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

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ECCN: 9E991

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3.0
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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 18

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 19

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 1] . . . . . . . . . . . . . . . 25

FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 1] . . . . . . . . . . . . . . . 30

FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 1] . . . . . . . . . . . . . . . 35

FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 2] . . . . . . . . . . . . . . . 40

FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 2] . . . . . . . . . . . . . . . 45

FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 2] . . . . . . . . . . . . . . . 50

APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB . . . . . . . . . . . . . . 55

APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT

TO UPPER AND LOWER CHORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL

STIFFENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

APPENDIX D: SCOPE OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Summary 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.

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

Airplanes Total Task Hours Elapsed Hours

Group 1 Airplanes 37.00 19.50

Group 2 airplanes 50.00 25.00

MATERIAL INFORMATION

None.

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BLANK PAGE
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.

GROUP CONFIGURATION DESCRIPTION

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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Variable Number Group

WA001 - WA017 1

WA076 - WA080 1

WA086 - WA093 1

WA101 - WA104 1

WA116 - WA119 1

WA131 - WA137 1

WA171 - WA175 1

WA196 - WA198 1

WA206 - WA212 1

WA221 - WA223 1

WA231 - WA232 1

WA241 - WA250 1

WA261 - WA266 1

WA281 - WA283 1

WA301 - WA304 1

WB001 - WB021 2

WB031 - WB046 2

WB051 - WB088 2

WB101 - WB106 2

WB121 - WB125 2

WB131 - WB148 2

WB151 - WB155 2

WB161 - WB177 2

WB181 - WB194 2

WB201 - WB215 2

WB231 - WB247 2

WB271 - WB273 2

WB276 - WB286 2

WB291 - WB302 2

WB306 - WB307 2

WB311 - WB337 2

WB341 - WB342 2

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ALERT ALERT
Variable Number Group

WB366 - WB368 2

WB371 - WB388 2

WB406 2

WB411 - WB413 2

WB416 - WB439 2

WB446 - WB453 2

WB476 2

WB481 - WB484 2

WB501 - WB512 2

WB531 - WB537 2

WB551 - WB554 2

WB591 - WB597 2

WB601 - WB606 2

WB611 - WB622 2

WB631 - WB638 2

WB646 - WB649 2

WC051 - WC073 2

WC101 - WC104 2

WC111 - WC120 2

WC221 - WC224 2

WC241 - WC243 2

WC281 - WC290 2

WC301 - WC308 2

WC361 - WC364 2

WC371 - WC374 2

WC381 - WC395 2

WC441 2

WC446 - WC449 2

WC456 - WC459 2

WC486 - WC493 2

WC506 - WC508 2

WC521 - WC522 2

WC531 - WC536 2

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ALERT ALERT
Variable Number Group

WC546 - WC548 2

WC556 2

WC566 - WC567 2

WC571 - WC574 2

WC581 2

WD001 - WD002 2

WD011 - WD018 2

WD031 - WD036 2

WD046 - WD055 2

WD066 - WD075 2

WD081 - WD088 2

WD091 2

WD096 2

WD101 - WD103 2

WD501 - WD513 2

WD521 - WD541 2

WD546 - WD554 2

WD561 - WD573 2

WD581 - WD599 2

WD606 - WD609 2

WD621 - WD632 2

WD651 - WD665 2

WD671 - WD676 2

WD691 - WD709 2

WD741 - WD752 2

WD761 - WD771 2

WD786 - WD788 2

WD796 - WD813 2

WD826 - WD837 2

WD846 - WD861 2

WD871 - WD883 2

WD911 - WD915 2

WD921 - WD922 2

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Variable Number Group

WD936 - WD939 2

WD946 - WD951 2

WD966 - WD970 2

WD981 - WD982 2

WD986 - WD987 2

WD996 2

WE001 - WE004 2

WE011 - WE012 2

WE021 - WE025 2

WE031 2

WE051 - WE052 2

WE071 2

WE081 - WE082 2

WE126 - WE133 2

WF001 - WF004 2

WF016 - WF020 2

WF031 - WF032 2

WF046 - WF054 2

WF076 - WF077 2

WF081 - WF088 2

WF096 - WF099 2

WF106 - WF107 2

WF111 - WF112 2

WF121 2

2. Spares Affected

None.

B. Concurrent Requirements

None.

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BOEING SERVICE BULLETIN 777-57A0087

ALERT ALERT
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

Model Zone

777-200 133, 134

Group 2:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777-300, 133, 134

777-300ER, 777F

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BOEING SERVICE BULLETIN 777-57A0087

ALERT ALERT
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 Interval (Not

to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 6,000 -

flight cycles or

1,125 days,

whichever occurs first, after

the original issue

date of this service bulletin.

Before 8,000

total flight cycles.

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 - Inspection.

No crack is found.

1) Any crack, 1.5 Do 1) or 2) - - -

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 repair 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 - Inspection.

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ALERT ALERT
TABLE 1: PART 1 - INSPECTION

Repeat Interval (Not

to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Before further - -

flight.

Contact The Boeing Company for repair instructions 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 installed).

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 - 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 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:

Number of Per- Task Hours Elapsed Hours

sons

Task

Open Access 1 1.00 1.00

Inspect

...Spanwise Beam No. 1 - FIGURE 1 2 14.50 7.25

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Group 1:

Number of Per- Task Hours Elapsed Hours

sons

Task

...Spanwise Beam No. 2 - FIGURE 2 2 9.50 4.75

...Spanwise Beam No. 3 - FIGURE 3 2 11.00 5.50

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 37.00 19.50

Group 2:

Task Number of Persons Task Hours Elapsed Hours

Defuel Center Tank 4 4.00 1.00

Purge and Prepare Center Tank for En- 2 6.00 3.00

try

Open Access 1 1.00 1.00

Inspect

...Spanwise Beam No. 1 - FIGURE 4 2 14.50 7.25

...Spanwise Beam No. 2 - FIGURE 5 2 9.50 4.75

...Spanwise Beam No. 3 - FIGURE 6 2 11.00 5.50

Close Access 2 3.00 1.50

Test 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 50.00 25.00

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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BOEING SERVICE BULLETIN 777-57A0087

ALERT ALERT
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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BLANK PAGE
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 1 Airplanes Group 2 Airplanes

FIGURE 1 FIGURE 4

b. Do DET and HFEC inspections of WCS Spanwise Beams Number 2 in accordance with the

figure below:

Figure

Group 1 Airplanes Group 2 Airplanes

FIGURE 2 FIGURE 5

c. Do DET and HFEC inspections of WCS Spanwise Beams Number 3 in accordance with the

figure below:

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Figure

Group 1 Airplanes Group 2 Airplanes

FIGURE 3 FIGURE 6

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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This Figure applies only to: Group 1.

FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 2 OF 5)

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ALERT ALERT
FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 3 OF 5)

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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 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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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.

1 Inspect Web / Web Pocket - 18

Do a HFEC inspection of the accessible areas of the indicated web pockets

adjacent to the radii in accordance with

777 NDT Part 6, 51-00-01.

2 Inspect Web / Web Pocket - 8

Do a DET of the visible portions of the

indicated web pockets between the

upper and lower chords from the forward side of the beam. Use the fastener 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.

3 Inspect Web / Web Pocket - 18

FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 4 OF 5)

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ALERT ALERT
GROUP 1 - WCS SPANWISE BEAM NUMBER 1 - INSPECTION

Airplane: Date:

DET

(FWD Side)

Step 3

HFEC

(Web Pocket Radius)

Step 2

DET

(Aft Side)

Step 1

Web Pocket

Thickness

Web Pocket (inches)

Left Side of Airplane

1 0.065

2 0.065

3 0.065 Not Applicable

4 0.060 Not Applicable

5 0.055

6 0.055

7 0.050 Not Applicable

8 0.050 Not Applicable

9 0.050 Not Applicable

Right Side of Airplane

10 0.050 Not Applicable

11 0.050 Not Applicable

12 0.050 Not Applicable

13 0.055

14 0.055

15 0.060 Not Applicable

16 0.065 Not Applicable

17 0.065

18 0.065

FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 5 OF 5)

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This Figure applies only to: Group 1.

FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 1 OF 5)

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FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 2 OF 5)

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FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 3 OF 5)

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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 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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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.

1 Inspect Web / Web Pocket - 12

Do a HFEC inspection of the accessible areas of the indicated web pockets

adjacent to the radii in accordance with

777 NDT Part 6, 51-00-01.

2 Inspect Web / Web Pocket - 8

Do a DET of the visible portions of the

indicated web pockets between the

upper and lower chords from the forward side of the beam. Use the fastener 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.

3 Inspect Web / Web Pocket - 12

FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 4 OF 5)

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GROUP 1 - WCS SPANWISE BEAM NUMBER 2 - INSPECTION

Airplane: Date:

DET

(FWD Side)

Step 3

HFEC

(Web Pocket Radius)

Step 2

DET

(Aft Side)

Step 1

Web Pocket

Thickness

Web Pocket (inches)

Left Side of Airplane

1 0.060 Not Applicable

2 0.060 Not Applicable

3 0.055

4 0.050

5 0.050

6 0.050

Right Side of Airplane

7 0.050

8 0.050

9 0.050

10 0.055

11 0.060 Not Applicable

12 0.060 Not Applicable

FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 5 OF 5)

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This Figure applies only to: Group 1.

FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 1 OF 5)

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FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 2 OF 5)

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FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 3 OF 5)

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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 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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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.

1 Inspect Web / Web Pocket - 14

Do a HFEC inspection of the accessible areas of the indicated web pockets

adjacent to the radii in accordance with

777 NDT Part 6, 51-00-01.

2 Inspect Web / Web Pocket - 8

Do a DET of the visible portions of the

indicated web pockets between the

upper and lower chords from the forward side of the beam. Use the fastener 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.

3 Inspect Web / Web Pocket - 14

FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 4 OF 5)

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GROUP 1 - WCS SPANWISE BEAM NUMBER 3 - INSPECTION

Airplane: Date:

DET

(FWD Side)

Step 3

HFEC

(Web Pocket Radius)

Step 2

DET

(Aft Side)

Step 1

Web Pocket

Thickness

Web Pocket (inches)

Left Side of Airplane

1 0.050

2 0.050

3 0.050

4 0.050

5 0.050 Not Applicable

6 0.050 Not Applicable

7 0.050 Not Applicable

Right Side of Airplane

8 0.050 Not Applicable

9 0.050 Not Applicable

10 0.050 Not Applicable

11 0.050

12 0.050

13 0.050

14 0.050

FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 5 OF 5)

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This Figure applies only to: Group 2.

FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 1 OF 5)

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FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 2 OF 5)

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FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 3 OF 5)

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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 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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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.

1 Inspect Web / Web Pocket - 26

Do a HFEC inspection of the accessible areas of the indicated web pockets

adjacent to the radii in accordance with

777 NDT Part 6, 51-00-01.

2 Inspect Web / Web Pocket - 16

Do a DET of the visible portions of the

indicated web pockets between the

upper and lower chords from the forward side of the beam. Use the fastener 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.

3 Inspect Web / Web Pocket - 26

FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 4 OF 5)

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GROUP 2 - WCS SPANWISE BEAM NUMBER 1 - INSPECTION

Airplane: Date:

DET

(FWD Side)

Step 3

HFEC

(Web Pocket Radius)

Step 2

DET

(AFT Side)

Step 1

Web Pocket

Thickness

Web Pocket (inches)

Left Side of Airplane

1A 0.065

1B 0.065

1C 0.065

2 0.065

3 0.065 Not Applicable

4 0.060 Not Applicable

5 0.055

6A 0.055

6B 0.055

6C 0.055

7 0.050 Not Applicable

8 0.050 Not Applicable

9 0.050 Not Applicable

Right Side of Airplane

10 0.050 Not Applicable

11 0.050 Not Applicable

12 0.050 Not Applicable

13A 0.055

13B 0.055

13C 0.055

14 0.055

15 0.060 Not Applicable

16 0.065 Not Applicable

17 0.065

18A 0.065

18B 0.065

18C 0.065

FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION

(SHEET 5 OF 5)

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ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 1 OF 5)

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FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 2 OF 5)

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ALERT ALERT
FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 3 OF 5)

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BOEING SERVICE BULLETIN 777-57A0087

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 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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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.

1 Inspect Web / Web Pocket - 20

Do a HFEC inspection of the accessible areas of the indicated web pockets

adjacent to the radii in accordance with

777 NDT Part 6, 51-00-01.

2 Inspect Web / Web Pocket - 12

Do a DET of the visible portions of the

indicated web pockets between the

upper and lower chords from the forward side of the beam. Use the fastener 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.

3 Inspect Web / Web Pocket - 20

FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 4 OF 5)

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ALERT ALERT
GROUP 2 - WCS SPANWISE BEAM NUMBER 2 - INSPECTION

Airplane: Date:

DET

(FWD Side)

Step 3

HFEC

(Web Pocket Radius)

Step 2

DET

(Aft Side)

Step 1

Web Pocket

Thickness

Web Pocket (inches)

Left Side of Airplane

1A 0.065 Not Applicable

1B 0.065 Not Applicable

1C 0.065 Not Applicable

2 0.065 Not Applicable

3 0.060

4 0.060

5 0.060

6A 0.060

6B 0.060

6C 0.060

Right Side of Airplane

7A 0.060

7B 0.060

7C 0.060

8 0.060

9 0.060

10 0.060

11 0.065 Not Applicable

12A 0.065 Not Applicable

12B 0.065 Not Applicable

12C 0.065 Not Applicable

FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION

(SHEET 5 OF 5)

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ALERT ALERT
This Figure applies only to: Group 2.

FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 1 OF 5)

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FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 2 OF 5)

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FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 3 OF 5)

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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 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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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.

1 Inspect Web / Web Pocket - 22

Do a HFEC inspection of the accessible areas of the indicated web pockets

adjacent to the radii in accordance with

777 NDT Part 6, 51-00-01.

2 Inspect Web / Web Pocket - 12

Do a DET of the visible portions of the

indicated web pockets between the

upper and lower chords from the forward side of the beam. Use the fastener 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.

3 Inspect Web / Web Pocket - 22

FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 4 OF 5)

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GROUP 2 - WCS SPANWISE BEAM NUMBER 3 - INSPECTION

Airplane: Date:

DET

(FWD Side)

Step 3

HFEC

(Web Pocket Radius)

Step 2

DET

(Aft Side)

Step 1

Web Pocket

Thickness

Web Pocket (inches)

Left Side of Airplane

1 0.060

2A 0.060

2B 0.060

2C 0.060

3 0.060

4 0.060

5 0.055 Not Applicable

6 0.055 Not Applicable

7A 0.055 Not Applicable

7B 0.055 Not Applicable

7C 0.055 Not Applicable

Right Side of Airplane

8A 0.055 Not Applicable

8B 0.055 Not Applicable

8C 0.055 Not Applicable

9 0.055 Not Applicable

10 0.055 Not Applicable

11 0.060

12 0.060

13A 0.060

13B 0.060

13C 0.060

14 0.060

FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION

(SHEET 5 OF 5)

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ALERT ALERT
APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB

(SHEET 1 OF 4)

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APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB

(SHEET 2 OF 4)

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ALERT ALERT
NOTE: 1. Cutout cracked area.

– 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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ALERT ALERT
– 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 Thickness)

Original Web Thickness

0.050 0.056

0.055 0.063

0.060 0.071

0.065 0.080

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG MORE DATA

NOTE

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. Example 1: If a 5/16 inch diameter 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)

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ALERT ALERT
APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT

TO UPPER AND LOWER CHORD

(SHEET 1 OF 5)

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ALERT ALERT
APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT

TO UPPER AND LOWER CHORD

(SHEET 2 OF 5)

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ALERT ALERT
NOTE: 1. Cutout cracked area.

– 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, except common to upper or lower chord

where only 1 fastener is between the cutout and the edge of the repair. 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 upper chord 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.

– At the existing lower chord locations, install oversize shear hi-loks. Refer to Table H:

Fastener Hole Dimensions For The Cold Worked Holes In The Wing Upper and Lower

Chord To Web (Positive Fit)" in 777-200 SRM 51-40-05, 777-300 SRM 51-40-05, or 777F

SRM 51-40-05 for hole sizes.

APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT

TO UPPER AND LOWER CHORD

(SHEET 3 OF 5)

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ALERT ALERT
– 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.

– Secure filler in place with 3/16 inch Shear hi-lok in transition fit hole through entire stack

up. Refer to 777-200 SRM 51-40-05, 777-300 SRM 51-40-05, or 777F SRM 51-40-05

for hole size.

3. Fabricate repair doublers (2), shim (to fill in the web pocket so doubler can be installed), filler

and repair stiffener.

– Fabricate repair doublers, and shim filler 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. Filler to have 0.016 to 0.031 clearance from cutout

all the way around. 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.

– Machine shim to the depth of the web pocket. Web pocket depth is approximately 0.125

minus web pocket thickness. Maximum gap after installation is 0.003 inch.

– Machine filler to same thickness as web pocket.

– 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 doublers, shim, filler, and repair stiffener.

– Locate repair doublers, shim, filler, and repair stiffener and drill holes, full size, including

fastener securing filler.

– Remove repair doublers, shim, filler, and repair stiffener. Deburr and clean repair doublers,

shim, filler, repair stiffener, and existing structure.

5. Install Doubler and Stiffeners.

APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT

TO UPPER AND LOWER CHORD

(SHEET 4 OF 5)

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ALERT ALERT
– Install repair doublers, shim, filler and repair stiffener. Install filler with Sealant, Fuel Tank,

BMS 5-45 (BMS 5-26 OPTIONAL).

– Install fasteners.

Table 1 - Repair Doubler and Repair Stiffener Thickness

Thickness of Repair Doubler

and Repair Stiffener

(Standard Stock Sheet Thickness)

Original Web Thickness

0.050 0.056

0.055 0.063

0.060 0.071

0.065 0.080

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG MORE DATA

NOTE

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. Example 1: If a 5/16 inch diameter 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 B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT

TO UPPER AND LOWER CHORD

(SHEET 5 OF 5)

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ALERT ALERT
APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL

STIFFENER

(SHEET 1 OF 4)

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ALERT ALERT
APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL

STIFFENER

(SHEET 2 OF 4)

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BOEING SERVICE BULLETIN 777-57A0087

ALERT ALERT
NOTE: 1. Cutout cracked area.

– 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 hole 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 cutouts 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. One row of fasteners around the cutout at

the closest adjacent stiffener is acceptable. 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 C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL

STIFFENER

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 777-57A0087

ALERT ALERT
– 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 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 repair 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 Thickness)

Original Web Thickness

0.050 0.056

0.055 0.063

0.060 0.071

0.065 0.080

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG MORE DATA

NOTE

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. Example 1: If a 5/16 inch diameter 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 C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL

STIFFENER

(SHEET 4 OF 4)

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ALERT ALERT
Location Figure

Group 2 Airplanes

(Airplanes with

wet center section.)

Group 1 Airplanes

(Airplanes with

dry center section.)

Inspection - Spanwise Beam No. 1 FIGURE 1 FIGURE 4

Inspection - Spanwise Beam No. 2 FIGURE 2 FIGURE 5

Inspection - Spanwise Beam No. 3 FIGURE 3 FIGURE 6

Repair - Crack (1.5 inch maximum) in Center of Web APPENDIX A APPENDIX A

Repair - Crack (1.5 inch maximum) at Top or Bottom Fillet Radius APPENDIX B APPENDIX B

Adjacent to Upper or Lower Chord

Repair - Crack (1.5 inch maximum) at Side Fillet Radius Adjacent APPENDIX C APPENDIX C

to Vertical Stiffener

APPENDIX D: SCOPE OF WORK

(SHEET 1 OF 1)

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ALERT ALERT