Commercial

Airplane

Group

777

Service Bulletin

Number: 777-55A0010 Revision Transmittal Sheet Date: October 26, 2000

Revision 1: April 17, 2001

ATA System: 5500

SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper

Additions

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed as shown in the initial release of this service bulletin.

REASON FOR REVISION

This revision is sent to do the following:

1. Replace solid rivets with blind rivets in 8 locations on the horizontal stabilizer.

2. Delete instruction to remove the VOR antenna for access.

3. Modify instruction to position rudder and elevator prior to modification.

4. Add instruction to remove additional access panels on vertical and horizontal stabilizers.

5. Add access panel numbers in access / restoration figures.

6. Clarify illustrations with bold lines to show removed panels.

The initial release of this service bulletin was validated at an operator's maintenance facility on an operator's

airplane.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the

Effectivity paragraph for changes.

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.

REVISION HISTORY

Original Release: October 26, 2000

Revision 1: April 17, 2001

777-55A0010

Revision Transmittal Page 1 of 1

Commercial

Airplane

Group

777

Service Bulletin

Number: 777-55A0010 Summary Date: October 26, 2000

Revision 1: April 17, 2001

ATA System: 5500

SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper

Additions

CONCURRENT REQUIREMENTS

None

BACKGROUND

Accomplishment of this service bulletin will reduce

potential high resistance bond paths between the

rudder / vertical fin and also between the elevator /

horizontal stabilizer. This modification will reduce the

potential effects of a large lightning strike on the

hydraulic and flight control system in the

empennage. A lightning strike to the empennage

with high resistance bond paths could cause

excessive current on hydraulic lines resulting in

pitting at in-line fittings causing pin-hole leaks on

hydraulic lines. Leaks due to lightning strikes could

lead to loss of hydraulic systems in the empennage

which could adversely affect airplane controllability.

In addition, excessive current through the elevator /

rudder graphite composite structure can lead to

melting / vaporization of epoxy and internal

structural damage that will reduce the life of the

parts.

Additional bonding jumpers in the empennage will

provide a lower resistance path during lightning

strikes. Low resistances are important in providing

an alternate path for large currents to be "grounded"

to the airplane structure instead of damaging

hydraulics and / or flight controls.

One operator has told Boeing of two separate

reports of lightning strikes which caused hydraulic

line leaks in Section 48 of a 777-200. High

resistance bond paths between the rudder / vertical

fin and also between the elevator / horizontal

stabilizer were found during certification testing for

the 777-300, and were later found to exist on the

777-200. Airplanes after line number 155 were

delivered with additional bonding jumpers installed

in production. The initial release of this service

bulletin was validated at an operator's maintenance

facility on an operator's airplane.

Accomplishment of this service bulletin will make

sure that high resistance bond paths are reduced

between the rudder / vertical fin and also between

the elevator / horizontal stabilizer to reduce the

damaging effects of airplane lightning strikes.

Boeing Service Related Problem (SRP)

777-SRP-55-0018 is related to this service bulletin.

ACTION (PRR 61847)

Install five bonding jumpers, related ground clips

and fasteners to the rudder / vertical fin. Install

fourteen (seven per side) bonding jumpers, related

ground clips and fasteners to the elevators /

horizontal stabilizers. Revise two fasteners from

titanium to corrosion resistant steel in the vertical fin

tip. Conduct resistance checks of installed bonding

jumpers.

EFFECTIVITY

All 777-200 airplanes and 777-300 airplanes line

numbers 002 through 155.

COMPLIANCE

Boeing recommends that operators do this service

bulletin as manpower, materials, and facilities are

available, but not later than 12 months after the date

on this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for

airplanes in warranty as of March 22, 1999. Please

refer to Paragraph 2.B., Industry Support

Information.

777-55A0010

Summary Page 1 of 2
BOEING SERVICE BULLETIN 777-55A0010

MANPOWER

Total Elapsed Time

Airplanes Man-Hours (Hours)

777-200 66 36

777-300 66 36

MATERIAL INFORMATION

Boeing Supplied Kits/Parts

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

Availability.

INSTALL FOURTEEN (SEVEN PER SIDE) BONDING

CONDUCT RESISTANCE CHECKS.

ELEVATORS/HORIZONTAL STABILIZERS.

JUMPERS AND RELATED HARDWARE TO

FIN TIP. CONDUCT RESISTANCE CHECKS.

CORROSION RESISTANT STEEL IN THE VERTICAL

REVISE TWO FASTENERS FROM TITANIUM TO

HARDWARE TO THE RUDDER/VERTICAL FIN.

INSTALL FIVE BONDING JUMPERS AND RELATED

V32373

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 Summary Page 2 of 2
Commercial

Airplane

Group

777

Service Bulletin

Number: 777-55A0010

Date: October 26, 2000

Revision 1: April 17, 2001

ATA System: 5500

SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper

Additions

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. An equivalent change is on subsequent

production airplanes. Refer to PRR61847 for data about this change.

Airplane Models:

777-200 777-300

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AEROFLOT (ARO)

WB336

AIR FRANCE (AFA)

WB311-WB313

ALL NIPPON AIRWAYS (ANA)

WA131-WA137 WA221-WA223 WA231-WA232 WB531-WB533

BRITISH AIRWAYS (BAB)

WA076-WA080 WB001-WB013

CATHAY PACIFIC AIRWAYS (CAT)

WA101-WA104 WB501-WB504

CHINA SOUTHERN AIRLINES (GUN)

WA116-WA119 WB121-WB125

EGYPTAIR (EGP)

WB151-WB153

EMIRATES (EAD)

WA196-WA198 WB101-WB104

JAPAN AIR SYSTEM (JAS)

WA206-WA210

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 Page 1 of 52
BOEING SERVICE BULLETIN 777-55A0010

JAPAN AIRLINES (JAL)

WA171-WA175 WB591

KOREAN AIR (KAL)

WB131-WB133 WB551

KUWAIT AIRWAYS (KUW)

WB306-WB307

LAUDA AIR (LAL)

WB271

MALAYSIA AIRLINES (MAS)

WB161-WB169

SAUDI ARABIAN AIRLINES (SVA)

WB276-WB286

SINGAPORE AIRLINES (SIA)

WB181-WB186 WB231-WB234

THAI (TII)

WA086-WA093

UNITED AIRLINES (UAL)

WA002-WA017 WB051-WB068

IDENTIFICATION BY VARIABLE NUMBER

WA002-WA017 WA076-WA080 WA086-WA093 WA101-WA104 WA116-WA119 WA131-WA137

WA171-WA175 WA196-WA198 WA206-WA210 WA221-WA223 WA231-WA232 WB001-WB013

WB051-WB068 WB101-WB104 WB121-WB125 WB131-WB133 WB151-WB153 WB161-WB169

WB181-WB186 WB231-WB234 WB271 WB276-WB286 WB306-WB307 WB311-WB313

WB336 WB501-WB504 WB531-WB533 WB551 WB591

2. Spares Affected

None

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 2
BOEING SERVICE BULLETIN 777-55A0010

B. Concurrent Requirements

None

C. Reason

Accomplishment of this service bulletin will reduce potential high resistance bond paths between the

rudder / vertical fin and also between the elevator / horizontal stabilizer. This modification will reduce

the potential effects of a large lightning strike on the hydraulic and flight control system in the

empennage. A lightning strike to the empennage with high resistance bond paths could cause

excessive current on hydraulic lines resulting in pitting at in-line fittings causing pin-hole leaks on

hydraulic lines. Leaks due to lightning strikes could lead to loss of hydraulic systems in the

empennage which could adversely affect airplane controllability. In addition, excessive current

through the elevator / rudder graphite composite structure can lead to melting / vaporization of epoxy

and internal structural damage that will reduce the life of the parts.

Additional bonding jumpers in the empennage will provide a lower resistance path during lightning

strikes. Low resistances are important in providing an alternate path for large currents to be

"grounded" to the airplane structure instead of damaging hydraulics and / or flight controls.

One operator has told Boeing of two separate reports of lightning strikes which caused hydraulic line

leaks in Section 48 of a 777-200. High resistance bond paths between the rudder / vertical fin and

also between the elevator / horizontal stabilizer were found during certification testing for the

777-300, and were later found to exist on the 777-200. Airplanes after line number 155 were

delivered with additional bonding jumpers installed in production. The initial release of this service

bulletin was validated at an operator's maintenance facility on an operator's airplane.

Accomplishment of this service bulletin will make sure that high resistance bond paths are reduced

between the rudder / vertical fin and also between the elevator / horizontal stabilizer to reduce the

damaging effects of airplane lightning strikes.

Revision 1 is sent to do the following:

1. Replace solid rivets with blind rivets in 8 locations on the horizontal stabilizer.

2. Delete instruction to remove the VOR antenna for access.

3. Modify instruction to position rudder and elevator prior to modification.

4. Add instruction to remove additional access panels on vertical and horizontal stabilizers.

5. Add access panel numbers in access / restoration figures.

6. Clarify illustrations with bold lines to show removed parts.

Boeing Service Related Problem (SRP) 777-SRP-55-0018 is related to this service bulletin.

D. Description

Install five bonding jumpers, related ground clips and fasteners to the rudder / vertical fin. Install

fourteen (seven per side) bonding jumpers, related ground clips and fasteners to the elevators /

horizontal stabilizers. Revise two fasteners from titanium to corrosion resistant steel in the vertical fin

tip. Conduct resistance checks of installed bonding jumpers.

Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this

service bulletin.

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 3
BOEING SERVICE BULLETIN 777-55A0010

An evaluation form is attached to this service bulletin. Please use this form to tell us what you think

of the quality of this service bulletin.

E. Compliance

Boeing recommends that operators do this service bulletin as manpower, materials, and facilities are

available, but not later than 12 months after the date on this service bulletin.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes

specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and

are FAA approved. This service bulletin and the FAA approval were based on the airplane in its

original Boeing delivery configuration or as modified by other FAA 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.

NOTE: Joint Airworthiness Requirements (JAR) compliance status may be found in the Service

Bulletin Index, Part 1.

G. Manpower

The tables below show an estimate of the man-hours necessary to do this change for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

man-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 examine the work

- Time to cure the materials

- Time to make the parts

- Time to find the tools.

BONDING JUMPER ADDITION TO RUDDER / VERTICAL FIN

Task Number of Persons Man-Hours Elapsed Time (Hours)

Open Access 1-2 6 3

Install Bonding

Jumpers and

related

hardware

1-2 5 3

Conduct

Resistance

Checks

1 1 1

Close Access 1-2 6 4

TOTAL FOR EACH AIRPLANE (a) 18 11

(a) Total is for bonding jumper addition to rudder / vertical fin.

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 4
BOEING SERVICE BULLETIN 777-55A0010

BONDING JUMPER ADDITION TO ELEVATORS / HORIZONTAL STABILIZERS

Task Number of Persons Man-Hours Elapsed Time (Hours)

Open Access 2 16 8

Install Bonding

Jumpers and

related

hardware

2 14 7

Conduct

Resistance

Checks

1 2 2

Close Access 2 16 8

TOTAL FOR EACH AIRPLANE (a) 48 25

(a) Total is for bonding jumper addition to elevators / horizontal stabilizers on both

sides of the airplane.

H. Weight and Balance Changes

Change in Weight Change in Moment

Airplane (Pounds) (Pound-Inches)

777-200 +6.2 +15128.0

777-300 +6.2 +16299.8

I. Electrical Load Data

Not changed

J. References

1. Existing Data:

a. Engineering Change Memo PRR 61847

b. 777 Maintenance Manual (AMM) Subjects 55-11-01, 55-15-01, 55-31-01, 55-31-02, 55-35-01,

55-36-01

c. Boeing Standard Overhaul Practices Manual (BSOPM) Subject 20-50-19

d. Boeing Standard Wiring Practices Manual (BSWPM) Subject 20-20-00

2. Data supplied with this service bulletin:

None

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 5
BOEING SERVICE BULLETIN 777-55A0010

3. Installation Drawings Used in the Preparation of This Service Bulletin:

Drawing Number Title

183W0001 Elevator Installation

173W0012 Rudder Installation

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Changed

Publication Chapter-Section

777 Maintenance Manual 05-55

L. Interchangeability and Intermixability of Parts

None

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 6
BOEING SERVICE BULLETIN 777-55A0010

2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane, as shown

below. If there is a limit in the quantity (QTY) of kits, a supply sequence is given by Spares.

Unit Price thru

Kit Number Name Date QTY Mar 31/01

005W3106-1 Top Kit (a) (a) $2,668.00

(a) Contact Boeing Spares for kit availability data.

The kits are subject to the terms and conditions of the Boeing standard purchase order

acknowledgment. After the Unit Price date, new price data is applicable. Prices are in United States

dollars. Terms: Net 30 days.

Send purchase orders and letters about the supply data to the Director of Spares and refer to this

service bulletin number.

B. Industry Support Information

Boeing warranty remedies are available for 777 airplanes in warranty as of March 22, 1999. For

man-hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Product Assurance Contracts. The kits for airplanes in warranty as of that date will be supplied at no

charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin

number and reference the airplane variable number in your purchase order.

C. Parts Necessary For Each Airplane

1. Kits:

To get the kits shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the

Operator, are necessary for each airplane.

005W3106 TOP KIT - LIGHTNING PROTECTION OF EMPENNAGE FLIGHT

CONTROL SURFACES

-3 -2 -1

Quantity Part Number Name

. . - 005W3106-1 Top Kit

. - 2 005W3106-2 Horizontal Subkit

- . 1 005W3106-3 Vertical Subkit

. 5 . 189W4000-14 Ground Clip

5 4 . 189W4000-32 Ground Clip

2 . . BACB30LH3-5 Bolt

8 12 . BACB30LJ4-4 Bolt

1 1 . BACB30LJ4U7 Bolt

. 5 . BACB30NX6K4X Bolt

2 . . BACB30VT6K3 Bolt

. 5 . BACC30BH6 Collar

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 7
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

005W3106 TOP KIT - LIGHTNING PROTECTION OF EMPENNAGE FLIGHT

CONTROL SURFACES

-3 -2 -1

Quantity Part Number Name

2 . . BACC30BP6 Collar

. 2 . BACJ40E20-20 Jumper

. 1 . BACJ40E20-24 Jumper

. 1 . BACJ40E20-26 Jumper

1 1 . BACJ40E20-30 Jumper

2 . . BACJ40E20-36 Jumper

1 . . BACJ40E20-38 Jumper

1 . . BACJ40E20-40 Jumper

. 1 . BACJ40E20-44 Jumper

. 1 . BACJ40E20-48 Jumper

8 12 . BACN10JC4CD Nut

1 1 . BACN10JC4CM Nut

2 . . BACR15BB6D8C Rivet

1 5 . BACR15BB7AD4C Rivet

3 3 . BACR15BB7AD5C Rivet

. 3 . BACR15BB7AD8C Rivet

. 4 . BACR15FR6E2R Rivet

4 7 . BACR15FT6KE6C Rivet

1 1 . BACW10BP4APU Washer

8 12 . BACW10BP4DP Washer

1 1 . 189W4000U31 Ground Clip

NOTE: The kit has more parts than are necessary for installation. Discard parts that are not used

or keep the parts for spares.

2. Parts and Materials Supplied by the Operator:

QTY Part Number Name

24 oz BMS 5-95 Sealant (a)

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

Specification (BMS) for supplier data.

D. Parts Necessary to Change Spares

None

E. Existing Parts Accountability

None

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 8
BOEING SERVICE BULLETIN 777-55A0010

F. Special Tooling - Price and Availability

None

G. 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.

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 9
BOEING SERVICE BULLETIN 777-55A0010

BLANK PAGE

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 10
BOEING SERVICE BULLETIN 777-55A0010

3. ACCOMPLISHMENT INSTRUCTIONS

GENERAL NOTES

1. The paragraphs identified with a letter give the general work instructions and the necessary tests.

The instructions identified with numbers on the figures give the recommended sequence of steps.

2. 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 given in 777 Structural Repair Manual, Chapter 51

- Torque limits to tighten nuts and bolts are given in 777 Structural Repair Manual, Chapter 51.

3. Alternative fasteners are given in 777 Structural Repair Manual, Chapter 51.

4. As an alternative to the Boeing specified Airplane Maintenance Manuals (AMM's), operator's

equivalent procedures can be used.

5. Obey all of the warnings and cautions given in the specified manual sections.

WORK INSTRUCTIONS

A. Set rudder and elevator in appropriate position for maintenance being performed. No specific

position is needed for access.

B. Remove Hydraulic power to rudder and elevators.

C. Obtain access for bonding jumper installation per Figure 1 (rudder / vertical fin), Figure 2 and

Figure 3 (elevator / horizontal stabilizer).

D. Install bonding jumpers and conduct resistance checks per Figure 4 (rudder / vertical fin), Figure 5

and Figure 6 (elevator / horizontal stabilizer).

E. Seal bonding jumpers per Figure 7 (rudder / vertical fin), Figure 8 and Figure 9 (elevator /

horizontal stabilizer).

F. Restore access per Figure 1 (rudder / vertical fin), Figure 2 and Figure 3 (elevator / horizontal

stabilizer).

G. Put the airplane back to a serviceable condition.

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 11
BOEING SERVICE BULLETIN 777-55A0010

FIGURE TABLE OF CONTENTS

Title Page

FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN . . . . . . . . . . . . . . 13

FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL

STABILIZER - OUTBOARD END. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

FIGURE 3. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL

STABILIZER - INBOARD END. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE

CHECKS ON THE RUDDER / VERTICAL FIN . . . . . . . . . . . . . . . . . . . . . . . 21

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE

CHECKS ON THE ELEVATOR / HORIZONTAL STABILIZER -

OUTBOARD END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE

CHECKS ON THE ELEVATOR / HORIZONTAL STABILIZER -

INBOARD END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER /

VERTICAL FIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END . . . . . . . . . . . . . . . . . . . . . 47

FIGURE 9. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR /

HORIZONTAL STABILIZER - INBOARD END . . . . . . . . . . . . . . . . . . . . . . . 51

October 26, 2000 777-55A0010

Revision 1: April 17, 2001 12
BOEING SERVICE BULLETIN 777-55A0010

4 9

1 12

10

2 11

3

A

SEE A

SEE B

FWD

DIVERTER

LIGHTNING

V32390

FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN

October 26, 2000 SHEET 1 OF 3 777-55A0010

Revision 1: April 17, 2001 13
BOEING SERVICE BULLETIN 777-55A0010

6 7

5 8

B

FWD

V32391

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the airplane.

ACCESS

STEP TASK NAME REFERENCES QTY NOTES

WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE RUDDER WHEN YOU

WORK ON OR NEAR IT. THE RUDDER MOVES QUICKLY AND WITH FORCE. IF THE

RUDDER MOVES WHEN PERSONS ARE NEAR IT, YOU CAN CAUSE INJURY TO

THEM.

WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE VERTICAL FIN.

FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP PERSONS AWAY

FROM THE AREA BELOW THE VERTICAL FIN. PARTS COULD ACCIDENTALLY FALL

AND CAUSE INJURY TO PERSONS.

1 Remove /

Discard

Bolt - 2 Removed titanium fasteners will

be replaced with corrosion

resistant steel fasteners.

2 Remove /

Keep

Vertical Stabilizer Tip

Fairing

777 AMM 55-31-01 1 -

3 Remove /

Keep

Aft Panel - 2 Remove / keep 179W3310-1 Aft

Panel (left side) and

179W3310-2 Aft Panel (right

side - not shown).

FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN

October 26, 2000 SHEET 2 OF 3 777-55A0010

Revision 1: April 17, 2001 14
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

ACCESS

4 Remove /

Keep

Trailing Edge Seal 777 AMM 55-36-01 2 Remove / keep left side trailing

edge seal (panel number

324WL) and right side trailing

edge seal (panel number

324WR - not shown).

5 Remove /

Keep

Leading Edge Panel 777 AMM 55-35-01 1 Remove / keep leading edge

panel number 321F.

6 Remove /

Keep

Auxiliary Spar to

Front Spar Panel

- 1 Remove / keep 177W300-45F

Auxiliary Spar to Front Spar

Panel (left side). Panel number

322HL.

RESTORATION

STEP TASK NAME REFERENCES QTY NOTES

WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE RUDDER WHEN YOU

WORK ON OR NEAR IT. THE RUDDER MOVES QUICKLY AND WITH FORCE. IF THE

RUDDER MOVES WHEN PERSONS ARE NEAR IT, YOU CAN CAUSE INJURY TO

THEM.

WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE VERTICAL FIN.

FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP PERSONS AWAY

FROM THE AREA BELOW THE VERTICAL FIN. PARTS COULD ACCIDENTALLY FALL

AND CAUSE INJURY TO PERSONS.

7 Install /

Kept

Auxiliary Spar to

Front Spar Panel

- 1 Install / kept 177W300-45F

Auxiliary Spar to Front Spar

Panel (left side). Panel number

322HL.

8 Install /

Kept

Leading Edge Panel 777 AMM 55-35-01 1 Install / kept leading edge panel

number 321F.

9 Install /

Kept

Trailing Edge Seal 777 AMM 55-36-01 2 Install / kept left side trailing

edge seal (panel number

324WL) and right side trailing

edge seal (panel number

324WR - not shown).

10 Install /

Kept

Aft Panel - 2 Install / kept 179W3310-1 Aft

Panel (left side) and

179W3310-2 Aft Panel (right

side).

11 Install /

Kept

Vertical Stabilizer Tip

Fairing

777 AMM 55-31-01 1 -

12 Install Bolt 777 AMM 55-31-02 2 Install two BACB30LH3-5 Bolts

per 777 AMM 55-31-02 Section

3.G.(2)(b).

FIGURE 1. ACCESS / RESTORATION IN RUDDER / VERTICAL FIN

October 26, 2000 SHEET 3 OF 3 777-55A0010

Revision 1: April 17, 2001 15
BOEING SERVICE BULLETIN 777-55A0010

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

FWD 4 7

3 8

10

SEE A

A

5 6

1

2 9

V32428

FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 1 OF 3 777-55A0010

Revision 1: April 17, 2001 16
BOEING SERVICE BULLETIN 777-55A0010

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.

ACCESS

STEP TASK NAME REFERENCES QTY NOTES

WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER

WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY

AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU

CAN CAUSE INJURY TO THEM.

WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL

STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP

PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS

COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.

1 Remove /

Keep

Lower Panel - 1 Remove / keep 189W4000-21

Lower Panel (panel number

355LB - left side), 189W4000-22

Lower Panel (panel number

345LB - right side).

2 Remove /

Keep

Forward Box Lower

Panel

- 1 Remove / keep forward box

lower panel number 333FB (left

side) and 343FB (right side).

3 Remove /

Keep

Leading Edge

Outboard Panel

777 AMM 55-15-01 1 Panel number 332EL (left side).

Panel number 342ER (right

side).

4 Remove /

Keep

Trailing Edge Seal - 2 Remove / keep 185W1102-41

(top left), -42 (top right) Trailing

Edge Seal and 185W1202-57

(bottom left), -58 (bottom right)

Trailing Edge Seal.

5 Remove /

Keep

Horizontal Stabilizer

Tip Fairing

777 AMM 55-11-01 1 -

RESTORATION

STEP TASK NAME REFERENCES QTY NOTES

WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER

WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY

AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU

CAN CAUSE INJURY TO THEM.

WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL

STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP

PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS

COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.

6 Install /

Kept

Horizontal Stabilizer

Tip Fairing

777 AMM 55-11-01 1 (a)

7 Install /

Kept

Trailing Edge Seal - 2 Install / kept 185W1102-41 (top

left), -42 (top right) Trailing Edge

Seal and 185W1202-57 (bottom

left), -58 (bottom right) Trailing

Edge Seal.

FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 2 OF 3 777-55A0010

Revision 1: April 17, 2001 17
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

RESTORATION

8 Install /

Kept

Leading Edge

Outboard Panel

777 AMM 55-15-01 1 Panel number 332EL (left side).

Panel number 342ER (right

side).

9 Install /

Kept

Forward Box Lower

Panel

- 1 Install / kept forward box lower

panel number 333FB (left side)

and 343FB (right side).

10 Install /

Kept

Lower Panel - 1 Install / kept 189W4000-21

Lower Panel (panel number

335LB - left side), 189W4000-22

Lower Panel (panel number

345LB - right side).

(a) One bonding jumper attaches to the fixed structure of the horizontal stabilizer and to the structure of

the removed tip fairing. With the tip fairing rotated on to the upper surface of the horizontal stabilizer,

connect this bonding jumper, measure resistance, and add required sealing. Rotate the tip fairing into

the installed position and complete installation per 777 AMM 55-11-01. Two bonding jumpers connect to

the bracket on the elevator front spar. Connect these bonding jumpers, measure resistance, and add

required sealing.

FIGURE 2. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 3 OF 3 777-55A0010

Revision 1: April 17, 2001 18
BOEING SERVICE BULLETIN 777-55A0010

3 4 2 5 1 6

V32877

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.

ACCESS

STEP TASK NAME REFERENCES QTY NOTES

WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER

WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY

AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU

CAN CAUSE INJURY TO THEM.

WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL

STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP

PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS

COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.

1 Remove /

Keep

Straklet Panel 777 AMM 55-15-01 1 Panel number 332BL (left side).

Panel number 342BR (right

side).

2 Remove /

Keep

Forward Box Lower

Panel

- 1 Panel number 333BB (left side).

Panel number 343BB (right

side).

3 Remove /

Keep

Inboard Lower Panel 777 AMM 55-10-01 1 Panel number 333AB (left side).

Panel number 343AB (right

side).

FIGURE 3. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - INBOARD END

October 26, 2000 SHEET 1 OF 2 777-55A0010

Revision 1: April 17, 2001 19
BOEING SERVICE BULLETIN 777-55A0010

RESTORATION

STEP TASK NAME REFERENCES QTY NOTES

WARNING: YOU MUST PREVENT ALL POSSIBLE OPERATION OF THE HORIZONTAL STABILIZER

WHEN YOU WORK ON OR NEAR IT. THE HORIZONTAL STABILIZER MOVES QUICKLY

AND WITH FORCE. IF THE STABILIZER MOVES WHEN PERSONS ARE NEAR IT, YOU

CAN CAUSE INJURY TO THEM.

WARNING: ATTACH A SAFETY HARNESS WHEN YOU DO WORK ON TOP OF THE HORIZONTAL

STABILIZER. FAILURE TO DO THIS CAN CAUSE INJURY OR DAMAGE. KEEP

PERSONS AWAY FROM THE AREA BELOW THE HORIZONTAL STABILIZER. PARTS

COULD ACCIDENTALLY FALL AND CAUSE INJURY TO PERSONS.

4 Install /

Kept

Inboard Lower Panel 777 AMM 55-10-01 1 Panel number 333AB (left side).

Panel number 343AB (right

side).

5 Install /

Kept

Forward Box Lower

Panel

- 1 Panel number 333BB (left side).

Panel number 343BB (right

side).

6 Install /

Kept

Straklet Panel 777 AMM 55-15-01 1 Panel number 332BL (left side).

Panel number 342BR (right

side).

FIGURE 3. ACCESS / RESTORATION IN ELEVATOR / HORIZONTAL STABILIZER - INBOARD END

October 26, 2000 SHEET 2 OF 2 777-55A0010

Revision 1: April 17, 2001 20
BOEING SERVICE BULLETIN 777-55A0010

FWD

SEE A

A

SEE D

SEE B

SEE C

C

C

A

A

B

B

OMITTED FOR CLARITY.

SPAR

AUXILIARY

NOTE: RIGHT SIDE CHORDS OF THE AUXILIARY

SPAR AND CLOSURE RIB ASSEMBLY ARE

CLOSURE RIB

ASSEMBLY

V32439

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 1 OF 8 777-55A0010

Revision 1: April 17, 2001 21
BOEING SERVICE BULLETIN 777-55A0010

1 1

FWD

A-A

V32910

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 2 OF 8 777-55A0010

Revision 1: April 17, 2001 22
BOEING SERVICE BULLETIN 777-55A0010

1

1

C-C

B-B

UP

UP

V32931

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 3 OF 8 777-55A0010

Revision 1: April 17, 2001 23
BOEING SERVICE BULLETIN 777-55A0010

2 4

2 4

4

3 C

2

B

C

2 4

4

7 8

4

5 6

UP

FWD

2

3 B

3

2

A 3

A

FWD

UP D-D

D

D

V33111

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 4 OF 8 777-55A0010

Revision 1: April 17, 2001 24
BOEING SERVICE BULLETIN 777-55A0010

10 10

D 14 15 12

11 13

9

20 21 18 19

16 17

D FWD

UP

BRACKET

0.43

0.43

CLIP

INSTALL NEW

E-E

REMOVE EXISTING

CLIP

RUDDER

FRONT

NEW GROUND

CLIP

SPAR

E

E

V33175

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 5 OF 8 777-55A0010

Revision 1: April 17, 2001 25
BOEING SERVICE BULLETIN 777-55A0010

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the airplane.

The parts necessary to do the steps in this figure are available in Boeing kit 005W3106-1.

NOTE: IF A BONDING JUMPER HAS ALREADY BEEN INSTALLED, REMOVAL AND

RE-INSTALLATION OF A NEW BONDING JUMPER IS NOT REQUIRED EXCEPT FOR THE

ONE BONDING JUMPER WHICH IS SPECIFIED FOR REMOVAL IN THIS FIGURE.

STEP TASK NAME PART NUMBER QTY NOTES

CAUTION: MAKE SURE THAT SURFACE PREPARATION IS ACCOMPLISHED ON AIRPLANE

STRUCTURE, BRACKET, GROUND CLIPS, AND JUMPERS PER THESE

ACCOMPLISHMENT INSTRUCTIONS IN ORDER TO PREPARE AN ACCEPTABLE

ELECTRICAL BOND.

1 Remove /

Discard

Fasteners - 8 Remove / discard existing

fasteners in locations shown.

2 Install Ground Clip 189W4000-32 5 (a)

3 Install Fasteners - 8 Install per Fastener

Identification Table.

4 Measure Resistance - - (b)

5 Install Jumper BACJ40E20-38 1 (c)(d)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 (e)

6 Measure Resistance - - (f)

7 Install Jumper BACJ40E20-30 1 (c)(d)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 (e)

8 Measure Resistance - - (f)

9 Remove /

Discard

Ground Clip - 1 Remove / discard existing

ground clip and attaching

jumper. Remove / discard all

bolts, washers, and nuts which

attach to this jumper on both

ends.

Jumper - 1

Bolt - 2

Washer - 2

Nut - 2

10 Install Rivet BACR15BB7AD4C 1 (g)

11 Install Ground Clip 189W4000U31 1 (a)

12 Install Fasteners - 3 Install per Fastener

Identification Table.

13 Measure Resistance - - (b)

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 6 OF 8 777-55A0010

Revision 1: April 17, 2001 26
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

STEP TASK NAME PART NUMBER QTY NOTES

14 Install Jumper BACJ40E20-36 1 (c)(h)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 (e)

15 Measure Resistance - - (f)

16 Install Jumper BACJ40E20-40 1 (c)(i)

Bolt BACB30LJ4-4 1 -

Washer BACW10BP4DP 1 Install between nut and ground

clip.

Nut BACN10JC4CD 1 (e)

17 Measure Resistance - - (f)

18 Install Jumper BACJ40E20-36 1 (c)(j)

Bolt BACB30LJ4-4 1 -

Washer BACW10BP4DP 1 Install between nut and ground

clip.

Nut BACN10JC4CD 1 (e)

19 Measure Resistance - - (f)

20 Install Bolt BACB30LJ4U7 1 Remove protective finish and

clean to bare metal surface of

173W3200-11 per Note (a). Bolt

is used to attach

BACJ40E20-40 Jumper and

BACJ40E20-36 Jumper to

173W3200-11 Bracket.

Washer BACW10BP4APU 1 Install between nut and existing

173W3200-11 Bracket.

Nut BACN10JC4CM 1 (e)

21 Measure Resistance - - (k)

(a) The protective finish on the airplane structure must be removed in the area where the clip is attached.

The protective finish on the ground clip must be removed from the flange that is in contact with the

airplane structure. The protective finish on the ground clip must be removed from the surface of the clip

where the jumper is attached. Remove the protective finish and clean to bare metal surfaces per

BSWPM 20-20-00, Section 2, Cleaning Procedure 1, 2, or 3.

(b) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 0.5 milliohms (0.0005

ohms) maximum between each ground clip installed and the airplane structure.

(c) The surface of the jumper that is in contact with the ground clip must be clean before installation.

Clean the jumper per BSWPM 20-20-00, Section 2, Cleaning Procedure 5.

(d) Install jumper between 189W4000-32 Ground Clips with fasteners specified.

(e) Torque to 65 - 70 inch-pounds.

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 7 OF 8 777-55A0010

Revision 1: April 17, 2001 27
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

STEP TASK NAME PART NUMBER QTY NOTES

(f) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001

ohms) maximum between each ground clip installed and each jumper installed.

(g) Rivet is used to fill one existing hole. Optional rivet is BACR15BB7D4C.

(h) Install jumper between 189W4000-32 Ground Clip and 189W4000U31 Ground Clip (center flange)

with fasteners specified.

(i) Install jumper on 189W4000U31 Ground Clip (upper flange) with fasteners specified.

(j) Install jumper on 189W4000U31 Ground Clip (lower flange) with fasteners specified.

(k) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001

ohms) maximum between 173W3200-11 Bracket and each jumper attached to 173W3200-11 Bracket.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

figure. A number in the lower right corner gives the grip length of the fastener. If grip length shown is not

available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.

EXAMPLE OF FASTENER SYMBOL

FASTENER

LENGTH/GRIP

FASTENER

D 6F

7

LETTER CODE

DIAMETER

(OPTIONAL)

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

A51639

CODE NAME PART NUMBER HOLE DIA NOTES

A Rivet BACR15FT6KE6C - -

B Bolt BACB30VT6K3 - -

Collar BACC30BP6 - -

C Rivet BACR15BB6D8C - -

D Rivet BACR15BB7AD5C - Optional rivet is

BACR15BB7D5C.

FIGURE 4. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE RUDDER /

VERTICAL FIN

October 26, 2000 SHEET 8 OF 8 777-55A0010

Revision 1: April 17, 2001 28
BOEING SERVICE BULLETIN 777-55A0010

RIGHT SIDE OPPOSITE

LEFT SIDE SHOWN

SEE C

SEE E

A

SEE D

SEE B

SEE A

INSTALLED FOR CLARITY

TIP FAIRING IS SHOWN

NOTE: HORIZONTAL STABILIZER FWD

TIP

FAIRING

B

B

C

C

A

A

V32544

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 1 OF 10 777-55A0010

Revision 1: April 17, 2001 29
BOEING SERVICE BULLETIN 777-55A0010

1 1

1

FWD B-B

INBD

A-A

V33215

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 2 OF 10 777-55A0010

Revision 1: April 17, 2001 30
BOEING SERVICE BULLETIN 777-55A0010

1

C-C

INBD

V32759

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 3 OF 10 777-55A0010

Revision 1: April 17, 2001 31
BOEING SERVICE BULLETIN 777-55A0010

3

B

5

B 4

2

7

5

A 4

6

C

8 9

3 5

4 C

2 5

4 D

FWD

FWD

D

D

E

E

V33238

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 4 OF 10 777-55A0010

Revision 1: April 17, 2001 32
BOEING SERVICE BULLETIN 777-55A0010

5

5

3

3

21 22

4 B

D

0.43 (TYPICAL)

0.34

FWD E-E

3.0

D-D

FWD

V37054

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 5 OF 10 777-55A0010

Revision 1: April 17, 2001 33
BOEING SERVICE BULLETIN 777-55A0010

FWD

12 14

13

10 11

23 24

17 18

19 20

16

F

E

15

2

E 4

3.84

0.43

(TYPICAL)

0.43 (TYPICAL)

0.34

F-F G-G

SPAR

FRONT

ELEVATOR

BRACKET

REMOVE EXISTING CLIP

INSTALL NEW CLIP

NEW GROUND CLIP

(VIEW LOOKING UP)

FWD

F

F

G

G

V33266

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 6 OF 10 777-55A0010

Revision 1: April 17, 2001 34
BOEING SERVICE BULLETIN 777-55A0010

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.

The parts necessary to do the steps in this figure are available in Boeing kit 005W3106-1.

NOTE: IF A BONDING JUMPER HAS ALREADY BEEN INSTALLED, REMOVAL AND

RE-INSTALLATION OF A NEW BONDING JUMPER IS NOT REQUIRED EXCEPT FOR THE

ONE BONDING JUMPER WHICH IS SPECIFIED FOR REMOVAL IN THIS FIGURE.

STEP TASK NAME PART NUMBER QTY NOTES

CAUTION: MAKE SURE THAT SURFACE PREPARATION IS ACCOMPLISHED ON AIRPLANE

STRUCTURE, BRACKET, GROUND CLIPS, AND JUMPERS PER THESE

ACCOMPLISHMENT INSTRUCTIONS IN ORDER TO PREPARE AN ACCEPTABLE

ELECTRICAL BOND.

1 Remove /

Discard

Fasteners - 10 Remove / discard existing

fasteners in locations shown.

2 Install Ground Clip 189W4000-32 3 (a)

3 Install Ground Clip 189W4000-14 4 (a)

4 Install Fasteners - 14 Install per Fastener

Identification table.

5 Measure Resistance - - (b)

6 Install Jumper BACJ40E20-24 1 (c)(d)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 (e)

7 Measure Resistance - - (f)

8 Install Jumper BACJ40E20-20 1 (c)(d)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 (e)

9 Measure Resistance - - (f)

10 Remove /

Discard

Ground Clip - 1 Remove / discard existing

ground clip and attaching

jumper. Remove / discard all

bolts, washers, and nuts which

attach to this jumper on both

ends.

Jumper - 1

Bolt - 2

Washer - 2

Nut - 2

11 Install Rivet BACR15BB7AD4C 1 (g)

12 Install Ground Clip 189W4000U31 1 (a)

13 Install Fasteners - 3 Install per Fastener

Identification table.

14 Measure Resistance - - (b)

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 7 OF 10 777-55A0010

Revision 1: April 17, 2001 35
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

STEP TASK NAME PART NUMBER QTY NOTES

15 Install Jumper BACJ40E20-20 1 (c)(h)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 (e)

16 Measure Resistance - - (f)

17 Install Jumper BACJ40E20-30 1 (c)(i)

Bolt BACB30LJ4-4 1 -

Washer BACW10BP4DP 1 Install between nut and ground

clip.

Nut BACN10JC4CD 1 (e)

18 Measure Resistance - - (f)

19 Install Jumper BACJ40E20-26 1 (c)(j)

Bolt BACB30LJ4-4 1 -

Washer BACW10BP4DP 1 Install between nut and ground

clip.

Nut BACN10JC4CD 1 (e)

20 Measure Resistance - - (f)

CAUTION: BE CAREFUL WHEN YOU MOVE THE HORIZONTAL STABILIZER TIP FAIRING NEAR

THE HORIZONTAL STABILIZER. INSTALL PROTECTIVE COVERS OVER THE END OF

THE HORIZONTAL STABILIZER.

21 Install Jumper BACJ40E20-48 1 (c)(d)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 (e)

NOTE: JUST PRIOR TO INSTALLATION OF THE JUMPER AND FASTENERS IN STEP 21

AND FASTENERS IN STEP 23 THE HORIZONTAL STABILIZER TIP FAIRING CAN BE

TEMPORARILY PLACED OVER THE TOP OF THE HORIZONTAL STABILIZER AND

ROTATED AROUND FOR INSTALLATION DURING RESTORATION OF ACCESS.

22 Measure Resistance - - (f)

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 8 OF 10 777-55A0010

Revision 1: April 17, 2001 36
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

STEP TASK NAME PART NUMBER QTY NOTES

23 Install Bolt BACB30LJ4U7 1 Remove the protective finish

and clean to bare metal surface

of 183W8101-3 Bracket per

Note (a) in the area where the

bolt, washer, and nut is

attached. Bolt is used to attach

BACJ40E20-30 Jumper and

BACJ40E20-26 Jumper to

183W8101-3 Bracket.

Washer BACW10BP4APU 1 Install between nut and existing

183W8101-3 Bracket.

Nut BACN10JC4CM 1 (e)

24 Measure Resistance - - (k)

(a) The protective finish on the airplane structure must be removed in the area where the clip is attached.

The protective finish on the ground clip must be removed from the flange that is in contact with the

airplane structure. The protective finish on the ground clip must be removed from the surface of the clip

where the jumper is attached. Remove the protective finish and clean to bare metal surfaces per

BSWPM 20-20-00, Section 2, Cleaning Procedure 1, 2, or 3.

(b) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 0.5 milliohms (0.0005

ohms) maximum between each ground clip installed and the airplane structure.

(c) The surface of the jumper that is in contact with the ground clip must be clean before installation.

Clean the jumper per BSWPM 20-20-00, Section 2, Cleaning Procedure 5.

(d) Install jumper between ground clips with fasteners specified.

(e) Torque to 65 - 70 inch-pounds.

(f) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001

ohms) maximum between each ground clip installed and each jumper installed.

(g) Rivet is used to fill one existing hole. Optional rivet is BACR15BB7D4C.

(h) Install jumper between 189W4000-32 Ground Clip and 189W4000U31 Ground Clip (center flange)

with fasteners specified.

(i) Install between 189W4000U31 Ground Clip (outboard flange) with fasteners specified.

(j) Install between 189W4000U31 Ground Clip (inboard flange) with fasteners specified.

(k) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001

ohms) maximum between 183W8103-3 Bracket and each jumper attached to 183W8103-3 Bracket.

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 9 OF 10 777-55A0010

Revision 1: April 17, 2001 37
BOEING SERVICE BULLETIN 777-55A0010

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

figure. A number in the lower right corner gives the grip length of the fastener. If grip length shown is not

available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.

EXAMPLE OF FASTENER SYMBOL

FASTENER

LENGTH/GRIP

FASTENER

D 6F

7

LETTER CODE

DIAMETER

(OPTIONAL)

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

A51639

CODE NAME PART NUMBER HOLE DIA NOTES

A Rivet BACR15FT6KE6C - -

B Bolt BACB30NX6K4X - -

Collar BACC30BH6 - -

C Rivet BACR15BB7AD8C - Optional rivet is

BACR15BB7D8C.

D Rivet BACR15FR6E2R - -

E Rivet BACR15FR6E2R - -

F Rivet BACR15BB7AD5C - Optional rivet is

BACR15BB7D5C.

FIGURE 5. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - OUTBOARD END

October 26, 2000 SHEET 10 OF 10 777-55A0010

Revision 1: April 17, 2001 38
BOEING SERVICE BULLETIN 777-55A0010

SEE A

SEE B

SEE C

A

FWD

A

A

V36958

FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - INBOARD END

October 26, 2000 SHEET 1 OF 4 777-55A0010

Revision 1: April 17, 2001 39
BOEING SERVICE BULLETIN 777-55A0010

FWD

1

B

1

A-A FWD

SPAR RIB NO. 3

V36974

FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - INBOARD END

October 26, 2000 SHEET 2 OF 4 777-55A0010

Revision 1: April 17, 2001 40
BOEING SERVICE BULLETIN 777-55A0010

FWD

6 7

A 4

2 5

A 4

3 5

C

V36986

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for one side of the airplane.

The parts necessary to do the steps in this figure are available in Boeing kit 005W3106-1.

STEP TASK NAME PART NUMBER QTY NOTES

CAUTION: MAKE SURE THAT SURFACE PREPARATION IS ACCOMPLISHED ON AIRPLANE

STRUCTURE, BRACKET, GROUND CLIPS, AND JUMPERS PER THESE

ACCOMPLISHMENT INSTRUCTIONS IN ORDER TO PREPARE AN ACCEPTABLE

ELECTRICAL BOND.

1 Remove /

Discard

Fasteners - 5 Remove / discard existing

fasteners in locations shown.

2 Install Ground Clip 189W4000-14 1 (a)

3 Install Ground Clip 189W4000-32 1 (a)

4 Install Fasteners - 5 Install per Fastener

Identification Table.

FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - INBOARD END

October 26, 2000 SHEET 3 OF 4 777-55A0010

Revision 1: April 17, 2001 41
BOEING SERVICE BULLETIN 777-55A0010

(Continued)

STEP TASK NAME PART NUMBER QTY NOTES

5 Measure Resistance - - (b)

6 Install Jumper BACJ40E20-44 1 (c)(d)

Bolt BACB30LJ4-4 2 -

Washer BACW10BP4DP 2 Install between nut and ground

clip.

Nut BACN10JC4CD 2 Torque to 65 - 70 inch-pounds.

7 Measure Resistance - - (e)

(a) The protective finish on the airplane structure must be removed in the area where the clip is attached.

The protective finish on the ground clip must be removed from the flange that is in contact with the

airplane structure. The protective finish on the ground clip must be removed from the surface of the clip

where the jumper is attached. Remove the protective finish and clean to bare metal surfaces per

BSWPM 20-20-00, Section 2, Cleaning Procedure 1, 2, or 3.

(b) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 0.5 milliohms (0.0005

ohms) maximum between each ground clip installed and the airplane structure.

(c) The surface of the jumper that is in contact with the ground clip must be clean before installation.

Clean the jumper per BSWPM 20-20-00, Section 2, Cleaning Procedure 5.

(d) Install jumper between ground clips with fasteners specified.

(e) Measure resistance per BSWPM 20-20-00, Section 6. Resistance should be 1.0 milliohms (0.001

ohms) maximum between each ground clip installed and each jumper installed.

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

figure. A number in the lower right corner gives the grip length of the fastener. If grip length shown is not

available at Boeing, fasteners supplied in kits may be one grip length longer than indicated.

EXAMPLE OF FASTENER SYMBOL

FASTENER

LENGTH/GRIP

FASTENER

D 6F

7

LETTER CODE

DIAMETER

(OPTIONAL)

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

A51639

CODE NAME PART NUMBER HOLE DIA NOTES

A Rivet BACR15FT6KE6C - -

FIGURE 6. INSTALLATION OF BONDING JUMPERS AND RESISTANCE CHECKS ON THE ELEVATOR /

HORIZONTAL STABILIZER - INBOARD END

October 26, 2000 SHEET 4 OF 4 777-55A0010

Revision 1: April 17, 2001 42
BOEING SERVICE BULLETIN 777-55A0010

FWD

SEE C

SEE A

SEE B

OMITTED FOR CLARITY.

AUXILIARY

SPAR

NOTE: RIGHT SIDE CHORDS OF THE AUXILIARY

SPAR AND CLOSURE RIB ASSEMBLY ARE

CLOSURE RIB

ASSEMBLY

V32831

FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN

October 26, 2000 SHEET 1 OF 4 777-55A0010

Revision 1: April 17, 2001 43
BOEING SERVICE BULLETIN 777-55A0010

1 2

1 2 UP

FWD

1 2

1 2

B

A

FWD

UP

V32838

FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN

October 26, 2000 SHEET 2 OF 4 777-55A0010

Revision 1: April 17, 2001 44
BOEING SERVICE BULLETIN 777-55A0010

C FWD

UP

1 2

1 2

RUDDER

FRONT

SPAR

BRACKET

V33275

FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN

October 26, 2000 SHEET 3 OF 4 777-55A0010

Revision 1: April 17, 2001 45
BOEING SERVICE BULLETIN 777-55A0010

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Apply Sealant BSOPM 20-50-19 - (a)

2 Apply Sealant BSOPM 20-50-19 - (b)

(a) Apply protective coating to bare surfaces of the airplane structure and the ground clips to match the

surrounding surface. Filet seal around the periphery of the ground clips with BMS 5-95 Sealant per

BSOPM 20-50-19. Encapsulate both ends of all fasteners which attach the ground clips to the airplane

structure with BMS 5-95 Sealant.

(b) Fillet seal around edge of jumper and around edge of ground clip where the jumper is attached.

Encapsulate both ends of the bolt which attach the jumper. Make sure to fully cover the bolt head, nut,

washer, and threaded end of the bolt with BMS 5-95 Sealant per BSOPM 20-50-19.

FIGURE 7. SEALING OF THE BONDING JUMPERS ON THE RUDDER / VERTICAL FIN

October 26, 2000 SHEET 4 OF 4 777-55A0010

Revision 1: April 17, 2001 46
BOEING SERVICE BULLETIN 777-55A0010

LEFT SIDE SHOWN

RIGHT SIDE OPPOSITE

SEE A

SEE C

SEE B

SEE D

FWD

NOTE: HORIZONTAL STABILIZER

TIP FAIRING IS SHOWN

INSTALLED FOR CLARITY

FAIRING

TIP

V32845

FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -

OUTBOARD END

October 26, 2000 SHEET 1 OF 4 777-55A0010

Revision 1: April 17, 2001 47
BOEING SERVICE BULLETIN 777-55A0010

B

A

1 2

1 2 1 2

1 2

FWD

FWD

V33276

FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -

OUTBOARD END

October 26, 2000 SHEET 2 OF 4 777-55A0010

Revision 1: April 17, 2001 48
BOEING SERVICE BULLETIN 777-55A0010

FWD

C

1 2

1 2

1 2

1 2

1 2

1 2

D

FWD

BRACKET

(VIEW LOOKING UP)

V33277

FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -

OUTBOARD END

October 26, 2000 SHEET 3 OF 4 777-55A0010

Revision 1: April 17, 2001 49
BOEING SERVICE BULLETIN 777-55A0010

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Apply Sealant BSOPM 20-50-19 - (a)

2 Apply Sealant BSOPM 20-50-19 - (b)

(a) Apply protective coating to bare surfaces of the airplane structure and the ground clips to match the

surrounding surface. Filet seal around the periphery of the ground clips with BMS 5-95 Sealant per

BSOPM 20-50-19. Encapsulate both ends of all fasteners which attach the ground clips to the airplane

structure with BMS 5-95 Sealant.

(b) Fillet seal around edge of jumper and around edge of ground clip where the jumper is attached.

Encapsulate both ends of the bolt which attach the jumper. Make sure to fully cover the bolt head, nut,

washer, and threaded end of the bolt with BMS 5-95 Sealant per BSOPM 20-50-19.

FIGURE 8. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -

OUTBOARD END

October 26, 2000 SHEET 4 OF 4 777-55A0010

Revision 1: April 17, 2001 50
BOEING SERVICE BULLETIN 777-55A0010

FWD

1 2

1 2

A

SEE A

FWD

V37064

FIGURE 9. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -

INBOARD END

October 26, 2000 SHEET 1 OF 2 777-55A0010

Revision 1: April 17, 2001 51
BOEING SERVICE BULLETIN 777-55A0010

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

The QTY numbers shown below are the numbers of parts necessary for the airplane.

STEP TASK NAME REFERENCES QTY NOTES

1 Apply Sealant BSOPM 20-50-19 - (a)

2 Apply Sealant BSOPM 20-50-19 - (b)

(a) Apply protective coating to bare surfaces of the airplane structure and the ground clips to match the

surrounding surface. Filet seal around the periphery of the ground clips with BMS 5-95 Sealant per

BSOPM 20-50-19. Encapsulate both ends of all fasteners which attach the ground clips to the airplane

structure with BMS 5-95 Sealant.

(b) Fillet seal around edge of jumper and around edge of ground clip where the jumper is attached.

Encapsulate both ends of the bolt which attach the jumper. Make sure to fully cover the bolt head, nut,

washer, and threaded end of the bolt with BMS 5-95 Sealant per BSOPM 20-50-19.

FIGURE 9. SEALING OF THE BONDING JUMPERS ON THE ELEVATOR / HORIZONTAL STABILIZER -

INBOARD END

October 26, 2000 SHEET 2 OF 2 777-55A0010

Revision 1: April 17, 2001 52
Commercial

Airplane

Group

777

Service Bulletin

Number: 777-55A0010 Evaluation Form Date: October 26, 2000

Revision 1: April 17, 2001

ATA System: 5500

Prepared By: Frank DiMiceli

SUBJECT: STABILIZERS - Lightning Protection of Empennage Flight Control Surfaces - Bonding Jumper

Additions

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that you give us to improve the quality of our service bulletins.

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these

changes, please use a Publication Change Request (PCR) form.

Please give us this data:

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OPERATOR: TODAY'S DATE:

PREPARED BY: TITLE:

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Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form

directly to this address:

Manager

Service Bulletin Engineering

Boeing Commercial Airplane Group

P.O. Box 3707, Mail Stop 2H-37

Seattle, WA 98124-2207