### 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. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 1 of 30 6.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 2 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Existing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Data supplied with this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3. Installation Drawings Used in the Preparation of this Service Bulletin. . . . . . . . . . . . 15 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 17 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 18 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION. . . . . . . . . 21 FIGURE 2: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION . . . . . . . . 23 FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE . . . 25 FIGURE 4: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE . . 28

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 3 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 4 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Summary**  **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. **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 5 of 30**ACTION** Drain and purge the main fuel tanks. Remove the access panel between rib numbers 8 (Wing Station (W.S.) 387) and rib 9 (W.S. 414.5). Do a High Frequency Eddy Current (HFEC) inspection of the keyway in the access door cutout for cracks. If no crack is found or any crack found is 0.050 inch in length or less, change the profile of the keyway to obtain a larger radius and remove the crack, if present. If any crack greater than 0.050 inch is found, contact The Boeing Company for repair instructions and do the repair. Install the access panel. **EFFECTIVITY** 777-200LR and 777-300ER Airplanes. Refer to Paragraph 1.A., Effectivity for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. See Paragraph 1.E., Compliance for compliance information. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of May 1, 2008. Please refer to Paragraph 2.B., Industry Support Information. **MANPOWER**

**Elapsed Hours Total Task Hours**  12.50 32.00
**MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 6 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 7 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 8 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**

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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.
**DESCRIPTION CONFIGURATION**  **GROUP** 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 9 of 30**DESCRIPTION CONFIGURATION**  **GROUP** 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 **Group Variable Number**  1 WD001 - WD002 1 WD011 - WD015 1 WD031 - WD036 1 WD046 - WD049 1 WD066 - WD067 2 WD501 - WD505 1 WD506 - WD507 1 WD521 - WD537 1 WD546 - WD552 2 WD561 - WD565 1 WD566 - WD572 1 WD581 - WD583 2 WD584 - WD591 1 WD592 - WD594 2 WD606 - WD609 1 WD621 - WD622 2 WD623 - WD632 1 WD651 - WD659 1 WD671 - WD675 1 WD691 - WD700 2 WD701 - WD702 1 WD703 - WD705

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 10 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT Group**  **Variable Number** 1 WD741 - WD747 1 WD761 - WD770 1 WD786 - WD788 1 WD796 - WD802 1 WD826 - WD829 1 WD846 - WD848 1 WD871 - WD872 1 WD911 - 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** 
0.126 12,600 1250 1 0.020 15,450 1500 2 0.067 11,750 1550 3 0.026 15,000 1700 4 0.078 13,200 2100 5 0.250 15,150 2600 6 0.380 15,050 3100 7

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 11 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**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 Zone**  **Model** 533, 633 777-200LR, 777-300ER **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 533, 633 777-300ER **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Accomplish Part 1 - Fuel Access Door Cutout Keyway Inspection and Part 2 - Fuel Access Door Cutout Keyway Change, as required in Tables 1 below in accordance with Paragraph 3., Accomplishment Instructions. **NOTE:** If allowed by Table 1 below, operators should consider accomplishment of this service bulletin within 750 days after the original issue date on the service bulletin to prevent cracks that would require significant manpower and extended downtime to repair.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 12 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT 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) Action**  **Condition**

- Within 500flight cycles after the original issue date onthe service bulletin. Before 3500 total flight cycles sincethe date of issuance of the original certificate of airworthiness or the original exportcertificate of airworthiness.Do a High Frequency Eddy Current (HFEC) inspection 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 Company 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) Action**  **Condition**

- - No action is required. Theseairplanes do not require an insurance 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 13 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT 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)**  **Action Condition** 

- Before further flight Do 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 flight Contact 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**

4.75 19.00 4 Open Access Inspect 1.00 1.00 1 ......Left wing - FIGURE 1

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 14 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT Elapsed**  **Hours Task**  **Hours Number of**  **Persons Task** 

1.00 1.00 1 ......Right wing - FIGURE 2 Change Keyway Profile 2.00 2.00 1 ......Left wing - FIGURE 3 2.00 2.00 1 ......Right wing - FIGURE 4 1.75 7 4 Close Access 12.50 32.00 TOTAL 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 15 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT L. Interchangeability and Intermixability of Parts**  Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 16 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT 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.
**Notes Name**  **QTY Part Number / Specifica-**  **tion** (b) Chemical Conversion Coating 2 Oz. ALODINE 600 (a) Primer - Fuel Tank 4 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 17 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 18 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 19 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**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 777-57A0069 20 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 21 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**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 DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a High Frequency Eddy Current (HFEC) inspection of the indicated area for cracks in accordance with 777 NDTPart 6, 51-00-01, Procedure 1 or Procedure 2. - - Access hole cutout keyway Inspect 1

**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 22 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT FIGURE 2: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 23 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**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 DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a High Frequency Eddy Current (HFEC) inspection of the indicated area for cracks in accordance with 777 NDTPart 6, 51-00-01, Procedure 1 or Procedure 2. - - Access hole cutout keyway Inspect 1

**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 24 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 25 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 26 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT NOTE:**  Material of the wing panel is 2324 T-39 aluminum.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Machine the wing panel to obtain a 3.0 inch diameter radius at the keyway asshown. Blend new radius into the existing cutout with a 3.0 inch return radius. - - Access hole cutout keyway Change 1

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 areas 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 crackis found after the radius has been machined to the maximum of 0.050 inch from the edge of the keyway, contactThe Boeing Company for additional instructions and do the repair. - - Access hole cutout keyway Inspect 2

Insurance cut.

- - Access hole cutout keyway Change 3 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 Change 4 Intensity: 0.004A to 0.012A.

- - Access hole cutout keyway Shot Peen 5 Coverage: 2.0. Shot peen machined edges. Refer toSOPM 20-10-03 as an accepted procedure. Touch-up machined areas. Refer toSOPM 20-43-03 as an accepted procedure. - ALODINE 600 Chemical Conversion Coating Apply 6

One coat to machined areas. Apply onlyto machined edges, do not apply to surface where the gasket seats. - BMS 10-20, TYPE II Primer - Fuel Tank Apply

**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 27 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT FIGURE 4: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE**  **(SHEET 1 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 28 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT**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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 05, 2009 777-57A0069 29 of 30 **BOEING SERVICE BULLETIN 777-57A0069 ALERT**  **ALERT NOTE:**  Material of the wing panel is 2324 T-39 aluminum.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Machine the wing panel to obtain a 3.0 inch diameter radius at the keyway asshown. Blend new radius into the existing cutout with a 3.0 inch return radius. - - Access hole cutout keyway Change 1

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 areas 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 crackis found after the radius has been machined to the maximum of 0.050 inch from the edge of the keyway, contactThe Boeing Company for additional instructions and do the repair. - - Access hole cutout keyway Inspect 2

Insurance cut.

- - Access hole cutout keyway Change 3 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 Change 4 Intensity: 0.004A to 0.012A.

- - Access hole cutout keyway Shot Peen 5 Coverage: 2.0. Shot peen machined edges. Refer toSOPM 20-10-03 as an accepted procedure. Touch-up machined areas. Refer toSOPM 20-43-03 as an accepted procedure. - ALODINE 600 Chemical Conversion Coating Apply 6

One coat to machined areas. Apply onlyto machined edges, do not apply to surface where the gasket seats. - BMS 10-20, TYPE II Primer - Fuel Tank Apply

**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 ALERT**  **ALERT**