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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-57A0097 Original Issue: January 10, 2014 ATA System: 5720 SUBJECT: WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2014 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: January 10, 2014 777-57A0097 1 of 45
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 2 of 45 BOEING SERVICE BULLETIN 777-57A0097
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BLANK PAGE
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 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 6 M. Software Accomplishment Summary ................................ 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 8 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 ....................................... 2 1 FIGURE 1: LEFT WING - WING SKIN PANEL GAP SEALANT INSPECTION [Group 1, 3] ...... 2 4 FIGURE 2: RIGHT WING - WING SKIN PANEL GAP SEALANT INSPECTION [Group 2-3] ...... 2 8 FIGURE 3: LEFT WING - WING SKIN PANEL GAP SEALANT REPAIR [Group 1, 3] ......... 3 2 FIGURE 4: RIGHT WING - WING SKIN PANEL GAP SEALANT REPAIR [Group 2-3] ......... 3 5 FIGURE 5: LEFT WING - WING SKIN PANEL GAP CORROSION INSPECTION [Group 1, 3] .... 3 8 FIGURE 6: RIGHT WING - WING SKIN PANEL GAP CORROSION INSPECTION [Group 2-3] .... 4 1 APPENDIX A: SEALANT REMOVAL TOOLS AND PROCEDURES ..................... 4 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 3 of 45 BOEING SERVICE BULLETIN 777-57A0097
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 4 of 45 BOEING SERVICE BULLETIN 777-57A0097
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BLANK PAGE
Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-57A0097Original Issue: January 10, 2014 ATA System: 5720 SUBJECT: WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection and Repair
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 this service bulletin will find if sealant was applied to the wing skin panel gaps above the underwing fittings. Missing sealant in the wing skin panel gaps above the underwing fittings can allow undetected corrosion to develop in the wing skin panels above the underwing fittings. Undetected corrosion in the wing skin panels above the underwing fittings can result in undetected fatigue cracks in the wing skin panels. Undetected fatigue cracks in the wing skin panels can result in the loss of limit load capability of the wing skins and structural failure of the wings.
Boeing found that sealant may not have been applied in production to the wing skin panel gaps above the underwing fittings on certain underwing fittings on certain 777 airplanes. Sealant is required to be applied to the wing skin panel gaps above the underwing fittings prior to installation of the underwing fittings. A review of Boeing installation records found that sealant may not have been applied above certain underwing fittings on certain previously delivered and in-production 777 airplanes. The affected in-production 777 airplanes have been inspected to make sure sealant is applied to the wing skin panel gaps above the underwing fittings. Production installation procedures have also been addressed to make sure sealant is applied to the wing skin panel gaps above the underwing fittings on future 777 production airplanes.
This service bulletin gives instructions to inspect and restore the sealant in the wing skin panel gaps above the underwing fittings. If sealant is missing, this service bulletin also gives instructions to inspect for corrosion in the wing skin panels gaps to prevent possible fatigue cracks in the wing skin panels, loss of limit load capability of the wing skins and potential subsequent structural failure of the wings.
Boeing Fleet Team Digest (FTD) 777 FTD 57-13003 is related to this service bulletin.
Boeing Service Related Problem (SRP) 777-SRP-57-0265 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 5 of 45
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin and APPENDIX A for additional optional tool information.
NoSpecial Tooling Required ACTION Do a Detailed Inspection (DET) of the wing skin panel gaps above the underwing fittings for any missing sealant, on the left wing (applicable to Groups 1,3) and on the right wing (applicable to Groups 2-3). If sealant is missing, do a DET of the wing skin panel gaps above the underwing fittings for corrosion. If any corrosion is found, contact Boeing for repair instructions, do the repair, and restore the missing sealant and the sealant that was previously removed to gain inspection access. If no corrosion is found, restore the missing sealant and the sealant that was previously removed to gain inspection access. If sealant is not missing, restore the sealant that was previously removed to gain inspection access.
EFFECTIVITY 777-200/-200LR/-300ER, 777F Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of August 7, 2013. Please refer to Paragraph
2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 6 of 45 BOEING SERVICE BULLETIN 777-57A0097
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MANPOWER Elapsed Hours Total Task Hours Airplanes
15.8551.85Group 1 and Group 2 Airplanes
19.70103.70Group 3 Airplanes
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 7 of 45 BOEING SERVICE BULLETIN 777-57A0097
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BOEING SERVICE BULLETIN 777-57A0097
ALERT ALERT
DO A DETAILED INSPECTION (DET) OF THE WING
SKIN PANEL GAPS ABOVE THE UNDERWING -ITINGS FOR ANY MISSING SEALANT, ON THE LEFT WING (APPLICABLE TO GROUPS 1,3) AND ON THE RIGHT WING (APPLICABLE TO GROUPS 2-3).
IF SEALANT IS MISSING, DO A DET OF THE WING
SKIN PANEL GAPS ABOVE THE UNDERWING OR CORROSION. IF ANY CORROSION IS
FOUND NTACT BOEING FOR REPAIR
INSTRI ONS, DO THE REPAIR, AND RESTORE
THE MISS NG SEA ANT AND THE SEALANT THAT
WAS PREV IOUSL REMOVED TO GAIN INSPE ACCESS. IF NO CORROSION IS FOUND. THE MISS G SEALANT AND
THE SEA VOUSLY REMOVED TO GAIN I NSPEC ESS. IF SEALANT IS NOT MISSING. RE STORE SEALANT THAT WAS
PREVIOUSLY REMOVED TO GAIN INSPECTION ACCESS _ TYPICAL LEFT WING SHOWN (APPLICABLE TO GROUPS 1,3) RIGHT WING OPPOSITE (APPLICABLE TO GROUPS 2-3) Original Issue: January 10, 2014 Export Controlled ECCN: 9E991 - BOEING 777-57A0097 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 45
Commercial Airplanes 777 Service Bulletin ALERT Number: 777-57A0097 Original Issue: January 10, 2014 ATA System: 5720 SUBJECT: WINGS - Outer Wing - Underwing Fittings Sealant at Wing Panel Gaps - Inspection and Repair
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 airplane(s) shown below.
Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 777-200/-200LR/-300ER and 777F airplanes that require inspection for missing sealant on the left wing only.
-1 777-300ER and 777F airplanes that require inspection for missing sealant on the right wing only.
-2 777-300ER and 777F airplanes that require inspection for missing sealant on both the left and the right wings.
-3 Airplane Models:
777-200, 777-200LR, 777-300ER, 777F GroupVariable Number 1WC593 1WD106 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 9 of 45
GroupVariable Number 2WD889 1WD890 - WD892 1WD918 1WD923 - WD925 1WD927 2WD928 1WD941 - WD943 1WD956 - WD957 1WD993 1WE094 1WE141 1WE159 - WE164 1WE203 3WE206 1WE207 - WE208 1WE240 1WE242 - WE243 2WE262 1WE263 - WE265 1WE272 3WE273 1WE274 1WE276 1WE301 1WE303 - WE304 1WE307 1WE331 1WE333 1WE351 1WE416 1WF035 3WF037 1WF038 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 10 of 45 BOEING SERVICE BULLETIN 777-57A0097
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GroupVariable Number 2WF062 1WF064 1WF146 - WF147 1WF152
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason Accomplishment of this service bulletin will find if sealant was applied to the wing skin panel gaps above the underwing fittings. Missing sealant in the wing skin panel gaps above the underwing fittings can allow undetected corrosion to develop in the wing skin panels above the underwing fittings. Undetected corrosion in the wing skin panels above the underwing fittings can result in undetected fatigue cracks in the wing skin panels. Undetected fatigue cracks in the wing skin panels can result in the loss of limit load capability of the wing skins and structural failure of the wings.
Boeing found that sealant may not have been applied in production to the wing skin panel gaps above the underwing fittings on certain underwing fittings on certain 777 airplanes. Sealant is required to be applied to the wing skin panel gaps above the underwing fittings prior to installation of the underwing fittings. A review of Boeing installation records found that sealant may not have been applied above certain underwing fittings on certain previously delivered and in-production 777 airplanes. The affected in-production 777 airplanes have been inspected to make sure sealant is applied to the wing skin panel gaps above the underwing fittings. Production installation procedures have also been addressed to make sure sealant is applied to the wing skin panel gaps above the underwing fittings on future 777 production airplanes.
This service bulletin gives instructions to inspect and restore the sealant in the wing skin panel gaps above the underwing fittings. If sealant is missing, this service bulletin also gives instructions to inspect for corrosion in the wing skin panels gaps to prevent possible fatigue cracks in the wing skin panels, loss of limit load capability of the wing skins and potential subsequent structural failure of the wings.
Boeing Fleet Team Digest (FTD) 777 FTD 57-13003 is related to this service bulletin.
Boeing Service Related Problem (SRP) 777-SRP-57-0265 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 11 of 45 BOEING SERVICE BULLETIN 777-57A0097
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D. Description Do a Detailed Inspection (DET) of the wing skin panel gaps above the underwing fittings for any missing sealant, on the left wing (applicable to Groups 1,3) and on the right wing (applicable to Groups 2-3). If sealant is missing, do a DET of the wing skin panel gaps above the underwing fittings for corrosion. If any corrosion is found, contact Boeing for repair instructions, do the repair, and restore the missing sealant and the sealant that was previously removed to gain inspection access. If no corrosion is found, restore the missing sealant and the sealant that was previously removed to gain inspection access. If sealant is not missing, restore the sealant that was previously removed to gain inspection access.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones ZoneModel 533777-200, 777-200LR, 777- 300ER, 777F Group 2:
Affected Maintenance Zones ZoneModel 633777-300ER, 777F Group 3:
Affected Maintenance Zones ZoneModel 533, 633777-300ER, 777F E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
The Conditions, Actions and Compliance times shown apply to each wing panel gap location independently.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: January 10, 2014 777-57A0097 12 of 45 BOEING SERVICE BULLETIN 777-57A0097