### 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 RELATEDV32373

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

9 4 12 1

10 211

3



## A SEEA

B SEE

FWD DIVERTER LIGHTNINGV32390

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

7 68

5



## B FWDV32391 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 Panel777 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 Panel777 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 7 4 8 3
10 SEEA



## A 6 5 1 9 2V32428

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

5 2 4 3 6 1V32877 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 Panel777 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 Panel777 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 SEEA



## A D SEE

B SEE C

SEE 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 ASSEMBLYV32439

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 777-55A001011FWDA-AV32910

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

UPV32931

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

4 2

4 2

4

3 C 

### 2 

## B

C 4 2

4 8 7 4

56

UP

FWD 2 3 B 

### 3 2 A 

### 3

A



### FWD UP 

## D-D

D DV33111

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 15 14 D 

### 12 13 11

9 21 20 19 18 17 16



## D FWD UP BRACKET

0.43 0.43

CLIP INSTALL NEW 

## E-EREMOVE EXISTING CLIP RUDDER FRONT NEW GROUND CLIP

SPAR E

EV33175

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 ISNOT REQUIREDEXCEPT 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 C SEE
E SEE


## A D SEE B SEE SEEA

INSTALLED FOR CLARITY TIP FAIRING IS SHOWN NOTE: HORIZONTAL STABILIZER FWD TIP FAIRING B

B C C A AV32544

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 777-55A0010111FWDB-BINBDA-AV33215

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 INBDV32759

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 5B 

### 4 2

7 5 A 

### 4

6



## C 89 5 3 4C 

### 2 5 4 D 

### FWD

FWD D

D

E EV33238

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

22 21 4B



## D0.43 (TYPICAL) 0.34

FWD 

## E-E

3.0



## D-D

FWDV37054

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

1214 13 11 10 24 23 18 17 19 20
16

F 

## E 152

E 

### 4 3.84

0.43 (TYPICAL) 0.43 (TYPICAL) 0.34



## F-F G-G SPAR FRONT ELEVATORBRACKET

REMOVE EXISTING CLIP

INSTALL NEW CLIP NEW GROUND CLIP (VIEW LOOKING UP)

FWD F

F G

GV33266

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 ISNOT REQUIREDEXCEPT 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
- 10Remove / 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
- 14Install 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

SEEA

B SEE

C SEE



## A FWD 

## A AV36958

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. 3V36974

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 7 6 A 

### 4 5 2

A 

### 4

35



## CV36986 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 C SEE

A SEE B

SEE

OMITTED FOR CLARITY. AUXILIARY SPAR

NOTE: RIGHT SIDE CHORDS OF THE AUXILIARY SPAR AND CLOSURE RIB ASSEMBLY ARE CLOSURE RIB ASSEMBLYV32831

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

12

2 1 UP

FWD 12 12



## B A FWD UPV32838

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 2 1

2 1 RUDDER FRONT SPAR

BRACKETV33275

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 A SEE

C SEE

B SEE D SEE
FWD NOTE: HORIZONTAL STABILIZER TIP FAIRING IS SHOWN INSTALLED FOR CLARITY FAIRING TIPV32845

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 2 1

2 1 2 1 2 1

FWD FWDV33276

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 2 1

2 1

2 1

2 1 2 1 2 1



## DFWD

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 12 12



## A A SEE FWDV37064

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 Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data 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: (If necessary, please use the other side. Thank you for the time you used to give us your comments.) OPERATOR: TODAY'S DATE: PREPARED BY: TITLE: ORGANIZATION: TELEX CODE: TELEPHONE NUMBER: BASE: Please rate the quality of this service bulletin: (good)4321(poor) Please rate the quality of the illustrations: (good)4321(poor) Will you do the change given by this service bulletin? Yes No If not, please explain: Is this service bulletin easy to understand? Yes No If not, please explain: Is this service bulletin easy to use? Yes No If not, please explain: Are the Planning Information, Material Information, and Accomplishment Instructions accurate? Yes No If not, please explain: Is the Manpower estimate accurate? Yes No If not, please explain:
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