### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Number: 777-78A0066**  Original Issue: June 05, 2008 Revision 2: April 08, 2010 ATA System: 7831 **SUBJECT:** EXHAUST (GE90 Engine) - Thrust Reverser System - Latch Beam Firewall - Install Insulation Blanket 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2008 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 1 of 46 2.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 2 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 17 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 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:. . . . . . . . . . . . . . . . . . . . . . . . 21 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 22 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FIGURE 1: THRUST REVERSER - LATCH BEAM - REMOVE AFT INSULATION BLANKET AND INSULATION FOAM [Group 1]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FIGURE 2: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION [Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FIGURE 3: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION [Group 1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 4: THRUST REVERSER - LATCH BEAM - REMOVE INSULATION FOAM [Group 2]. . . . 35 FIGURE 5: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 6: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION [Group 2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Appendix A: COMPOSITE STUD - ADHESIVE BONDED INSTALLATION. . . . . . . . . . . . . . . . 45

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 3 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 4 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Revision Transmittal Sheet**  **Number: 777-78A0066** Original Issue: June 05, 2008 Revision 2: April 08, 2010 ATA System: 7831 **SUBJECT:** EXHAUST (GE90 Engine) - Thrust Reverser System - Latch Beam Firewall - Install Insulation Blanket This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** Federal Aviation Administration (FAA) Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD, is related to this service bulletin. No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. **REASON FOR REVISION** This revision is sent to add airplanes that were inadvertantly omitted in the original issue of this service bulletin, to change information in the compliance section, and to add an optional instruction to mark the thrust reverser identifcation plate. The following sections have been changed: 1. Paragraph 1.A.1., Airplanes - Airplanes with variable numbers WB372-WB388 were added to Group 1. 2. In the Compliance section and Paragraph 1.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," has been changed to, "Federal Aviation Administration Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD is related to this service bulletin." 3. In Paragraph 3.B, Work Instructions, Step 8 - "OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number to show the change was done. Refer to SOPM 20-50-10 as an accepted procedure," was added. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 5 of 46**REVISION HISTORY** June 05, 2008 Original Issue: March 12, 2009 Revision 1: April 08, 2010 Revision 2:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 6 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Summary**  **Number: 777-78A0066** Original Issue: June 05, 2008 Revision 2: April 08, 2010 ATA System: 7831 **SUBJECT:** EXHAUST (GE90 Engine) - Thrust Reverser System - Latch Beam Firewall - Install Insulation Blanket 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** This service bulletin tells the operator to add a thermal insulation blankets, and attachments, to the rear section of the latch beam of each Thrust Reverser (T/R) half. This change will make sure that a fire can not breach the bolt-on aluminum plate at the rear of the latch beam and move into the transcowl cavity. A fire that is not contained could move to other cowl or strut areas. This could cause weakened structural pieces of the T/R to separate in flight, with the result of a damaged airplane or injury to persons on the ground. An operator performed an In Flight Shut Down (IFSD) because of an engine fire indication. An air turn back and satisfactory landing was completed without incident. An under cowl engine fire was put out on the ground. The cause was determined to be an uncontained failure of the starter in the engine core compartment, which progressed into the latch beam cavity fuelled by oil supplied by a damaged Integrated Drive Generator (IDG) oil line. The fire breached the bolt-on aluminum plate on the rear of the latch beam fire wall and moved inside the translating sleeve. This caused damage to inner and outer walls of the T/R translating sleeve. Installation of a thermal insulation blanket over the bolt-on aluminum plate area at the rear of the latch beam will protect this area of the firewall so that it is not breached by a fire. This retrofit is not necessary on T/Rs after airplane line 413, because of a design change. The design change to the T/R, integrated the bolt on the aluminum plate area into the main latch beam casting and incorporated thermal insulation blankets across the area. Boeing Service Related Problem (SRP) 777-SRP-78-0059 is related to this service bulletin. **ACTION (PRR 62777-57RS)** Open a T/R and accomplish the work below:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 7 of 46**Group 1:** 1. Remove and keep the existing latch beam insulation blanket. 2. Remove insulation foam on the aft fire wall. 3. Install bonded studs on fire wall. 4. Install new thermal insulation blanket on fire wall. 5. Install removed latch beam insulation blanket. 6. Apply sealant around new thermal insulation blanket. 7. Repeat the work for the opposite T/R. Close the T/R when the work is complete. **NOTE:** Service Bulletin 777-24-0058 which installs a check valve in the IDG oil supply should also be done. The bulletin addresses the potential event of failure of the oil supply line, stopping the flow of oil which can help feed a fire in the area of the IDG. **Group 2:** 1. Remove insulation foam on the aft fire wall. 2. Install bonded studs on fire wall. 3. Install new thermal insulation blanket on fire wall. 4. Install new latch beam insulation blanket. 5. Apply sealant around new thermal insulation blanket. 6. Repeat the work for the opposite T/R. Close the T/R when the work is complete. **NOTE:** Service Bulletin 777-24-0058 which installs a check valve in the IDG oil supply should also be done. The bulletin addresses the potential event of failure of the oil supply line, stopping the flow of oil which can help feed a fire in the area of the IDG. **EFFECTIVITY** 777-200 Airplanes with GE-90 engines. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. **COMPLIANCE** Federal Aviation Administration Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD is related to this service bulletin. Boeing recommends that the change, given in this service bulletin be done within 1, 825 days or 4, 500 flight cycles after the original issue date of this service bulletin, whichever occurs first. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 8 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MANPOWER**  **Group 1:**
**EACH ENGINE Elapsed Hours**  **Total Task Hours** 7.50 7.50 **Group 2:**
**EACH ENGINE Elapsed Hours**  **Total Task Hours** 7.25 7.25
**MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 9 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 10 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**

### Commercial **Airplanes** 

# 777 Service Bulletin **ALERT Number: 777-78A0066**  Original Issue: June 05, 2008 Revision 2: April 08, 2010 ATA System: 7831 **SUBJECT:** EXHAUST (GE90 Engine) - Thrust Reverser System - Latch Beam Firewall - Install Insulation Blanket 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 Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below. Refer to PRR 62777-57RS for data about this change.
**DESCRIPTION CONFIGURATION**  **GROUP** All 777-200 airplanes with GE90 engines through line number 413 with a forward insulation blanket. - 1
All 777-200 airplanes with GE90 engines through line number 413 without a forward insulation blanket. - 2

Airplane Models: 777-200 **Group Variable Number**  2 WA076 - WA080 2 WA116 - WA119 2 WB001 - WB009

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 11 of 46**Group Variable Number**  1 WB010 - WB021 2 WB121 - WB122 1 WB123 - WB125 1 WB271 - WB273 1 WB276 - WB286 1 WB291 - WB302 1 WB306 - WB307 2 WB311 - WB313 1 WB314 - WB337 1 WB341 - WB342 1 WB371 - WB388 1 WB406 1 WB411 - WB413 1 WB476 1 WC241 1 WC281 2. Spares Affected Spare Thrust Reversers (T/R) are affected. Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for parts necessary to change spares. **B. Concurrent Requirements** None. **C. Reason** This service bulletin tells the operator to add a thermal insulation blankets, and attachments, to the rear section of the latch beam of each Thrust Reverser (T/R) half. This change will make sure that a fire can not breach the bolt-on aluminum plate at the rear of the latch beam and move into the transcowl cavity. A fire that is not contained could move to other cowl or strut areas. This could cause weakened structural pieces of the T/R to separate in flight, with the result of a damaged airplane or injury to persons on the ground.. An operator performed an In Flight Shut Down (IFSD) because of an engine fire indication. An air turn back and satisfactory landing was completed without incident. An under cowl engine fire was put out on the ground. The cause was determined to be an uncontained failure of the starter in the engine core compartment, which progressed into the latch beam cavity fuelled by oil supplied by a damaged Integrated Drive Generator (IDG) oil line. The fire breached the bolt-on aluminum plate on the rear of the latch beam fire wall and moved inside the translating sleeve. This caused damage to inner and

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 12 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**outer walls of the T/R translating sleeve. Installation of a thermal insulation blanket over the bolt-on aluminum plate area at the rear of the latch beam will protect this area of the firewall so that it is not breached by a fire. This retrofit is not necessary on T/Rs after airplane line 413, because of a design change. The design change to the T/R, integrated the bolt on the aluminum plate area into the main latch beam casting and incorporated thermal insulation blankets across the area. Boeing Service Related Problem (SRP) 777-SRP-78-0059 is related to this service bulletin. Revision 1 is sent to change the assigned grouping of three airplanes that were assigned to the incorrect group in the original issue of this service bulletin. Also, the Summary illustration and Figures 1 thru 6 are corrected to show and accurate view of the lower attachment points for insulation blanket assemblies 315W1654-31 and 315W1654-32. These sections have changed: 1. Summary: – Illustration: changed to show the correct insulation blanket attachment points. – Compliance: changed to inform operators to do the tasks in this service bulletin within a given time after the original issue of this service bulletin. 2. Paragragh 1.A., Effectivity: Airplanes variable numbers WB311 thru WB313 are moved from Group 1 to Group 2. 3. FIGURE 1: Illustration changed to show the correct view of insulation blanket installation. 4. FIGURE 2: Sheet 2 - Illustration changed to show the correct insulation blanket fastener locations. 5. FIGURE 3: Sheet 2 - Changed to show correct insulation blanket fastener locations. 6. FIGURE 4: Illustration changed to show corrected view of insulation blanket. 7. FIGURE 5: Sheet 2 - Changed to show correct insulation blanket fastener locations. 8. FIGURE 6: Sheet 2 - Changed to show correct insulation blanket fastener loactions. The data given in Information Notice 777-78A0066 IN 01 is included in this revision. Revision 2 is sent to add airplanes that were inadvertantly omitted in the original issue of this service bulletin, to change information in the compliance section, and to add an optional instruction to mark the thrust reverser identifcation plate.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 13 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**The following sections have been changed: 1. Paragraph 1.A.1., Airplanes - Airplanes with variable numbers WB372-WB388 were added to Group 1. 2. In the Compliance section and Paragraph 1.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," has been changed to, "Federal Aviation Administration Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD is related to this service bulletin." 3. In Paragraph 3.B, Work Instructions, Step 8 - "OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number to show the change was done. Refer to SOPM 20-50-10 as an accepted procedure," was added. **D. Description** Open a T/R and accomplish the work below. **Group 1:** 1. Remove and keep the existing latch beam insulation blanket. 2. Remove insulation foam on the aft fire wall. 3. Install bonded studs on fire wall. 4. Install new thermal insulation blanket on fire wall. 5. Install removed latch beam insulation blanket. 6. Apply sealant around new thermal insulation blanket. 7. Repeat the work for the opposite T/R. Close the T/R when the work is complete. **NOTE:** Service Bulletin 777-24-0058 which installs a check valve in the IDG oil supply should also be done. The bulletin addresses the potential event of failure of the oil supply line, stopping the flow of oil which can help feed a fire in the area of the IDG. **Group 2:** 1. Remove insulation foam on the aft fire wall. 2. Install bonded studs on fire wall. 3. Install new thermal insulation blanket on fire wall. 4. Install new latch beam insulation blanket. 5. Apply sealant around new thermal insulation blanket. 6. Repeat the work for the opposite T/R. Close the T/R when the work is complete.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 14 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT NOTE:**  Service Bulletin 777-24-0058 which installs a check valve in the IDG oil supply should also be done. The bulletin addresses the potential event of failure of the oil supply line, stopping the flow of oil which can help feed a fire in the area of the IDG. Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. Revision 2 - Federal Aviation Administration (FAA) Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD, is related to this service bulletin. No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 415, 416, 425, 426 777-200 **E. Compliance** Federal Aviation Administration Notice of Proposed Rule Making FAA NPRM 2008-NM-148-AD is related to this service bulletin. Boeing recommends that the change given in this service bulletin be done within 1,825 days or 4,500 flight cycles after the original issue date of this service bulletin, whichever occurs first. **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 service bulletin for each engine. 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 15 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**— 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** 
0.50 0.50 1 Open Access 1.00 1.00 1 Figure 1 2.75 2.75 1 Figure 2 2.75 2.75 1 Figure 3 0.50 0.50 1 Close Access 7.50 7.50 TOTAL FOR EACH ENGINE **Group 2: Elapsed Hours**  **Task Hours Number of Per-**  **sons Task** 
0.50 0.50 1 Open Access 0.75 0.75 1 Figure 4 2.75 2.75 1 Figure 5 2.75 2.75 1 Figure 6 0.50 0.50 1 Close Access 7.25 7.25 TOTAL FOR EACH ENGINE **H. Weight and Balance Changes Group 1:**  **Change in Moment (Pound-Inches)**  **Change in Weight (Pounds)**  **Airplane**
+ 3431.7 + 3.2 For Each Engine **Group 2: Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane** 
+ 4288.0 Ib-in + 4.0 Ibs For Each Engine
**I. Electrical Load Data** Not changed.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 16 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT J. References**  1. Existing Data: a. Engineering Change Memo PRR 62777-57RS b. Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2008-NM-148-AD c. Standard Overhaul Practices Manual (SOPM) 20-30-03, 20-41-02, 20-50-10, 20-50-12, 20-50-19 d. 777 Aircraft Maintenance Manual (AMM) 78-31-00 e. Boeing Drawing 012W6100 f. Boeing Parts Standards Document D-590 g. Service Related Problem (SRP) 777-SRP-78-0059 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. **K. Publications Affected Chapter-Section** 

**Publication** 78-31 777 Maintenance Manual 78-31 777 Illustrated Parts Catalog 78-31 Component Maintenance Manual **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: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 17 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 18 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**

BLANK PAGE**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary For Each Airplane Engine and Paragraph 2.D., Parts Necessary to Change Spares, as shown below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order. **Group 1:**
**Unit Price thru December 31,**  **2008 ROLT**  **(Weeks) QTY**  **Date Name**  **Kit Number**

$3,546 30 10 April 14, 2008 Top Kit - GE90 Latch Beam Insulation Blanket 005W3346-1
**Group 2:**
**Unit Price thru December 31,**  **2008 ROLT**  **(Weeks) QTY**  **Date Name**  **Kit Number**

$5,253 30 10 Nov 06, 2008 Top Kit - GE90 Latch Beam Insulation Blanket 005W3346-4
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. **Reference this service bulletin and submit your purchase order by one of the methods that follow:**  1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane engine.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 19 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **Figure Kit 6**  **5 3**  **2 Top Kit** 

- - 1 1 005W3346-1 1 1
- - 005W3346-4 **Group 1:**
**KIT 005W3346-1**

**NOTES Existing Part**  **Number Name**  **Figure**

**New Part Number 3**  **2 QTY**  WASHER 3 4 315W1163-26 KIT - LATCH BEAM BLANKET ASSY 1 315W1257-1

KIT - LATCH BEAM BLANKET ASSY 1 315W1257-2

BUSHING, PLAIN 3 4 BACB28AK04-030 NUT 3 4 BACN10JC3C STUD, COMPOSITE BASE 3 4 CB4017C3CRA12R
**Group 2:**
**KIT 005W3346-4**

**NOTES Existing Part**  **Number Name**  **Figure**

**New Part Number 6**  **5 QTY**  KIT - LATCH BEAM BLANKET ASSY 1 315W1257-1

KIT - LATCH BEAM BLANKET ASSY 1 315W1257-2

BLANKET ASSY 1 315W1654-31 BLANKET ASSY 1 315W1654-32 BUSHING, PLAIN 3 4 BACB28AK04-030

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 20 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT Group 2:** 
**KIT 005W3346-4**

**NOTES Existing Part**  **Number Name**  **Figure**

**New Part Number 6**  **5 QTY**  NUT 3 4 BACN10JC3C SCREW, CAP 3 3 BACS12GU3K15 WASHER, PLAIN 3 3 BACW10P392CC WASHER 3 4 BACW10P458CD STUD, COMPOSITE BASE 3 4 CB4017C3CRA12R
2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number/ Specification**  PRIMER 1 Pt BMS 10-11,TYPE 1 ADHESIVE 1 Pt BMS 5-109, TYPE 2, CLASS 2 SEALANT 1 Pt BMS 5-63, TYPE 1, CLASS B- 4
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** To get the kit shown below, refer to Paragraph 2.A., Material - Price and Availability.
**QTY Name**  **Part Number** 1(a) Top Kit - GE90 Latch Beam Insulation Blanket 005W3346-1 1(a) (b) Top Kit - GE90 Latch Beam Insulation Blanket 005W3346-4 (a) The top kit has parts to modify the left and right halves of a T/R. (b) This kit contains the additional 315W1654-31 and 315W1654-32 insulation blankets and the attached hardware necessary for the Group 2 airplane configuration.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 21 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT E. Special Tooling - Price and Availability**  None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 22 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: — Torque limits to tighten nuts and bolts are given in 777 SRM, Chapter 51. 4. For approved fastener and process material substitutions, refer to 777 SRM, Chapter 51, Alternate fasteners are given in 777 SRM Chapter 51 and Boeing Drawing 012W6100. 5. These work instructions refer to procedures included on 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 "as given in" are included in the instruction, the procedure in the Boeing document must be used. 6. This service bulletin is done on each engine's Thrust Reverser (T/R) on the airplane. 7. Refer to Appendix A as an accepted procedure to install bonded studs. **B. WORK INSTRUCTIONS** 1. Open a T/R. Refer to 777 AMM 78-31-00, as an accepted procedure to open a T/R.
2. **Group 1:** Remove the aft most latch beam insulation blanket and insulation foam as given in FIGURE 1. 3. **Group 2:** Remove the latch beam insulation foam as given in FIGURE 4.
4. **Group 1:** Install studs, blankets and sealant for the left side T/R half, as given in FIGURE 2.
5. **Group 1:** Install studs, blankets and sealant for the right side T/R half, as given in FIGURE 3. 6. **Group 2:** Install studs, blankets and sealant for the left side T/R half, as given in FIGURE 5.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 23 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**7. **Group 2:** Install studs, blankets and sealant for the right side T/R half, as given in FIGURE 6. 8. OPTIONAL: Operators can mark the T/R identification plate with the service bulletin number to show the change was done. Refer to SOPM 20-50-10 as an accepted procedure. 9. Close the T/R. Refer to 777 AMM 78-31-00, as an accepted procedure to close the T/R. 10. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2: April 08, 2010 24 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 1: THRUST REVERSER - LATCH BEAM - REMOVE AFT INSULATION BLANKET AND INSULATION FOAM**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 25 of 46 **BOEING SERVICE BULLETIN 777-78A0066 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 both left and right T/R halves.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  6
- SCREW Remove / Keep 1 6
- WASHER Remove / Keep (a) 2
- BLANKET, INSULA- TION Remove / Keep 2 (b)

- - INSULATION Remove 3 (c)

- - SCRAPED AREA Clean 4 (a) Carefully lift corner of the over-lapping insulation blanket to remove the aft-most insulation blanket. Loosen other insulation blanket fasteners as necessary to remove the aft-most insulation blanket. (b) Remove all insulation from the latch beam that the new insulation blanket will cover. Use a hard resin phenolic scraper to remove as much as possible. Remove all loose material with a soft bristle brush or a clean cotton wiper. If the exposed metal has hydraulic fluid on it, dry it with a cotton wiper. (c) Refer to SOPM 20-30-03 as an accepted procedure to clean the scraped area. Make sure to dry the area with a cotton wiper.

**FIGURE 1: THRUST REVERSER - LATCH BEAM - REMOVE AFT INSULATION BLANKET AND INSULATION FOAM**  **(SHEET 2 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 26 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 2: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 27 of 46 **BOEING SERVICE BULLETIN 777-78A0066 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 the left T/R half.

**FIGURE 2: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 28 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a)

- BMS 10-11,TYPE 1 PRIMER Apply 1 (b) 1 315W1257-1 KIT - LATCH BEAM BLANKET ASSY Put / Hold 2 (c) 3
- MARK Apply 3 1 315W1257-1 KIT - LATCH BEAM BLANKET ASSY Remove / Keep 4 (d) 3
- PIN, PILOT Remove 5 (e) (f) (g) 4 CB4017C3CRA12R STUD, COMPOSITE BASE Install (New) 6 (e)

- BMS 5-109, TYPE 2, CLASS 2 ADHESIVE Apply (g) 4 BACB28AK04-030 BUSHING, PLAIN Install (New) 7 1 315W1257-1 KIT - LATCH BEAM BLANKET ASSY Install (New) 8 (g) (h) 4 315W1163-26 WASHER Install (New) 9 (g) (i) 4 BACN10JC3C NUT Install (New) 10 (j) 1
- BLANKET, INSULA- TION Install (Kept) 11
3
- WASHER Install (Kept) 12 (i) 3
- SCREW Install (Kept) 13 (k)

- BMS 5-63, TYPE 1, CLASS B-4 SEALANT Apply 14 (a) If the removal of the insulation material removed primer, touch up the latch beam as necessary. Refer to SOPM 20-41-02 as an accepted procedure to apply primer. (b) Position the latch beam insulation blanket in the latch beam to mark the locations for the studs. The part name indicates a kit, but the part is supplied assembled (c) Use the insulation blanket holes to locate and mark the location for the three studs that will be bonded to the latch beam. Center a Pressure Application Fixture (PAF), supplied with a composite stud, over the hole marks and mark the latch beam around the bottom of the PAF. This mark will be used to locate the PAF and composite stud with adhesive. Refer to APPENDIX A for PAF description. (d) Cut off the pilot pin from the stud base of the composite stud as close as possible to the stud base. Abrade or scrape the stud base if necessary to give a flat base. (e) Clean stud base and latch beam mating area. Apply BMS 5-109, Type 2, Class 2, adhesive. Put, hold,and cure stud to the latch beam with a PAF. Refer to Appendix A and SOPM 20-50-12, Type 94, as accepted procedures to install composite studs. (f) Composite studs are supplied with a Pressure Application Fixture (PAF). Refer to APPENDIX A to see how the PAF is used.

**FIGURE 2: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 29 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (g) The qty given is one more than necessary. Return part to your stores if it is not used (h) Washer BACW10P458CD is optional to 315W1163-26. (i) Torque to 20-25 in-lb. Make sure other insulation blanket fasteners that were loosened to remove the kept insulation blanket, are tightened. (j) Clean the mating areas of the two insulation blankets. Apply BMS 5-109, Type 2, Class 2, adhesive. Refer to SOPM 20-50-12, Type 94, as an accepted procedure to apply the adhesive. Make sure the insulation blanket that is forward of this insulation blanket, overlaps it. (k) Seal where shown in bold line. Seal edge common to both blankets. Seal new blanket edges common to the latch beam. Seal gap that forms next to the two blankets and the forward stiffener. Seal gap that forms at the lower end of the stiffeners. DO NOT SEAL edges of new blanket that are directly above the access door. DO NOT SEAL edges of new blanket around the upper end of the stiffeners. Be careful to not plug drain holes when the sealant is applied. Refer to SOPM 20-50-19 as an accepted procedure to seal the blanket.

**FIGURE 2: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 30 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT This Figure applies only to: Group 1.** 

**FIGURE 3: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 31 of 46 **BOEING SERVICE BULLETIN 777-78A0066 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 the rightft T/R half.

**FIGURE 3: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 32 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a)

- BMS 10-11,TYPE 1 PRIMER Apply 1 (b) 1 315W1257-2 KIT - LATCH BEAM BLANKET ASSY Put / Hold 2 (c) 3
- MARK Apply 3 1 315W1257-2 KIT - LATCH BEAM BLANKET ASSY Remove / Keep 4 (d) 3
- PIN, PILOT Remove / Keep 5 (e) (f) 3 CB4017C3CRA12R STUD, COMPOSITE BASE Install (New) 6 (e)

- BMS 5-109, TYPE 2, CLASS 2 ADHESIVE Apply
3 BACB28AK04-030 BUSHING, PLAIN Install (New) 7 1 315W1257-2 KIT - LATCH BEAM BLANKET ASSY Install (New) 8 (g) 3 315W1163-26 WASHER Install (New) 9 (h) 3 BACN10JC3C NUT Install (New) 10 (i) 1
- BLANKET, INSULA- TION Install (Kept) 11
3
- WASHER Install (Kept) 12 (h) 3
- SCREW Install (Kept) 13 (j)

- BMS 5-63, TYPE 1, CLASS B-4 SEALANT Apply 14 (a) If the removal of the insulation material removed primer then apply primer to the latch beam as necessary. Refer to SOPM 20-41-02 as an accepted procedure to apply primer. (b) Position the latch beam insulation blanket in the latch beam to mark the locations for the studs. The part name indicates a kit, but the part is supplied assembled (c) Use the insulation blanket holes to locate and mark the location for the three studs that will be bonded to the latch beam. Center a Pressure Application Fixture (PAF), supplied with a composite stud, over the hole marks and mark the latch beam around the bottom of the PAF. This mark will be used to locate the PAF and composite stud with adhesive. Refer to APPENDIX A for PAF description. (d) Cut off the pilot pin from the stud base of the composite stud as close as possible to the stud base. Abrade or scrape the stud base if necessary to give a flat base. (e) Clean stud base and latch beam mating area. Apply BMS 5-109, Type 2, Class 2, adhesive. Put, hold,and cure stud to the latch beam with a PAF. Refer to Appendix A and SOPM 20-50-12, Type 94, as accepted procedures to install composite studs. (f) Composite studs are supplied with a Pressure Application Fixture (PAF). Refer to APPENDIX A to see how the PAF is used.

**FIGURE 3: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 33 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (g) Washer BACW10P458CD is optional to 315W1163-26. (h) Torque to 20-25 in-lb. Make sure that other insulation blanket fasteners that were loosened to remove the kept insulation blanket, are tightened. (i) Clean the mating areas of the two insulation blankets. Apply BMS 5-109, Type 2, Class 2, adhesive. Refer to SOPM 20-50-12, Type 94 as an accepted procedure to install the adhesive. Make sure the insulation blanket that is forward of this insulation blanket, overlaps it. (j) Seal where shown in bold line. Seal edge common to both blankets. Seal new blanket edges common to the latch beam. Seal gap that forms next to the two blankets and the forward stiffener. Seal gap that forms at the lower end of the stiffeners. DO NOT SEAL edges of new blanket that are directly above the access door. DO NOT SEAL edges of new blanket around the upper end of the stiffeners. Be careful to not plug drain holes when the sealant is applied. Refer to SOPM 20-50-19 as an accepted procedure to seal the blanket.

**FIGURE 3: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKET INSTALLATION (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 34 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 4: THRUST REVERSER - LATCH BEAM - REMOVE INSULATION FOAM (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 35 of 46 **BOEING SERVICE BULLETIN 777-78A0066 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 both the left and right T/R halves..
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a)

- - INSULATION Remove 1 (b)

- - SCRAPED AREA Clean 2 (a) Remove all insulation from the latch beam that the new insulation blanket will cover. Use a hard resin phenolic scraper to remove as much as possible. Remove all loose material with a soft bristle brush or a clean cotton wiper. If the exposed metal has hydraulic fluid on it, dry it with a cotton wiper. (b) Refer to SOPM 20-30-03 as an accepted procedure to clean the scraped area. Make sure to dry the area with a cotton wiper.

**FIGURE 4: THRUST REVERSER - LATCH BEAM - REMOVE INSULATION FOAM (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 36 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 5: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 37 of 46 **BOEING SERVICE BULLETIN 777-78A0066 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 the left T/R half.

**FIGURE 5: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 38 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a)

- BMS 10-11,TYPE 1 PRIMER Apply 1 (b) 1 315W1257-1 KIT - LATCH BEAM BLANKET ASSY Put / Hold 2 (c) 3
- MARK Apply 3 1 315W1257-1 KIT - LATCH BEAM BLANKET ASSY Remove / Keep 4 (d) 3
- PIN, PILOT Remove 5 (e) (f) 4 CB4017C3CRA12R STUD, COMPOSITE BASE Install (New) 6 (e)

- BMS 5-109, TYPE 2, CLASS 2 ADHESIVE Apply (g) 4 BACB28AK04-030 BUSHING, PLAIN Install (New) 7 1 315W1257-1 KIT - LATCH BEAM BLANKET ASSY Install (New) 8 (g) (h) 4 BACW10P458CD WASHER Install (New) 9 (g) (i) 4 BACN10JC3C NUT Install (New) 10 (j) 1 315W1654-31 BLANKET ASSY Install (New) 11 3 BACW10P392CC WASHER, PLAIN Install (New) 12 (i) 3 BACS12GU3K15 SCREW, CAP Install (New) 13 (k)

- BMS 5-63, TYPE 1, CLASS B-4 SEALANT Apply 14 (a) If the removal of the insulation material removed primer then apply primer to the latch beam as necessary. Refer to SOPM 20-41-02 as an accepted procedure to apply primer. (b) Position the latch beam insulation blanket in the latch beam to mark the locations for the studs. The part name indicates a kit, but the part is supplied assembled (c) Use the insulation blanket holes to locate and mark the location for the three studs that will be bonded to the latch beam. Center a Pressure Application Fixture (PAF), supplied with a composite stud, over the hole marks and mark the latch beam around the bottom of the PAF. This mark will be used to locate the PAF and composite stud with adhesive. Refer to APPENDIX A for PAF description. (d) Cut off the pilot pin from the stud base of the composite stud as close as possible to the stud base. Abrade or scrape the stud base if necessary to give a flat base. (e) Clean stud base and latch beam mating area. Apply BMS 5-109, Type 2, Class 2, adhesive. Put, hold, and cure stud to the latch beam with a PAF. Refer to APPENDIX A and SOPM 20-50-12, Type 94, as accepted procedures to install composite studs. (f) Composite studs are supplied with a Pressure Application Fixture (PAF). Refer to APPENDIX A to see how the PAF is used. (g) The qty given is one more than necessary. Return part to your stores if it is not used

**FIGURE 5: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 39 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (h) Washer 315W1163-26 is optional to BACW10P458CD. (i) Torque to 20-25 in-lb. Make sure other insulation blanket fasteners that were loosened to remove the kept insulation blanket, are tightened. (j) Clean the mating areas of the two insulation blankets. Apply BMS 5-109, Type 2, Class 2, adhesive. Refer to SOPM 20-50-12, Type 94, as an accepted procedure to apply the adhesive. Make sure the insulation blanket that is forward of this insulation blanket, overlaps it. (k) Seal where shown in bold line. Seal edge common to both blankets. Seal new blanket edges common to the latch beam. Seal gap that forms next to the two blankets and the forward stiffener. Seal gap that forms at the lower end of the stiffeners. DO NOT SEAL edges of new blanket that are directly above the access door. DO NOT SEAL edges of new blanket around the upper end of the stiffeners. Be careful to not plug drain holes when the sealant is applied. Refer to SOPM 20-50-19 as an accepted procedure to seal the blanket.

**FIGURE 5: LEFT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 40 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT This Figure applies only to: Group 2.** 

**FIGURE 6: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 41 of 46 **BOEING SERVICE BULLETIN 777-78A0066 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 the right T/R half.

**FIGURE 6: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 42 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a)

- BMS 10-11,TYPE 1 PRIMER Apply 1 (b) 1 315W1257-2 KIT - LATCH BEAM BLANKET ASSY Put / Hold 2 (c) 3
- MARK Apply 3 1 315W1257-2 KIT - LATCH BEAM BLANKET ASSY Remove / Keep 4
3
- PIN, PILOT Remove / Keep 5 (e) (f) 3 CB4017C3CRA12R STUD, COMPOSITE BASE Install (New) 6 (e)

- BMS 5-109, TYPE 2, CLASS 2 ADHESIVE Apply
3 BACB28AK04-030 BUSHING, PLAIN Install (New) 7 1 315W1257-2 KIT - LATCH BEAM BLANKET ASSY Install (New) 8 (g) 3 BACW10P458CD WASHER Install (New) 9 (h) 3 BACN10JC3C NUT Install (New) 10 (i) 1 315W1654-32 BLANKET ASSY Install (New) 11 3 BACW10P392CC WASHER, PLAIN Install (New) 12 (h) 3 BACS12GU3K15 SCREW, CAP Install (New) 13 (j)

- BMS 5-63, TYPE 1, CLASS B-4 SEALANT Apply 14 (a) If the removal of the insulation material removed primer, touch up the latch beam as necessary. Refer to SOPM 20-41-02 as an accepted procedure to apply primer. (b) Position the latch beam insulation blanket in the latch beam to mark the locations for the studs. The part name indicates a kit, but the part is supplied assembled (c) Use the insulation blanket holes to locate and mark the location for the three studs that will be bonded to the latch beam. Center a Pressure Application Fixture (PAF), supplied with a composite stud, over the hole marks and mark the latch beam around the bottom of the PAF. This mark will be used to locate the PAF and composite stud with adhesive. Refer to APPENDIX A for PAF description. (d) Cut off the pilot pin from the stud base of the composite stud as close as possible to the stud base. Abrade or scrape the stud base if necessary to give a flat base. (e) Clean stud base and latch beam mating area. Apply BMS 5-109, Type 2, Class 2, adhesive. Put, hold, and cure stud to the latch beam with a PAF. Refer to APPENDIX A and SOPM 20-50-12, Type 94, as accepted procedures to install composite studs. (f) Composite studs are supplied with a Pressure Application Fixture (PAF). Refer to APPENDIX A to see how the PAF is used. (g) Washer 315W1163-26 is optional to BACW10P458CD.

**FIGURE 6: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 3 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 43 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (h) Torque to 20-25 in-lb. Make sure that other insulation blanket fasteners that were loosened to remove the kept insulation blanket, are tightened. (i) Clean the mating areas of the two insulation blankets. Apply BMS 5-109, Type 2, Class 2, adhesive. Refer to SOPM 20-50-12, Type 94 as an accepted procedure to install the adhesive. Make sure the insulation blanket that is forward of this insulation blanket, overlaps it. (j) Seal where shown in bold line. Seal edge common to both blankets. Seal new blanket edges common to the latch beam. Seal gap that forms next to the two blankets and the forward stiffener. Seal gap that forms at the lower end of the stiffeners. DO NOT SEAL edges of new blanket that are directly above the access door. DO NOT SEAL edges of new blanket around the upper end of the stiffeners. Be careful to not plug drain holes when the sealant is applied. Refer to SOPM 20-50-19 as an accepted procedure to seal the blanket.

**FIGURE 6: RIGHT THRUST REVERSER - LATCH BEAM - INSULATION BLANKETS INSTALLATION (SHEET 4 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 44 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT Appendix A: COMPOSITE STUD - ADHESIVE BONDED INSTALLATION**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 45 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**1. Each adhesive bonded composite stud has a Pressure Application Fixture (PAF) to aid in location and installation. Refer to Steps 1 thru 5 in the illustration for installation. 2. Clean and prepare the base of the composite stud and the surface of the structure where the composite stud is to be installed. Refer to Boeing Standard Operating Procedures Manual SOPM 20-50-12, Type 94 as an accepted procedure to install the composite stud, except do not remove the PAF to look for unwanted adhesive before it has cured. a. Apply a thin, equal coat of BMS 5-109 Type 2, Class 2, adhesive to the composite stud base and latch beam area. Refer to step 1. **NOTE:** Make sure base of composite stud is above the bottom of the PAF. b. Remove the release liner ring to expose the pressure sensitive adhesive on the bottom of the PAF. Refer to step 2. c. Position the PAF centered to the area of the latch beam assembly where the composite stud is to be installed. d. Press down (P) around the outer edge of the PAF to bond the fixture to the structure. DO NOT apply pressure to the center the fixture. Refer to step 3. **NOTE:** Make sure that the base of the click bond stud is above the bottom of the PAF. e. Press down (P) near the center of the fixture until a click is felt or heard. Refer to step 4. **NOTE:** The above step will cause the base of the composite stud to come in contact with the structure and apply pressure to the composite stud and will cause the adhesive to come out. No other clamp pressure is necessary. f. Allow adhesive to cure as given in SOPM 20-50-12, Type 94. g. After adhesive cures, peel off and discard the PAF. Refer to step 5. 3. Look at the installation of the composite stud. a. Make sure there is a continuous bead of adhesive all the way around the base of the composite stud. b. Make sure that no cured adhesive is on the stud threads of the composite stud. Remove cured adhesive from threads with Scotch-Brite or equivalent.

**Appendix A: COMPOSITE STUD - ADHESIVE BONDED INSTALLATION (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 05, 2008 777-78A0066 Revision 2 April 08, 2010 46 of 46 **BOEING SERVICE BULLETIN 777-78A0066 ALERT**  **ALERT**