E "Fastener Hole Dimensions For Holes In The Upper Chord To
Web and The Stiffeners To Web That Are Not Cold Worked (Shifted Positive Fit)" in
777-200 SRM 51-40-05, 777-300 SRM 51-40-05, or 777F SRM 51-40-05 for hole sizes.
– For field fasteners, fasteners installed in the web pocket and doubler, install standard
size (1/64 or 1/32 inch oversize acceptable, if hole was damaged) shear hi-loks in transition
fit holes. Refer to 777-200 SRM 51-40-05, 777-300 SRM 51-40-05, or 777F SRM 51-40-05
for hole sizes. Field fastener diameter is based on the size of the existing fasteners in
the existing stiffener on each side of the web bay. The field fastener should be the same
standard size as the smallest fastener in the existing stiffener on each side of the web
bay where the repair is being installed.
3. Fabricate repair doubler and stiffeners.
APPENDIX A:  REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB
(SHEET 3 OF 4)
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777-57A0087
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BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 58

– Fabricate repair doubler from 2024-T3 bare aluminum sheet. Fabricate repair stiffeners
from 2024-0 bare aluminum sheet and then heat treat to -T42 condition. Maintain minimum
63 Microinch Ra finish on all edges. Minimum 0.50 inch radius on all trimmed edges.
Break all sharp edges. Adjust flange of stiffener to pick up fastener if different size fasteners
at different spacing are installed in the existing stiffeners.
– Thickness of repair doublers, and repair stiffener per Table 1.
– Apply Chemical Conversion Coating, ALODINE 600 after fabrication. Refer to SOPM
20-43-03 as an accepted procedure.
– Apply Primer, Fuel Tank, BMS 10-20, TYPE II after fabrication. Refer to 777 AMM 51-21-10
as an accepted procedure.
4. Locate repair doubler and stiffeners.
– Locate repair doubler and stiffeners and drill holes, full size.
– Remove doubler and stiffeners. Deburr and clean doubler, stiffeners, and existing structure.
5. Install repair doubler and stiffeners.
– Install doubler and stiffeners.
– Install fasteners.
Table 1 - Repair Doubler and Repair Stiffener Thickness
Thickness of Repair Doubler
and Repair Stiffener
(Standard Stock Sheet Thick-
ness)
Original Web Thickness
0.0560.050
0.0630.055
0.0710.060
0.0800.065
The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
MORE DATAFLAG
NOTE
The field fastener should be the same standard size as the smallest fastener in the existing stiff-
ener on each side of the web bay where the repair is being installed. Example 1: If a 5/16 inch di-
ameter rivet is the smallest fastener which was installed in the existing stiffeners in the repair area,
use a standard size 5/16 inch shear hi-loks in transition fit holes for the field fasteners. Example
2: If a 1/4 inch hi-lok is the smallest fastener which was installed in the existing stiffeners in the
repair area, use 1/4 inch shear hi-loks in transition fit holes for the field fasteners. Refer to 777-
200 SRM 51-40-05, 777-300 SRM 51-40-05, or 777F SRM 51-40-05 for hole sizes.
1
APPENDIX A:  REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB
(SHEET 4 OF 4)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 11, 2010
777-57A0087
58 of 68
BOEING SERVICE BULLETIN 777-57A0087
ALERTALERT

### Page 59 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
REPAIR
DOUBLER  UPPER OR
LOWER CHORD
SHIM  CRACKED AREA
FILLER
FILLER
ATTACH
FASTENER
FIELD
FASTENER
(TYPICAL)
REPAIR
‚DOUBLER
EXISTING
WEB
REPAIR
STIFFENER
EXISTING
STIFFENERS
EXISTING FASTENER  2001212
LOCATION
APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT
TO UPPER AND LOWER CHORD
(SHEET 1 OF 5)
Original Issue: November 11, 2010
777-57A0087
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  59 of 68

### Page 60 (OCR)

BOEING SERVICE BULLETIN 777-57A0087
ALERT  ALERT
REPAIR
DOUBLER
TYPICAL
FILLER  CRACK
SHIM  REPAIR
(UNDER AFT SIDE  REPAIR DOUBLER)  StIFFENEF  • EXISTING FASTENER  2000760
A-A  LOCATION
APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT
TO UPPER AND LOWER CHORD
(SHEET 2 OF 5)
Original Issue: November 11, 2010
BOEING PROPRIETARY -  777-57A0087
Copyright © Unpublished Work - See page 1 for details.  60 of 68

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