### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Number: 777-57A0087**  Original Issue: November 11, 2010 ATA System: 5710 **SUBJECT:** WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 1 of 68 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 2 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 3 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 4 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**

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### 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 5 of 68**ACTION (PRR 62777-72S)** Drain center tank (airplanes with wet center sections). Purge and prepare center tank for entry (airplanes with wet center sections). Remove the keel beam access door, the center section access door and the WCS spanwise beam baffle doors. Do a detailed inspection (DET) and High Frequency Eddy Current (HFEC) Inspection of selected web bays of Spanwise Beams numbers 1, 2, and 3 for cracks. Install the WCS spanwise beam baffle doors, center section access door, and the keel beam access door. **EFFECTIVITY** 777-200, -200LR, -300, -300ER, and 777F Airplanes. Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Refer to Paragraph 1.E., Compliance. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the inspection,and/or repair procedures given in this service bulletin. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  19.50 37.00 Group 1 Airplanes 25.00 50.00 Group 2 airplanes
**MATERIAL INFORMATION** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 6 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 7 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 8 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**

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### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Number: 777-57A0087**  Original Issue: November 11, 2010 ATA System: 5710 **SUBJECT:** WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - Inspection THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-72S for data about this change. Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. **NOTE:** This service bulletin is for the airplanes identified below. The effectivity list shown below is complete for airplanes through line number 919. At least one airplane after line number 919 is also affected by this service bulletin, and these airplanes are in Group(s) 1,2. These airplanes will be added to the service bulletin's MyBoeingFleet.com (MBF) \"get effectivity\" result when they are added to the MBF Fleet Profile Page.
**DESCRIPTION CONFIGURATION**  **GROUP** 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 9 of 68**Group Variable Number**  1 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 2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 10 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT Group**  **Variable Number** 2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 11 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT Group**  **Variable Number** 2 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 12 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT Group**  **Variable Number** 2 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. Spares Affected None. **B. Concurrent Requirements** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 13 of 68 **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 Zone**  **Model** 133, 134 777-200 **Group 2:**
**Affected Maintenance Zones Zone**  **Model** 133, 134 777-200, 777-200LR, 777-300, 777-300ER, 777F

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 14 of 68 **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 In**  **terval (Not to Ex**  **ceed) Compliance Time (Whichever**  **Occurs Later) Action**  **Condition**

- Within 6,000 flight cycles or 1,125 days,whichever occurs first, after the original issuedate of this service bulletin. Before 8,000total 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 forcracks in accordance with Part 1 - Inspection. No crack is found.

- - - Do 1) or 2) 1) Any crack, 1.5 inch or less, is found; and 2) no crack is found in a repair (if repair is installed). Before further flight. 1) Repair in accordance with Appendix A, B, or C.
or Before further flight.2) Contact The Boeing Company for repair instructions and do the repair. and 8,000 flight cycles. - - Repeat DET and a HFEC inspection of the WCS Spanwise Beam web pockets forcracks in accordance with Part 1 - Inspection.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 15 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT TABLE 1: PART 1 - INSPECTION**  **Repeat In terval (Not** **to Ex ceed)**  **Compliance Time (Whichever Occurs Later)**  **Action Condition** 

- - 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 forcracks 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: Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 

1.00 1.00 1 Open Access Inspect 7.25 14.50 2 ...Spanwise Beam No. 1 - FIGURE 1

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 16 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT Group 1:**  **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task**

4.75 9.50 2 ...Spanwise Beam No. 2 - FIGURE 2 5.50 11.00 2 ...Spanwise Beam No. 3 - FIGURE 3 1.00 1.00 1 Close Access 19.50 37.00 TOTAL FOR EACH AIRPLANE **Group 2: Elapsed Hours**  **Task Hours Number of Persons**  **Task** 1.00 4.00 4 Defuel Center Tank 3.00 6.00 2 Purge and Prepare Center Tank for En- try 1.00 1.00 1 Open Access Inspect 7.25 14.50 2 ...Spanwise Beam No. 1 - FIGURE 4 4.75 9.50 2 ...Spanwise Beam No. 2 - FIGURE 5 5.50 11.00 2 ...Spanwise Beam No. 3 - FIGURE 6 1.50 3.00 2 Close Access 1.00 1.00 1 Test 25.00 50.00 TOTAL FOR EACH AIRPLANE

**H. Weight and Balance Changes** None. **I. Electrical Load Data** Not changed. **J. References** 1. Existing Data a. Engineering Change Memo PRR 62777-72S b. Boeing Service Letter 777-SL-51-013 c. Boeing Service Related Problem (SRP) 777-777-57-0238 d. Standard Overhaul Practices Manual (SOPM) 20-43-03

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 17 of 68 **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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 18 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 19 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 20 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**

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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 21 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 22 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT Part 1 - Inspection**  1. Access

a. **Group 2:** Defuel center tank. Refer to 777 AMM 28-26-00 as an accepted procedure. b. **Group 2:** Purge and prepare to enter center tank. Refer to 777 AMM 28-11-00 as an accepted procedure. c. Remove the forward keel beam access panel 139AL. Refer to 777 AMM 06-41-00 for location of these panels. d. Remove the wing center section access door 139AZ. Refer to as 777 AMM 28-11-02 an accepted procedure. e. Remove the wing center section spanwise beam baffle doors 133AZ, 133BZ, 133CZ. Refer to 777 AMM 28-11-04 as an accepted procedure. 2. Inspection a. Do DET and HFEC inspections of WCS Spanwise Beams Number 1 in accordance with the figure below: **Figure Group 2 Airplanes**  **Group 1 Airplanes** FIGURE 4 FIGURE 1 b. Do DET and HFEC inspections of WCS Spanwise Beams Number 2 in accordance with the figure below: **Figure Group 2 Airplanes**  **Group 1 Airplanes** FIGURE 5 FIGURE 2 c. Do DET and HFEC inspections of WCS Spanwise Beams Number 3 in accordance with the figure below:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 23 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT Figure**  **Group 2 Airplanes Group 1 Airplanes**  FIGURE 6 FIGURE 3
3. Restoration a. Install the wing center section spanwise beam baffle doors 133AZ, 133BZ, 133CZ. Refer to 777 AMM 28-11-04 as an accepted procedure. b. Install the wing center section access door 139AZ. Refer to as 777 AMM 28-11-02 an accepted procedure. c. Install the forward keel beam access panel 139AL. Refer to 777 AMM 06-41-00 for location of these panels. 4. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 24 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 25 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 26 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 27 of 68 **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 1 - WCS Spanwise Beam No. 1 Inspection can be used as a guide to accomplishing and recording the inspections.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a DET of the visible portions of the indicated web pockets, including the radius, from the aft side of the beam. If repair is installed, do a DET of the repair for cracks. 18

- Web / Web Pocket Inspect 1

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. 8

- Web / Web Pocket Inspect 2

Do a DET of the visible portions of the indicated web pockets between theupper 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. 18

- Web / Web Pocket Inspect 3

**FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 28 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT GROUP 1 - WCS SPANWISE BEAM NUMBER 1 - INSPECTION** 
**Date: Airplane:**  **DET (FWD Side)**  **Step 3 HFEC**  **(Web Pocket Radius) Step 2**  **DET (Aft Side)** 

**Step 1 Web Pocket**  **Thickness**

**(inches) Web Pocket**  Left Side of Airplane0.065 1 0.065 2 Not Applicable 0.065 3 Not Applicable 0.060 4 0.055 5 0.055 6 Not Applicable 0.050 7 Not Applicable 0.050 8 Not Applicable 0.050 9 Right Side of Airplane Not Applicable 0.050 10 Not Applicable 0.050 11 Not Applicable 0.050 12 0.055 13 0.055 14 Not Applicable 0.060 15 Not Applicable 0.065 16 0.065 17 0.065 18

**FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 29 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 30 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 31 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 32 of 68 **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 1 - WCS Spanwise Beam No. 2 Inspection can be used as a guide to accomplishing and recording the inspections.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a DET of the visible portions of the indicated web pockets, including the radius, from the aft side of the beam. If repair is installed, do a DET of the repair for cracks. 12

- Web / Web Pocket Inspect 1

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. 8

- Web / Web Pocket Inspect 2

Do a DET of the visible portions of the indicated web pockets between theupper 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. 12

- Web / Web Pocket Inspect 3

**FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 33 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT GROUP 1 - WCS SPANWISE BEAM NUMBER 2 - INSPECTION** 
**Date: Airplane:**  **DET (FWD Side)**  **Step 3 HFEC**  **(Web Pocket Radius) Step 2**  **DET (Aft Side)** 

**Step 1 Web Pocket**  **Thickness**

**(inches) Web Pocket**  Left Side of Airplane Not Applicable 0.060 1 Not Applicable 0.060 2 0.055 3 0.050 4 0.050 5 0.050 6 Right Side of Airplane 0.050 7 0.050 8 0.050 9 0.055 10 Not Applicable 0.060 11 Not Applicable 0.060 12

**FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 34 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 35 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 36 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 37 of 68 **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 1 - WCS Spanwise Beam No. 3 Inspection can be used as a guide to accomplishing and recording the inspections.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a DET of the visible portions of the indicated web pockets, including the radius, from the aft side of the beam. If repair is installed, do a DET of the repair for cracks. 14

- Web / Web Pocket Inspect 1

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. 8

- Web / Web Pocket Inspect 2

Do a DET of the visible portions of the indicated web pockets between theupper 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. 14

- Web / Web Pocket Inspect 3

**FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 38 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT GROUP 1 - WCS SPANWISE BEAM NUMBER 3 - INSPECTION** 
**Date: Airplane:**  **DET (FWD Side)**  **Step 3 HFEC**  **(Web Pocket Radius) Step 2**  **DET (Aft Side)** 

**Step 1 Web Pocket**  **Thickness**

**(inches) Web Pocket**  Left Side of Airplane0.050 1 0.050 2 0.050 3 0.050 4 Not Applicable 0.050 5 Not Applicable 0.050 6 Not Applicable 0.050 7 Right Side of Airplane Not Applicable 0.050 8 Not Applicable 0.050 9 Not Applicable 0.050 10 0.050 11 0.050 12 0.050 13 0.050 14

**FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 39 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 40 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 41 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 42 of 68 **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. 1 Inspection can be used as a guide to accomplishing and recording the inspections.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a DET of the visible portions of the indicated web pockets, including the radius, from the aft side of the beam. If repair is installed, do a DET of the repair for cracks. 26

- Web / Web Pocket Inspect 1

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. 16

- Web / Web Pocket Inspect 2

Do a DET of the visible portions of the indicated web pockets between theupper 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. 26

- Web / Web Pocket Inspect 3

**FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 43 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT GROUP 2 - WCS SPANWISE BEAM NUMBER 1 - INSPECTION** 
**Date: Airplane:**  **DET (FWD Side)**  **Step 3 HFEC**  **(Web Pocket Radius) Step 2**  **DET (AFT Side)**  **Step 1 Web Pocket**  **Thickness**

**(inches) Web Pocket**  Left Side of Airplane0.065 1A 0.065 1B 0.065 1C 0.065 2 Not Applicable 0.065 3 Not Applicable 0.060 4 0.055 5 0.055 6A 0.055 6B 0.055 6C Not Applicable 0.050 7 Not Applicable 0.050 8 Not Applicable 0.050 9 Right Side of Airplane Not Applicable 0.050 10 Not Applicable 0.050 11 Not Applicable 0.050 12 0.055 13A 0.055 13B 0.055 13C 0.055 14 Not Applicable 0.060 15 Not Applicable 0.065 16 0.065 17 0.065 18A 0.065 18B 0.065 18C

**FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 44 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 45 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 46 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 47 of 68 **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.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a DET of the visible portions of the indicated web pockets, including the radius, from the aft side of the beam. If repair is installed, do a DET of the repair for cracks. 20

- Web / Web Pocket Inspect 1

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. 12

- Web / Web Pocket Inspect 2

Do a DET of the visible portions of the indicated web pockets between theupper 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. 20

- Web / Web Pocket Inspect 3

**FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 48 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT GROUP 2 - WCS SPANWISE BEAM NUMBER 2 - INSPECTION** 
**Date: Airplane:**  **DET (FWD Side)**  **Step 3 HFEC**  **(Web Pocket Radius) Step 2**  **DET (Aft Side)** 

**Step 1 Web Pocket**  **Thickness**

**(inches) Web Pocket**  Left Side of Airplane Not Applicable 0.065 1A Not Applicable 0.065 1B Not Applicable 0.065 1C Not Applicable 0.065 2 0.060 3 0.060 4 0.060 5 0.060 6A 0.060 6B 0.060 6C Right Side of Airplane 0.060 7A 0.060 7B 0.060 7C 0.060 8 0.060 9 0.060 10 Not Applicable 0.065 11 Not Applicable 0.065 12A Not Applicable 0.065 12B Not Applicable 0.065 12C

**FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 49 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION (SHEET 1 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 50 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION**  **(SHEET 2 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 51 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION**  **(SHEET 3 OF 5)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 52 of 68 **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. 3 Inspection can be used as a guide to accomplishing and recording the inspections.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  Do a DET of the visible portions of the indicated web pockets, including the radius, from the aft side of the beam. If repair is installed, do a DET of the repair for cracks. 22

- Web / Web Pocket Inspect 1

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. 12

- Web / Web Pocket Inspect 2

Do a DET of the visible portions of the indicated web pockets between theupper 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. 22

- Web / Web Pocket Inspect 3

**FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION (SHEET 4 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 53 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT GROUP 2 - WCS SPANWISE BEAM NUMBER 3 - INSPECTION** 
**Date: Airplane:**  **DET (FWD Side)**  **Step 3 HFEC**  **(Web Pocket Radius) Step 2**  **DET (Aft Side)** 

**Step 1 Web Pocket**  **Thickness**

**(inches) Web Pocket**  Left Side of Airplane0.060 1 0.060 2A 0.060 2B 0.060 2C 0.060 3 0.060 4 Not Applicable 0.055 5 Not Applicable 0.055 6 Not Applicable 0.055 7A Not Applicable 0.055 7B Not Applicable 0.055 7C Right Side of Airplane Not Applicable 0.055 8A Not Applicable 0.055 8B Not Applicable 0.055 8C Not Applicable 0.055 9 Not Applicable 0.055 10 0.060 11 0.060 12 0.060 13A 0.060 13B 0.060 13C 0.060 14

**FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION (SHEET 5 OF 5)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 54 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB**  **(SHEET 1 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 55 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB**  **(SHEET 2 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 56 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT NOTE:**  Cutout cracked area. 1. – Cutout cracked area,1.94 inch maximum diameter, 0.94 inch minimum, before insurance cut. Cutout does not need be round. 0.50 minimum radius on all corners – Do a HFEC inspection around the edge of the cutout for cracks in accordance with 777 NDT Part 6, 51-00-01. If cracks are found, continue to oversize cutout up to maximum before insurance cut hole size. If crack still exists contact The Boeing Company for additional instructions. – Make an insurance cut, increase cutout size by 1/16 (0.0625) inch minimum on the diameter or 1/32 (0.03125) inch minimum from the edge on oblong cutouts. Maximum hole size after insurance cut is 2.0 inch, 1.00 minimum. Maintain minimum 63 Microinch Ra finish on all edges. Break all sharp edges. Oblong cutout can be maximum 2.00 inch in length with a minimum width of 1.00 inch. – Apply Chemical Conversion Coating, ALODINE 600 to trimmed edges. Refer to SOPM 20-43-03 as an accepted procedure. – Apply Primer, Fuel Tank, BMS 10-20, TYPE II to trimmed edges. Refer to 777 AMM 51-21-10 as an accepted procedure. 2. Design repair. – Use two rows of fasteners around the cutout. Spacing for field fasteners is 4D to 6D, where D is the diameter of the hole. For 1/64 and 1/32 inch oversize fasteners, use the hole size of the standard size fastener for spacing calculation. Use existing fastener in the stiffeners on each side of the web bay and the upper and lower chord at the top and bottom of each web bay as a guide in locating fastener holes. – Adjust size of repair doubler and the location of the field fasteners as required to to maintain 2.0 e/D edge margin from edge of the repair doubler and edge of repair cutout in web, where e is the distance from the center of the hole to the edge of the part and D is the diameter of the hole. – Adjust location of field fasteners in the area of the trimmed out area to maintain minimum edge margin and meet spacing requirements between fasteners. – At the existing stiffener locations, install oversize (1/64 minimum, 1/32 maximum) shear hi-loks. Refer to Table E "Fastener Hole Dimensions For Holes In The Upper Chord To Web and The Stiffeners To Web That Are Not Cold Worked (Shifted Positive Fit)" in 777-200 SRM 51-40-05, 777-300 SRM 51-40-05, or 777F SRM 51-40-05 for hole sizes. – For field fasteners, fasteners installed in the web pocket and doubler, install standard size (1/64 or 1/32 inch oversize acceptable, if hole was damaged) shear hi-loks in transition fit holes. Refer to 777-200 SRM 51-40-05, 777-300 SRM 51-40-05, or 777F SRM 51-40-05 for hole sizes. Field fastener diameter is based on the size of the existing fasteners in the existing stiffener on each side of the web bay. The field fastener should be the same standard size as the smallest fastener in the existing stiffener on each side of the web bay where the repair is being installed. 3. Fabricate repair doubler and stiffeners.

**APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 57 of 68 **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 of repair doublers, and repair stiffener per Table 1. – Apply Chemical Conversion Coating, ALODINE 600 after fabrication. Refer to SOPM 20-43-03 as an accepted procedure. – Apply Primer, Fuel Tank, BMS 10-20, TYPE II after fabrication. Refer to 777 AMM 51-21-10 as an accepted procedure. 4. Locate repair doubler and stiffeners. – Locate repair doubler and stiffeners and drill holes, full size. – Remove doubler and stiffeners. Deburr and clean doubler, stiffeners, and existing structure. 5. Install repair doubler and stiffeners. – Install doubler and stiffeners. – Install fasteners. **Table 1 - Repair Doubler and Repair Stiffener Thickness Thickness of Repair Doubler**  **and Repair Stiffener (Standard Stock Sheet Thick**  **ness) Original Web Thickness** 

0.056 0.050 0.063 0.055 0.071 0.060 0.080 0.065 The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA FLAG**  **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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 58 of 68 **BOEING SERVICE BULLETIN 777-57A0087 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 59 of 68 **BOEING SERVICE BULLETIN 777-57A0087 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)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 60 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT NOTE:**  Cutout cracked area. 1. – Cutout Cracked area, ,1.94 inch maximum diameter, 0. 94 inch minimum, before insurance cut. Cutout does not need be round. 0.50 minimum radius on all corners – Do a HFEC inspection around the edge of the cutout for cracks in accordance with 777 NDT Part 6, 51-00-01. If cracks are found, continue to oversize cutout up to maximum before insurance cut hole size. If crack still exists contact The Boeing Company for additional instructions. – Make an insurance cut, increase cutout size by 1/16 (0.0625) inch minimum on the diameter or 1/32 (0.03125) inch minimum from the edge on oblong cutouts. Maximum hole size after insurance cut is 2.0 inch, 1.00 minimum. Maintain minimum 63 Microinch Ra finish on all edges. Break all sharp edges. Oblong cutout can be maximum 2.00 inch in length with a minimum width of 1.00 inch. – Apply Chemical Conversion Coating, ALODINE 600 to trimmed edges. Refer to SOPM 20-43-03 as an accepted procedure. – Apply Primer, Fuel Tank, BMS 10-20, TYPE II to trimmed edges. Refer to 777 AMM 51-21-10 as an accepted procedure. 2. Design repair. – Use two rows of fasteners around the cutout, 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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 61 of 68 **BOEING SERVICE BULLETIN 777-57A0087 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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 62 of 68 **BOEING SERVICE BULLETIN 777-57A0087 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 Thick**  **ness) Original Web Thickness** 

0.056 0.050 0.063 0.055 0.071 0.060 0.080 0.065 The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA FLAG**  **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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 63 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL**  **STIFFENER (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 64 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL**  **STIFFENER (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 65 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT NOTE:**  Cutout cracked area. 1. – Cutout Cracked area,1.94 inch maximum diameter, 0. 94 inch minimum, before insurance cut. Cutout does not need be round. 0.50 minimum radius on all corners – Do a HFEC inspection around the edge of the cutout for cracks in accordance with 777 NDT Part 6, 51-00-01. If cracks are found, continue to oversize cutout up to maximum before insurance cut hole size. If crack still exists contact The Boeing Company for additional instructions. – Make an insurance cut, increase 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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 66 of 68 **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 Thick**  **ness) Original Web Thickness** 

0.056 0.050 0.063 0.055 0.071 0.060 0.080 0.065 The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA FLAG**  **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)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 67 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT Figure**  **Location Group 2 Airplanes**  **(Airplanes with wet center sec**  **tion.) Group 1 Airplanes**  **(Airplanes with dry center sec**  **tion.)** FIGURE 4 FIGURE 1 Inspection - Spanwise Beam No. 1 FIGURE 5 FIGURE 2 Inspection - Spanwise Beam No. 2 FIGURE 6 FIGURE 3 Inspection - Spanwise Beam No. 3 APPENDIX A APPENDIX A Repair - Crack (1.5 inch maximum) in Center of Web APPENDIX B APPENDIX B Repair - Crack (1.5 inch maximum) at Top or Bottom Fillet Radius Adjacent to Upper or Lower Chord APPENDIX C APPENDIX C Repair - Crack (1.5 inch maximum) at Side Fillet Radius Adjacent to Vertical Stiffener

**APPENDIX D: SCOPE OF WORK (SHEET 1 OF 1)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: November 11, 2010 777-57A0087 68 of 68 **BOEING SERVICE BULLETIN 777-57A0087 ALERT**  **ALERT**