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.

ECCN: 9E991

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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Unpublished Work - All Rights Reserved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,

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6.0
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BOEING SERVICE BULLETIN 777-57A0069

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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

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BLANK PAGE
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.

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ACTION

Drain and purge the main fuel tanks. Remove the access panel between rib numbers 8 (Wing Station (W.S.)

387) and rib 9 (W.S. 414.5). Do a High Frequency Eddy Current (HFEC) inspection of the keyway in the access

door cutout for cracks. If no crack is found or any crack found is 0.050 inch in length or less, change the profile

of the keyway to obtain a larger radius and remove the crack, if present. If any crack greater than 0.050 inch is

found, contact The Boeing Company for repair instructions and do the repair. Install the access panel.

EFFECTIVITY

777-200LR and 777-300ER Airplanes. Refer to Paragraph 1.A., Effectivity for the list of affected airplanes.

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin

mandatory.

See Paragraph 1.E., Compliance for compliance information.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of May 1, 2008. Please refer to Paragraph

2.B., Industry Support Information.

MANPOWER

Total Task Hours Elapsed Hours

32.00 12.50

MATERIAL INFORMATION

Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability.

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ALERT ALERT

BLANK PAGE
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.

GROUP CONFIGURATION DESCRIPTION

777-200LR and 777-300ER Airplanes line numbers 466 through 713,

except line numbers 488, 511, 521, 527, 529, 535, 536, 539, 540,

542, 549, 551, 556, 557, 560, 568, 569, 571, 576, 577, 578, 582,

585, 590, 594, 598, 619, 622, 628, 641, 673, and 701.

1 -

Airplanes which the access door cutout keyway was not changed to

the dimension in Figure 3 or Figure 4 of this service bulletin or were

not High Frequency Eddy Current (HFEC) inspected prior to being

changed.

1

Airplanes which the access door cutout keyway was High Frequency

Eddy Current (HFEC) inspected and changed to the dimension shown

in Figure 3 or Figure 4 this service bulletin.

2

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GROUP CONFIGURATION DESCRIPTION

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

Variable Number Group

WD001 - WD002 1

WD011 - WD015 1

WD031 - WD036 1

WD046 - WD049 1

WD066 - WD067 1

WD501 - WD505 2

WD506 - WD507 1

WD521 - WD537 1

WD546 - WD552 1

WD561 - WD565 2

WD566 - WD572 1

WD581 - WD583 1

WD584 - WD591 2

WD592 - WD594 1

WD606 - WD609 2

WD621 - WD622 1

WD623 - WD632 2

WD651 - WD659 1

WD671 - WD675 1

WD691 - WD700 1

WD701 - WD702 2

WD703 - WD705 1

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ALERT ALERT
Variable Number Group

WD741 - WD747 1

WD761 - WD770 1

WD786 - WD788 1

WD796 - WD802 1

WD826 - WD829 1

WD846 - WD848 1

WD871 - WD872 1

WD911 - WD912 1

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

1 1250 12,600 0.126

2 1500 15,450 0.020

3 1550 11,750 0.067

4 1700 15,000 0.026

5 2100 13,200 0.078

6 2600 15,150 0.250

7 3100 15,050 0.380

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Inspection of the keyway will detect cracks in the keyway before the cracks can grow to the point the

lower wing skin load path is lost. Changing the profile of the keyway will improve the fatigue

characteristics of the keyway which will help prevent cracks in the future. The change in the profile of

the keyway can also be used to repair cracks up to 0.050 inch in length.

If any crack is found that is greater than 0.45 inch in length, skin panel replacement may be required.

Skin panel replacement would require significant manpower and extended downtime.

Boeing Service Related Problem (SRP) 777-SRP-57-0222 is related to this service bulletin.

D. Description

Drain and purge the main fuel tanks. Remove the access panel between rib number 8 (Wing Station

(W.S.) 387) and rib 9 (W.S. 414.5). Do a High Frequency Eddy Current (HFEC) inspections of the

keyway in the access door cutout for cracks. If no crack is found or any crack found is 0.050 inch in

length or less, change the profile of the keyway to obtain a larger radius and remove the crack, if

present. If any crack greater than 0.050 inch is found, contact The Boeing Company for repair instructions

and do the repair. Install the access panel.

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

777-200LR, 777-300ER 533, 633

Group 2:

Affected Maintenance Zones

Model Zone

777-300ER 533, 633

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this

service bulletin mandatory.

Accomplish Part 1 - Fuel Access Door Cutout Keyway Inspection and Part 2 - Fuel Access Door Cutout

Keyway Change, as required in Tables 1 below in accordance with Paragraph 3., Accomplishment

Instructions.

NOTE: If allowed by Table 1 below, operators should consider accomplishment of this service bulletin

within 750 days after the original issue date on the service bulletin to prevent cracks that would

require significant manpower and extended downtime to repair.

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BOEING SERVICE BULLETIN 777-57A0069

ALERT ALERT
Group 1, Configuration 1:

Table 1: Fuel Access Door Cutout Keyway Inspection and Change

Repeat Interval (Not

to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 500 -

flight cycles after the original

issue date on

the service bulletin.

Before 3500 total

flight cycles since

the date of issuance of the original certificate of

airworthiness or

the original export

certificate 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 Interval (Not

to Exceed)

Compliance Time

(Whichever Occurs

Later)

Condition Action

No action is required. These - -

airplanes 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.

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Group 1, Configuration 2; Group 2:

Table 2: Fuel Access Door Cutout Keyway Inspection and Change

Repeat Interval (Not

to Exceed)

Compliance Time

(Whichever Occurs

Later)

Condition Action

Do an insurance cut of the key- Before further flight -

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

Contact The Boeing Company Before further flight -

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

Open Access 4 19.00 4.75

Inspect

......Left wing - FIGURE 1 1 1.00 1.00

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Elapsed

Hours

Task

Hours

Number of

Persons

Task

......Right wing - FIGURE 2 1 1.00 1.00

Change Keyway Profile

......Left wing - FIGURE 3 1 2.00 2.00

......Right wing - FIGURE 4 1 2.00 2.00

Close Access 4 7 1.75

TOTAL FOR EACH AIRPLANE 32.00 12.50

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Boeing Service Related Problem (SRP) 777-SRP-57-0222

b. Component Maintenance Manual (CMM) 20-10-03, 20-43-03

c. 777 Aircraft Maintenance Manual (AMM) 06-44-00, 28-11-00, 28-26-00

d. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-01

2. Data supplied with this Service Bulletin

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin

None.

K. Publications Affected

1. Publications:

None.

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated this service bulletin for effects on Fatigue Critical Structure (FCS) and for

changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This

service bulletin does not affect FCS, therefore DTIs are not necessary.

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L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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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.

Part Number / Specifica- QTY Name Notes

tion

ALODINE 600 2 Oz. Chemical Conversion Coating (b)

BMS 10-20, TYPE II 4 Oz. Primer - Fuel Tank (a)

(a) See the Qualified Products List at the end of the Boeing Material Specification

(BMS) for supplier data.

(b) Refer to CMM 20-43-03 for supplier data.

3. Parts Modified and Reidentified

None.

4. Parts Removed and Not Replaced

None.

D. Parts Necessary to Change Spares

None.

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E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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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.

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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.

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ALERT ALERT
FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION

(SHEET 1 OF 2)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Do a High Frequency Eddy Current

(HFEC) inspection of the indicated area

for cracks in accordance with 777 NDT

Part 6, 51-00-01, Procedure 1 or Procedure 2.

Access hole cutout - -

keyway

1 Inspect

FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION

(SHEET 2 OF 2)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Do a High Frequency Eddy Current

(HFEC) inspection of the indicated area

for cracks in accordance with 777 NDT

Part 6, 51-00-01, Procedure 1 or Procedure 2.

Access hole cutout - -

keyway

1 Inspect

FIGURE 2: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION

(SHEET 2 OF 2)

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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)

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BOEING SERVICE BULLETIN 777-57A0069

ALERT ALERT
NOTE: Material of the wing panel is 2324 T-39 aluminum.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Machine the wing panel to obtain a 3.0

inch diameter radius at the keyway as

shown. Blend new radius into the existing cutout with a 3.0 inch return radius.

Access hole cutout - -

keyway

1 Change

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 crack

is found after the radius has been machined to the maximum of 0.050 inch

from the edge of the keyway, contact

The Boeing Company for additional instructions and do the repair.

Access hole cutout - -

keyway

2 Inspect

Access hole cutout - - Insurance cut.

keyway

3 Change

Machine an additional 0.020 to 0.025

inch from the keyway edge.

Maintain a 63 microinch or better surface

finish.

Access hole cutout - - Break sharp edges.

keyway

4 Change

Access hole cutout - - Intensity: 0.004A to 0.012A.

keyway

5 Shot Peen

Coverage: 2.0.

Shot peen machined edges. Refer to

SOPM 20-10-03 as an accepted procedure.

Touch-up machined areas. Refer to

SOPM 20-43-03 as an accepted procedure.

Chemical Conversion ALODINE 600 -

Coating

6 Apply

One coat to machined areas. Apply only

to machined edges, do not apply to surface where the gasket seats.

BMS 10-20, TYPE -

II

Apply Primer - Fuel Tank

FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE

(SHEET 3 OF 3)

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Original Issue: November 05, 2009

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

Machine the wing panel to obtain a 3.0

inch diameter radius at the keyway as

shown. Blend new radius into the existing cutout with a 3.0 inch return radius.

Access hole cutout - -

keyway

1 Change

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 crack

is found after the radius has been machined to the maximum of 0.050 inch

from the edge of the keyway, contact

The Boeing Company for additional instructions and do the repair.

Access hole cutout - -

keyway

2 Inspect

Access hole cutout - - Insurance cut.

keyway

3 Change

Machine an additional 0.020 to 0.025

inch from the keyway edge.

Maintain a 63 microinch or better surface

finish.

Access hole cutout - - Break sharp edges.

keyway

4 Change

Access hole cutout - - Intensity: 0.004A to 0.012A.

keyway

5 Shot Peen

Coverage: 2.0.

Shot peen machined edges. Refer to

SOPM 20-10-03 as an accepted procedure.

Touch-up machined areas. Refer to

SOPM 20-43-03 as an accepted procedure.

Chemical Conversion ALODINE 600 -

Coating

6 Apply

One coat to machined areas. Apply only

to machined edges, do not apply to surface where the gasket seats.

BMS 10-20, TYPE -

II

Apply Primer - Fuel Tank

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