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Commercial

Airplane

Group 777

Service Bulletin

Number: 777-23-0142

Date: November 25, 2003

ATA System: 2339

MDN

SUBJECT: COMMUNICATIONS - Passenger Address and Entertainment - Cabin Management

System - Cabin Services System Hardware and Software Change

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2003 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third

parties. Treatment of the document and the information it contains is governed by contract with Boeing. For

more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9,

DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery are all trademarks

owned by The Boeing Company; and no trademark license is granted in connection with this document unless

provided in writing by Boeing.
BLANK PAGE

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BOEING SERVICE BULLETIN 777-23-0142

BLANK PAGE
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Commercial

Airplane

Group 777

Service Bulletin

Number: 777-23-0142 Summary

Date: November 25, 2003

ATA System: 2339

MDN

SUBJECT: COMMUNICATIONS - Passenger Address and Entertainment - Cabin Management

System - Cabin Services System Hardware and Software Change

CONCURRENT REQUIREMENTS

For airplanes in Group 4, Boeing Service Bulletin 777-23-0057, is necessary to be accomplished prior to or

concurrent with this service bulletin.

For airplanes in Group 4, the related JAMCO service letter is SL-K0789.

BACKGROUND

This service bulletin gives instructions to change the hardware and software for the cabin services system (CSS)

from the version 1 (CSS v1) configuration to the version 2 (CSS v2) configuration.

– Cabin services system version 1 (CSS v1) was installed on twelve airplanes when the cabin management

system (CMS) was changed to separate the in-flight entertainment functions from the passenger service

system functions. CSS v1 is an intermediate system with new software and the original CMS hardware

panels. Because CSS v1 was only delivered on twelve airplanes, it is difficult to support and maintain.

– The installation of CSS v2 will prevent a problem with decreased lamp life of the fluorescent backlights that

occurs with CSS v1 installed.

The change described in this service bulletin will also change the operation of cabin lighting system when the

CABIN/UTILITY switch is installed.

– We have received numerous reports of smoke or flames in the passenger cabin related to the wiring for the

passenger cabin in-flight entertainment system, cabin lighting and passenger seats. It is not easy to

remove the electrical power to these systems to stop the smoke and flames.

– A CABIN/UTILITY switch can be installed to remove power to some systems in the passenger cabin. This

change to the cabin services system (CSS) operational software (OPS) will change the way various lighting

systems operate when the switch is set to "OFF".

– When the CABIN/UTILITY switch is set to OFF, all night lights, reading lights and attendant work lights will

come on. Commands from the cabin control panels for night light operation will be ignored. A message

will be shown on the cabin control panels which says "REDUCED POWER CONDITION - Fluorescent

lights may be off. Night lights are locked on". This message replaces the Function Lock-Out - Reduced

Power pop-up screen.

– When the CABIN/UTILITY switch is set to ON, control of the cabin lighting systems by the cabin control

panels is put back to normal and the REDUCED POWER CONDITION message is removed.

– The cabin control panels will show the state of the CABIN/UTILITY switch on the Input Monitor - ARINC

629 Bus screen.

– Boeing Service Related Problem (SRP) 777-SRP-24-0091 is related to this part of the change in the service

bulletin.
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BOEING SERVICE BULLETIN 777-23-0142

Boeing did a cost benefit analysis on the changes given in this service bulletin. Refer to Appendix C for the

analysis.

ACTION (PRR 61877-1, PRR 61887)

Remove the three CACPs.

On Group 1 airplanes, change wires at the P101 distribution integration panel and at the CACP location at door

2-Left.

On Group 2 airplanes, change wires at the P101 and P102 distribution integration panels and at the CACP

locations at door 1-Left and door 2-Left.

On Group 3 airplanes, change wires at the P101 and P102 distribution integration panels, at the CACP location

at door 1-Left and from AP0715 to lavatory 2F-1L at door 2-Left.

On Group 4 airplanes, change wires at the P102 and P103 distribution integration panels and at the CACP

location at door 2-Left.

Install one cabin control panel (CCP) as a CSCP and two CCPs as CACPs.

On Group 1, 2, and 3 airplanes, remove the CSCP and modify the purser station.

On Group 4 airplanes, remove the CSCP and modify the A-4 galley as given in a JAMCO service letter.

Install operational program software (OPS) for the CACP, zone management units (ZMUs), and cabin system

management unit (CSMU). If necessary, install OPS for the overhead electronics units (OEUs).

Make a change to the CSS configuration database (CDB). Install the new database in the CSS components.

Do a test of the cabin services system (CSS).

EFFECTIVITY

COMPLIANCE

No compliance time is given.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of January 6, 1997. Please refer to

Paragraph 2.B., Industry Support Information.

Operator Airplanes

ANA (Group 1) WA221-WA222

EGP (Group 2) WB151-WB153

MAS (Group 3) WB161-WB164

SIA (Group 4) WB181-WB183
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BOEING SERVICE BULLETIN 777-23-0142

MANPOWER

On Group 4 airplanes, the change to the galley as given in the JAMCO service letter is not included.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

Airplanes Total Task Hours Elapsed Hours

Group 1 9.0 7.5

Group 2 9.0 7.5

Group 3 12.0 10.5

Group 4 8.25 6.75
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BOEING SERVICE BULLETIN 777-23-0142

PURSER STATION

AND 3, MODIFY

ON GROUPS 1, 2

(EXAMPLE)

PURSER STATION

PANEL (CSCP)

SYSTEM CONTROL

REMOVE CABIN

LETTER

PER JAMCO SERVICE

MODIFY GALLEY A-4

ON GROUP 4,

CONTROL PANELS (CCP)

INSTALL THREE CABIN

CONTROL PANELS (CACP)

REMOVE THREE CABIN AREA

(EXAMPLE)

ATTENDANT STATION

FWD

W44286

GROUPS 2, 3 AND 4,

P102 PANEL P103 PANEL

CHANGE WIRE AT

GROUP 4,

P101 PANEL

CHANGE WIRE AT

GROUPS 1, 2 AND 3,

CHANGE WIRE AT

2F-1L

AP0715 TO LAVATORY

CHANGE WIRES FROM

GROUP 3,

LOCATIONS

DOOR 1 AND DOOR 2

CHANGE WIRES AT

GROUPS 1, 2 AND 3,

DOOR 2 LOCATIONS

CHANGE WIRES AT

GROUP 4,
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Commercial

Airplane

Group 777

Service Bulletin

Number: 777-23-0142

Date: November 25, 2003

ATA System: 2339

MDN

SUBJECT: COMMUNICATIONS - Passenger Address and Entertainment - Cabin Management

System - Cabin Services System Hardware and Software Change

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-24W001 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 PRR 61877-1 and PRR 61887 for data about this change.

Airplane models:

777-200

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

ALL NIPPON AIRWAYS (ANA)

1 WA221–WA222

EGYPTAIR (EGP)

2 WB151–WB153

MALAYSIA AIRLINES (MAS)

3 WB161–WB164

SINGAPORE AIRLINES (SIA)

4 WB181–WB183
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BOEING SERVICE BULLETIN 777-23-0142

IDENTIFICATION BY VARIABLE NUMBER

2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for

the recommended use.

B. Concurrent Requirements

For airplanes in Group 4, you cannot make the changes given in this service bulletin unless the

changes given in Boeing Service Bulletin 777-23-0057 are made.

For airplanes in Group 4, the related JAMCO service letter is SL-K0789.

C. Reason

This service bulletin gives instructions to change the hardware and software for the cabin services

system (CSS) from the version 1 (CSS v1) configuration to the version 2 (CSS v2) configuration.

– Cabin services system version 1 (CSS v1) was installed on twelve airplanes when the cabin

management system (CMS) was changed to separate the in-flight entertainment functions from

the passenger service system functions. CSS v1 is an intermediate system with new software

and the original CMS hardware panels. Because CSS v1 was only delivered on twelve airplanes,

it is difficult to support and maintain.

– The installation of CSS v2 will prevent a problem with decreased lamp life of the fluorescent

backlights that occurs with CSS v1 installed.

The change described in this service bulletin will also change the operation of cabin lighting system

when the CABIN/UTILITY switch is installed.

– We have received numerous reports of smoke or flames in the passenger cabin related to the

wiring for the passenger cabin in-flight entertainment system, cabin lighting and passenger seats.

It is not easy to remove the electrical power to these systems to stop the smoke and flames.

– A CABIN/UTILITY switch can be installed to remove power to some systems in the passenger

cabin. This change to the cabin services system (CSS) operational software (OPS) will change

the way various lighting systems operate when the switch is set to "OFF".

– When the CABIN/UTILITY switch is set to OFF, all night lights, reading lights and attendant work

lights will come on. Commands from the cabin control panels for night light operation will be

ignored. A message will be shown on the cabin control panels which says "REDUCED POWER

CONDITION - Fluorescent lights may be off. Night lights are locked on". This message replaces

the Function Lock-Out - Reduced Power pop-up screen.

– When the CABIN/UTILITY switch is set to ON, control of the cabin lighting systems by the cabin

control panels is put back to normal and the REDUCED POWER CONDITION message is

removed.

– The cabin control panels will show the state of the CABIN/UTILITY switch on the Input Monitor -

ARINC 629 Bus screen.

Variable Group

WA221–WA222 1

WB151–WB153 2

WB161–WB164 3

WB181–WB183 4
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BOEING SERVICE BULLETIN 777-23-0142

– Boeing Service Related Problem (SRP) 777-SRP-24-0091 is related to this part of the change in

the service bulletin.

Boeing did a cost benefit analysis on the changes given in this service bulletin. Refer to Appendix C

for the analysis.

D. Description

Remove the three CACPs.

On Group 1 airplanes, change wires at the P101 distribution integration panel and at the CACP

location at door 2-Left.

On Group 2 airplanes, change wires at the P101 and P102 distribution integration panels and at the

CACP locations at door 1-Left and door 2-Left.

On Group 3 airplanes, change wires at the P101 and P102 distribution integration panels, at the CACP

location at door 1-Left, and from AP0715 to lavatory 2F-1L at door 2-Left.

On Group 4 airplanes, change wires at the P102 and P103 distribution integration panels and at the

CACP location at door 2-Left.

Install one cabin control panel (CCP) as a CSCP and two CCPs as CACPs.

On Group 1, 2, and 3 airplanes, remove the CSCP and modify the purser station.

On Group 4 airplanes, remove the CSCP and modify the A-4 galley as given in a JAMCO service

letter.

Install operational program software (OPS) for the CACP, zone management units (ZMUs) and cabin

system management unit (CSMU). If necessary, install OPS for the overhead electronics units

(OEUs).

Make a change to the CSS configuration database (CDB). Install the new database in the CSS

components.

Do a test of the cabin services system (CSS).

The airplane effectivity is divided into 4 groups. The groups have different locations for their CSCPs

and CACPs.

Note: On Group 1 and Group 3 airplanes, after incorporation of this service bulletin, you will no longer

be able to print from the CSCP if that feature was previously available. A subsequent service

bulletin will install the necessary lavatory wiring to allow printing from the CSCP.

E. Compliance

No compliance time is given.
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BOEING SERVICE BULLETIN 777-23-0142

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 (14 CFR Part

25) and Joint Aviation Requirements (JAR-25) and are FAA/JAA approved. This service bulletin and

FAA/JAA approval were based on the airplane in it's original Boeing delivery configuration or as

modified by other FAA/JAA 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 table below shows an estimate of the task-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

task-hour data if necessary. The estimate does not include lost time. These are some examples of

lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

Group 1 Airplanes

Task

Number of

Persons Task-Hours Elapsed Hours

Open Access 2 1.0 0.5

Remove CACPs 1 0.5 0.5

Change Wires 1 0.25 0.25

Install CCPs 1 0.5 0.5

Remove CSCP 1 0.25 0.25

Modify Purser

Station

1 1.5 1.5

Close Access 2 1.0 0.5

Install Software 1 3.0 3.0

Test 2 1.0 0.5

TOTAL FOR EACH AIRPLANE 9.0 7.5
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BOEING SERVICE BULLETIN 777-23-0142

Group 2 Airplanes

Task

Number of

Persons Task-Hours Elapsed Hours

Open Access 2 1.0 0.5

Remove CACPs 1 0.5 0.5

Change Wires 1 0.75 0.75

Install CCPs 1 0.5 0.5

Remove CSCP 1 0.25 0.25

Modify Purser

Station

1 1.0 1.0

Close Access 2 1.0 0.5

Install Software 1.0 3.0 3.0

Test 2 1.0 0.5

TOTAL FOR EACH AIRPLANE 9.0 7.5

Group 3 Airplanes

Task

Number of

Persons Task-Hours Elapsed Hours

Open Access 2 1.0 0.5

Remove CACPs 1 0.5 0.5

Change Wires 1 3.25 3.25

Install CCPs 1 0.5 0.5

Remove CSCP 1 0.25 0.25

Modify Purser

Station

1 1.5 1.5

Close Access 2 1.0 0.5

Install Software 1 3.0 3.0

Test 2 1.0 0.5

TOTAL FOR EACH AIRPLANE 12 10.5

Group 4 Airplanes

Task

Number of

Persons Task-Hours Elapsed Hours

Open Access 2 1.0 0.5

Remove CACPs 1 0.5 0.5

Change Wires 1 0.75 0.75

Install CCPs 1 0.5 0.5

Remove CSCP

and Tray Assembly

1 0.5 0.5

Close Access 2 1.0 0.5
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BOEING SERVICE BULLETIN 777-23-0142

On Group 4 airplanes, the change to the galley, as given in JAMCO Service Letter No. SL-K0789, is

not included.

H. Weight and Balance Changes

I. Electrical Load Data

1. Alternating Current (AC) Loads

J. References

1. Existing Data:

a. Engineering Change Memo PRR 61877-1, PRR 61887

b. Service Related Problem (SRP) 777-SRP-24-0091

c. 777 Maintenance Manual (AMM) Subject 20-10-01/401, 23-39-00/201, 23-39-16/201, 25-

21-06/401

d. 777 Wiring Diagram 23-33-12, 23-33-13, 23-33-14, 23-42-21, 33-22-31

e. Boeing Standard Wiring Practices Manual (BSWPM) 20-10-11, 20-10-12, 20-10-15, 20-10-

19, 20-30-16, 20-25-14, 20-35-11, 20-61-00, 20-61-11, 20-90-11

f. Boeing Standard Overhaul Practices Manual (BSOPM) 20-30-03, 20-50-10

g. Boeing Service Bulletin 777-23-0057, "COMMUNICATIONS - Passenger Address and

Entertainment - Cabin Management System - Cabin System Control Panel Wire Change"

Install Software 1 3.0 3.0

Test 2 1.0 0.5

TOTAL FOR EACH AIRPLANE 8.25 6.75

Airplane

Change in Weight

(Pounds)

Change in Moment

(Pound-Inches)

Group 1 -38.0 -43624.0

Group 2 -37.5 -43050.0

Group 3 -37.1 -42590.8

Group 4 -41.1 -47182.8

Watts Bus Circuit Breaker

Name Number Location

-19 R Bus AREA CONTROL

PANELS

C23444 P210 / D9

Group 4 Airplanes

Task

Number of

Persons Task-Hours Elapsed Hours
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BOEING SERVICE BULLETIN 777-23-0142

h. JAMCO Service Letter No. SL-K0789

Note: The supplier was told to send copies of the service letter to the operator.

i. Boeing Parts Standards Document D-590

j. Boeing Drawing 012W6100

k. Boeing Configuration Database Generator (CDG) User Guide, D634W602-1, Rev 2

2. Data supplied with this Service Bulletin:

None.

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

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.

Drawing Number Title

288W5541 Wire Bundle Instl - Purser Station

439W1006 Module Instl - Purser Station

439W1009 Module Instl - Purser Station, Flex Zone

439W1010 Module Instl - Purser Station

439W1106 Equipment Instl - Purser Station

439W1109 Equipment Instl - Purser Station, Flex Zone

439W1110 Equipment Instl - Purser Station, 1F-1C

439W1208 Module and Equipment Instl - Video Control Center, A-4 Galley

439W2006 Module Assy - Wiring, Purser Station

439W2009 Module Assy - Wiring Purser Station

439W2010 Module Assy - Wiring, Purser Station

439W3201 Shell Assy - Purser Station

439W3206 Shell Assy - Purser Station

439W3209 Shell Assy - Purser Station

476W1000 Instl Details - Cabin Controls

476W6306 Cabin Control Panel Instl
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BOEING SERVICE BULLETIN 777-23-0142

K. Publications Affected

L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability

information.

Publication Chapter-Section

777 Wiring Diagram Manual 23-33

777 Illustrated Parts Catalog 23-39, 25-29 (Group 4), 25-31 (Group 4)
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BOEING SERVICE BULLETIN 777-23-0142

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.

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.

Reference this service bulletin and submit your purchase order by one of the methods that follow:

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207

B. Industry Support Information

Boeing warranty remedies are available for 777 airplanes in warranty as of January 6, 1997. For manhour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing

Commercial Airplanes Group - Warranties. 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 numbers in your purchase order.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

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

Kit Number Name Date QTY

Unit Price thru

Dec 31/03

005W3210-1

(Group 1 airplanes)

Topkit - Cabin Control

Panel Installation

Oct 24/03 1 $119,842.00

Nov 07/03 1

005W3210-2

(Group 2 airplanes)

Topkit - Cabin Control

Panel Installation

Jan 30/04 3 $119,948.00

005W3210-3

(Group 3 airplanes)

Topkit - Cabin Control

Panel Installation

Jan 30/04 4 $120,338.00

005W3210-4

(Group 4 airplanes)

Topkit - Cabin Control

Panel Installation

Nov 07/03 3 $119,709.00
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BOEING SERVICE BULLETIN 777-23-0142

Operator, are necessary for each airplane.

Kit 005W3210

New Part

Number

QTY

Name

Existing Part

-4 -3 -2 -1 Number Notes

005W3210-1 . . . - Top Kit, Group 1

Airplanes

005W3210-2 . . - . Top Kit, Group 2

Airplanes

005W3210-3 . - . . Top Kit, Group 3

Airplanes

005W3210-4 - . . . Top Kit, Group 4

Airplanes

005W3210-10 . 1 1 1 Subkit, CCP/CSCP

005W3210-11 1 . . . Subkit, CCP/CSCP

005W3210-12 . 2 2 2 Subkit, CCP/CACP

005W3210-13 2 . . . Subkit, CCP/CACP

439W1403-1B . . . 1 Retrofit Kit, Purser

Station

439W1403-2B . 1 . . Retrofit Kit, Purser

Station

439W1403-3B . . 1 . Retrofit Kit, Purser

Station

280W5112-1 . . . 1 Wirekit

280W5112-2 . . 1 . Wirekit

280W5112-3 1 . . . Wirekit

280W5112-4 . 1 . . Wirekit

Kit 005W3210

New Part

Number

QTY

Name

Existing Part

-13 -12 -11 -10 Number Notes

005W3210-10 . . . - Subkit, CCP/CSCP

005W3210-11 . . - . Subkit, CCP/CSCP

005W3210-12 . - . . Subkit, CCP/CACP

005W3210-13 - . . . Subkit, CCP/CACP

285W0863-6 1 1 1 1 Cabin Control

Panel

285W0012-3 or

285W0012-4

(a)(b)(c)

285W0895-1 . . 1 1 Disk Drive (b)

285W0925-3 . . 1 1 Mass Memory Card (b)

476W2110-3D . . 1 . Front Shroud 476W2110-1( ) (a)(b)(c)

476W2110-3G . . . 1 Front Shroud 476W2110-1( ) (a)(b)(c)

476W2111-5D . . 1 . Rear Shroud Assy 476W2111-1( ) (a)(b)(c)
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BOEING SERVICE BULLETIN 777-23-0142

476W2111-5G . . . 1 Rear Shroud Assy 476W2111-1( ) (a)(b)(c)

285W0896-2 1 1 . . Mass Memory Card (b)

476W2110-2D 1 . . . Front Shroud 476W2110-1( ) (a)(b)(c)

476W2110-2G . 1 . . Front Shroud 476W2110-1( ) (a)(b)(c)

476W2111-4D 1 . . . Rear Shroud Assy 476W2111-1( ) (a)(b)(c)

476W2111-4G . 1 . . Rear Shroud Assy 476W2111-1( ) (a)(b)(c)

(a) Discard the existing part. Keep the existing part if there are other uses for it.

(b) This part is used in production.

(c) You cannot use the existing part to replace the new or changed part.

Kit 439W1403

New Part

Number

QTY

Name

Existing Part

-3B -2B -1B Number Notes

439W1403-1B . . - Top Kit, Retrofit Kit

439W1403-2B . - . Top Kit, Retrofit Kit

439W1403-3B - . . Top Kit, Retrofit Kit

439W3271-16B . 1 . Cover 439W3271-28A (a)(c)

439W3271-47B 1 . . Cover 439W3271-41B (a)(c)

439W3278-144B . 1 1 Plate (b)

439W3278-145B 1 . . Plate (b)

BACN10YD1G 2 . . Nut, Clip-On

BACN10YD3G 2 . . Nut, Clip-On

BACS12FA3K5 . 4 4 Screw

BACS12FA3K6 2 . . Screw

BACS12FA3K7 2 . . Screw

SL2334-3A3 . 4 4 Insert

(a) Discard the existing part. Keep the existing part if there are other uses for it.

(b) This part is not used in production.

(c) You cannot use the existing part to replace the new or changed part.

(e) If grip length shown is not available at Boeing, fasteners supplied in kits may be one

grip length longer than indicated. Also, if any fasteners part numbers listed are not

available or have been superseded, substitute fasteners may be supplied in kits. Boeing

Document D-590 and Boeing Drawing 012W6100 are used to determine the part

numbers used as substitutes.

Kit 005W3210

New Part

Number

QTY

Name

Existing Part

-13 -12 -11 -10 Number Notes
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Kit 280W5112

New Part

Number

QTY Name Existing Part

Number

Notes

-102 -101 -4 -3 -2 -1

280W5112-1 . . . . . - Wirekit

280W5112-2 . . . . - . Wirekit

280W5112-3 . . . - . . Wirekit

280W5112-4 . . - . . . Wirekit

280W5112-101 . - . . . 1 Kit Subassembly

(W0479)

280W5112-10101 . 1 . . . . I. D. Tape

280W5112-10102 . 1 . . . . Tie Wrap, 18DZ-A,

White

280W5112-102 - . 1 . 1 1 Kit Subassembly

(W1011)

280W5112-10201 1 . . . . . Tie Wrap, 18DZ-A,

Brown

280W5112-103 . . . 1 . . Kit Subassembly

(W1031)

280W5112-104 . . 1 . 1 . Kit Subassembly

(W6087)

280W5112-105 . . 1 1 1 1 Kit Subassembly

(W6943)

280W5112-107 . . 1 . . . Kit Subassembly

(W6023)

324484 1 . . . . . End Cap

Kit 280W5112

New Part

Number

QTY Name Existing Part

Number

Notes

-107 -105 -104 -103

280W5112-103 . . . - Kit Subassembly

(W1031)

280W5112-104 . . - . Kit Subassembly

(W6087)

280W5112-10401 . . 1 . I. D. Tape

280W5112-10402 . . 1 . Tie Wrap, 18DZ-A,

White

280W5112-105 . - . . Kit Subassembly

(W6943)

280W5112-10501 . 1 . . I. D. Tape

280W5112-10502 . 1 . . I. D. Tape

280W5112-10503 . 1 . . Tie Wrap, 18DZ-A,

Brown

280W5112-10504 . 1 . . I. D. Tape
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280W5112-10505 . 1 . . Shielding Tape,

Scotch No. 24

280W5112-10506 . 1 . . Insulation Tape,

Scotch No. 70

280W5112-10507 . 1 . . Insulation Tape,

Permacel P-421

280W5112-107 - . . . Kit Subassembly

(W6023)

280W5112-107W 1 . . . Wire

280W5112-10701 1 . . . I. D. Tape

280W5112-10702 1 . . . Tie Wrap, 18DZ-A,

White

280W5112-10703 1 . . . I. D. Tape

324484 . 7 . 1 End Cap

557B071NF530S . 1 . . Backshell

(DM23555BT)

BACB42F3 1 1 . . Band, Shield

Terminator

BACC47CN1S 4 . . . Pin Contact

BACC47CP1S 4 . . . Socket Contact

BACC63CB12-

12S6

1 . . . Plug Connector

(D01607P)

BACS13CT3B . 1 . . Solder Sleeve with

Shield Ground

BACS13CT5C 2 . . . Solder Sleeve with

Shield Ground

CDMA50P-K87 . 1 . . Plug Connector

(DM23555B)

M39029/64-369 . 4 . . Pin Contact

S280W603-302 1 . . . Backshell

(D06107PQ)

Kit 280W5112

New Part

Number

QTY Name Existing Part

Number

Notes

-107 -105 -104 -103
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2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the

number of parts changed on each airplane.

Part Number /

Specification QTY Name Existing Part Number Notes

BMS 5-28, Type

18, Class 2

1 Potting Compound (a)(b)

(a) Group 1 and Group 3 Airplanes

(b) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

Existing Part

Number QTY Name New Part Number Notes

439W3217-126A 1 Close Out Panel (b) (a)(e)

439W3217-264A 1 Close Out Panel (b) (a)(c)

476W2126-4 1 Angle (b) (a)(d)

476W2126-5 1 Angle (b) (a)(d)

(a) Make the change given in this service bulletin.

(b) There is no equivalent Boeing part number for the changed part. Identify on the part that

the change given in this service bulletin was made.

(c) Group 1 Airplanes.

(d) Group 2 Airplanes.

(e) Group 3 Airplanes.
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4. Parts Removed and Not Replaced:

Group 1 Airplanes

Existing

Part Number Name QTY Notes

285W0011-4 or

285W0011-5

Cabin System

Control Panel

(CSCP)

1 (a)

476W0733-1 Bracket Assembly 1 (a)

476W0734-3 Tray Assembly 1 (a)

476W2100-1G Bezel Assembly 1 (a)

BAC27WEL531 Placard 1 (a)

(a) Keep the part if there are other uses for it.

Group 2 Airplanes

Existing

Part Number Name QTY Notes

285W0011-4 or

285W0011-5

Cabin System

Control Panel

(CSCP)

1 (a)

476W0734-3 Tray Assembly 1 (a)

476W2100-1G Bezel Assembly 1 (a)

476W2732-7 Tray Support

Assembly

1 (a)

476W2732-9 Tray Support

Assembly

1 (a)

476W2732-11 Tray Support

Assembly

1 (a)

BAC27WEL531 Placard 1 (a)

(a) Keep the part if there are other uses for it.

Group 3 Airplanes

Existing

Part Number Name QTY Notes

285W0011-3,

285W0011-4, or

285W0011-5

Cabin System

Control Panel

(CSCP)

1 (a)

476W0733-1 Bracket Assembly 1 (a)

476W0734-3 Tray Assembly 1 (a)

476W2100-1G Bezel Assembly 1 (a)

BAC27WEL531 Placard 1 (a)

(a) Keep the part if there are other uses for it.
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D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But,

maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be

necessary. Examine operator tool supply to make sure all necessary tools are available.

Group 4 Airplanes

Existing

Part Number Name QTY Notes

285W0011-4 or

285W0011-5

Cabin System

Control Panel

(CSCP)

1 (a)

476W0734-4 Tray Assembly 1 (a)

476W2100-1D Bezel Assembly 1 (a)

476W3007-1 Shell Assembly 1 (a)

(a) Keep the part if there are other uses for it.
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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED

MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES

CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE

SPARKS OR OTHER ELECTRICAL DAMAGE.

Note:

1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

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

3. Unless shown differently, these dimensions and tolerances are used:

— 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.

4. For approved fastener and process material substitutions, refer to 777 Structural Repair

Manual, Chapter 51, Alternate fasteners are given in 777 Structural Repair Manual

Chapter 51 and Boeing Drawing 012W6100.

5. Refer to the Boeing Standard Wiring Practices Manuals 20-10-11 and 20-10-12 for the

wire installation procedures and 20-10-19 for wire separation requirements.

6. If the length of fasteners specified in this service bulletin do not meet the installation

standards, fasteners of the same specification, or an approved substitute, one grip length

longer or shorter may be used.

7. The Configuration Database Generator (CDG) is a ground support engineering software

tool that is hosted on a personal computer (PC) and used to build the Configuration

Database (CDB) media sets for individual airplanes.

B. WORK INSTRUCTIONS

1. Open these circuit breakers and attach DO-NOT-CLOSE tags:

Location

(Panel/Position)

Nomenclature Circuit Breaker

P110 / A16 CAB SYS MGMT UNIT C23400

P110 / F1 ZONE MGMT UNIT 1 C23415

P110 / H4 ZONE MGMT UNIT 3 C23419
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2. On Group 1, Group 2 and Group 3 airplanes, at station 450, left aisle, remove the inboard main

ceiling panel to access the P101 distribution integration panel. Refer to 777 AMM 25-21-06/401.

3. On Group 2, Group 3 and Group 4 airplanes, at station 950, left aisle, remove the inboard main

ceiling panel to access the P102 distribution integration panel. Refer to 777 AMM 25-21-06/401.

4. On Group 4 airplanes, at station 1730, left aisle, remove the inboard main ceiling panel to access

the P103 distribution integration panel. Refer to 777 AMM 25-21-06/401.

5. On Group 3 airplanes, at station 711, left aisle, remove the outboard main ceiling panel to access

the AP0715 disconnect bracket above lavatory 2F-1L. Refer to 777 AMM 25-21-06/401.

6. Remove the three CACPs as shown in Figure 1.

7. On Group 1 airplanes, change wires as follows:

a. Change wires at the P101 distribution integration panel as shown in Figure 2.

b. Change wires at the CACP 2 location at door 2-Left as shown in Figure 8.

8. On Group 2 airplanes, change wires as follows:

a. Change wires at the P101 distribution integration panel as shown in Figure 3.

b. Change wires at the P102 distribution integration panel as shown in Figure 5.

c. Change wires at the CACP 1 location at door 1-Left as shown in Figure 7.

d. Change wires at the purser station at door 2-Left as shown in Figure 9.

9. On Group 3 airplanes, change wires as follows:

a. Change wires at the P101 distribution integration panel as shown in Figure 4.

b. Change wires at the P102 distribution integration panel as shown in Figure 5.

c. Change wires at the CACP 1 location at door 1-Left as shown in Figure 7.

d. Add wires from AP0715 disconnect bracket to lavatory 2F-1L at door 2-Left as shown in

Figure 11.

10. On Group 4 airplanes, change wires as follows:

a. Change wires at the P102 distribution integration panel as shown in Figure 5.

P210 / D9 AREA CONTROL

PANELS

C23444

P210 / E5 VIDEO PGMS & CTRL C23403

P210 / E25 ZONE MGMT UNIT 2 C23417

Location

(Panel/Position)

Nomenclature Circuit Breaker
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b. Change wires at the P103 distribution integration panel as shown in Figure 6.

c. Change wires at the purser station at door 2-Left as shown in Figure 10.

11. Install a CCP as the CSCP as shown in Figure 12.

12. Install two CCPs as CACPs as shown in Figure 13.

13. On Group 1 airplanes, do these steps to remove the CSCP and modify the purser station at

station 288:

a. Remove the CSCP as shown in Figure 14.

b. Change the wires in the purser station as shown in Figure 15

c. Modify the close-out panel as shown in Figure 16.

d. Modify the purser station as shown in Figure 17.

14. On Group 2 airplanes, do these steps to remove the CSCP and modify the purser station at

station 695:

a. Remove the CSCP as shown in Figure 18.

b. Change the wires in the purser station as shown in Figure 19.

c. Modify the purser station as shown in Figure 20.

15. On Group 3 airplanes, do these steps to remove the CSCP and modify the purser station at

station 247:

a. Remove the CSCP as shown in Figure 21.

b. Change the wires in the purser station as shown in Figure 22.

c. Modify the close-out panel as shown in Figure 23.

d. Modify the purser station as shown in Figure 24.

16. On Groups 4 airplanes, do these steps to remove the CSCP and modify the A-4 galley at station

2008:

a. Remove the CSCP and tray assembly as shown in Figure 25.

b. Modify the A-4 galley as given in JAMCO Service Letter SL-K0789.

17. Install removed ceiling panels as given in 777 AMM 25-21-06/401.
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18. Remove the DO-NOT-CLOSE tags and close these circuit breakers:

19. Do a phase two installation of the new CSMU software part number 2313-BCE-01T-03. Refer to

the 777 AMM 23-39-00/201, Operational Program Software Installation (Phase II).

20. Do a phase two installation of the new CACP software part number 2313-BCE-01U-02. Refer to

the 777 AMM 23-39-00/201, Operational Program Software Installation (Phase II).

21. Do a phase two installation of the new ZMU software part number 2374-BCE-021-02. Refer to

the 777 AMM 23-39-00/201, Operational Program Software Installation (Phase II).

22. If necessary, do a phase two installation of the OEU software part number 2310-BCE-01V-02.

Refer to the 777 AMM 23-39-00/201, Operational Program Software Installation (Phase II).

23. Do a phase I installation of the new configuration database. Refer to the 777 AMM 23-39-00/201,

Phase I Data Installation From the CSCP Disk Drive to the CSCP Mass Storage. To get the new

database, do these steps:

Note: Refer to the Boeing Configuration Database Generator (CDG) User Guide, Version

285W0881-3, D634W602-1, Rev 2. CDG software part number 285W0550-03 is

necessary to change the database.

a. Get ready to make a change to the configuration database (CDB):

(1) Load the serviceable database file into a personal computer with Windows 95. Open

the 285W0550-03 CDG tool. Open the database file. Follow the directions to convert

the file if prompted.

(2) Do a consistency check. Make the menu selections "Utilities - Check Consistency".

(3) When the check is completed, make the menu selection "Print". Keep the printed data

to use in a subsequent step.

(4) Make the menu selections "Utilities - Generate reports".

(5) Put a check mark in the box for "Special Functions" (Section 16). Make the selection

"Accept".

(6) When the report is completed, make the selections "Print". Keep the printed data to

use in a subsequent step.

Location

(Panel/Position)

Nomenclature Circuit Breaker

P110 / A16 CAB SYS MGMT UNIT C23400

P110 / F1 ZONE MGMT UNIT 1 C23415

P110 / H4 ZONE MGMT UNIT 3 C23419

P210 / D9 AREA CONTROL

PANELS

C23444

P210 / E5 VIDEO PGMS & CTRL C23403

P210 / E25 ZONE MGMT UNIT 2 C23417
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(7) Make the menu selections "File - Save as". Make a new name for the database and

save the file.

Note: The use of the characters “CDB” (i.e. “mmm” code) in the software part number

is exclusively reserved for Boeing generated CMS database software. Boeing

recommends the use of the customer three letter manufacturing designator.

b. Change the CSCP and CACP functions in the CDB:

(1) Change the CSCP:

(a) Make the menu selections "Data menu - LRU configuration - Primary LRU".

(b) Select the "CSCP Address" button and select the ZMU port address for the CSCP

from the dropdown list.

(c) Close the screen.

(d) Revise the CSCP Location Description with the new M number and the new

location.

(2) Change the CACP:

(a) From the same screen, remove the check mark from the "In Config" box for the

deleted CACP.

(b) For the other two CACPs, revise the CACP Location Description with the new M

number.

(c) Accept the screen when done.

Note: A warning message will show that states: This LRU has been removed from

the configuration. This will result in deletion from the database of any

subordinate LRUs or assignments relating to this LRU.

(d) Select "Yes" to continue.

(e) Make the menu selections "Data menu - Panel setup - Panel capabilities".

(f) Make sure that the CACP that you removed the check mark from is deleted.

(3) Change the panel capabilities:

(a) From the same screen in the CDB, scroll to each programmable screen section

and change the panel capabilities for each panel, as necessary.

(b) Click the box as (Blank=NO, X=YES, D=DEFAULT)

(c) Accept the screen when done.

(4) Save the changed CSCP and CACP functions in the CDB:

(a) Make the menu selections "File-Save".
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c. Change the cabin attendant work lights functions in the CDB:

(1) Make the menu selections "Data menu-Attendant Work Lights"

(2) See the printed data made before and find all the attendant work lights in the Special

Functions part.

(3) For each attendant work light found in Special Functions, enter the same OEU data

(Input, Output and Location Description) into the new attendant work lights.

(4) Accept the screen when done.

(5) Make the menu selections "Data menu-Special Functions".

(6) Remove the attendant work lights from the special functions by removing the check

mark in the In-Config box.

(7) Accept the screen when done.

(8) Make the menu selections "File-Save".

d. Change the Cabin Utility Switch functions for the crew rest areas in the CDB.

(1) Make the Special Functions for the ground service bus loss outputs and crew rest

reading light outputs.

(a) Make the menu selections "Data - Special Functions".

(b) Find the special function that has "Ground service bus loss" as the input type (i.e.

Special Function number 62). Find any special function that has the crew rest

reading lights. Use the printed data made before to find the special function

number.

Note: If no ground service bus loss or crew rest reading light special functions are

found, no more changes to the database are necessary. Go to the step to

check the database and make the data load discs.

(c) Go to the special function number 79 and put an X in the "In-Config" box. If this

special function number is already used, find a special function number that is not

used and is higher than the one for the Ground service bus loss entry.

(d) From the Input Type box pull down menu, make the selection "CSS Discrete/

Signal". In the CSS Discrete/Signal menu, make the Input Type "Cabin Utility

Switch"

(e) Make the selection "Output Type 2" , then "Edit - Insert Record".

(f) Enter all the same output data from the "Ground service bus loss" special function

and the crew rest reading lights special function.

(g) For each crew rest reading light, make the Initial/Inactive setting "NULL" and the

Active setting "ON". Make the selection "Close" to get to the Special Functions

screen.
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(h) Make the selection "Description". Write a new description for the Cabin Utility

Switch special function. If both ground service bus loss and crew rest reading light

special functions are found, include information from both descriptions to make

one description. Use the words "Cabin Utility Switch" instead of "Ground Service

Bus Loss" in the new description.

(i) Make the selection "Accept".

(j) Make the menu selections "File - Save".

e. Do a check of the database and make the data load disks for the new CDB.

(1) Do a consistency check. Make the menu selections "Utilities - Check Consistency".

(2) Change the database as necessary to remove any critical errors.

(3) Optional - It can be a help to examine the warnings before and after the database

changes. A differences report can also give more information. Refer to the CDG Users

Manual D634W602-1 to get the necessary instructions to make these reports.

(4) Make the menu selections "Utilities - Create Data Load disk". Use an operator selected

diskette set part number and make the selection "Accept".

Note: Do not use the characters "222W0014-" in the diskette set part number. These

characters are to be used only for Boeing made database disk sets.

(5) When told, put the first blank disk in the drive a: and make the selection "OK".

Note: Use only new or reformatted High Density 1.44 Mb disks. Errors can occur if the

disk is not reformatted before use.

(6) When told, remove the disk. Read the instructions to make a label for the removed

disk.

(7) When told, put the second blank disk in the drive a: and make the selection "OK".

(8) When told, remove the disk. Read the instructions to make a label for the removed

disk.

24. Install the new configuration database to the CSS LRUs. Refer to the 777 AMM 23-39-00/201,

Configuration Database Installation.

25. Do this functional test of the cabin services system (CSS):

a. Make sure all the CSS circuit breakers are closed as follows:

Location

(Panel/Position)

Nomenclature Circuit Breaker

P110 / A15 OEU ZONE 1 MAIN BUS C23437

P110 / A16 CAB SYS MGMT UNIT C23400

P110 / D15 OEU ZONE 3 RIGHT

MAIN BUS

C23445
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Note: All CSS circuit breakers are closed to prevent nuisance messages. If some circuit

breakers cannot be closed, ignore fault messages not related to the replaced LRUs.

b. Touch these selections on the CSCP:

(1) CABIN MAINTENANCE

(2) CABIN CONFIGURATION

(3) CONFIGURATION CHECK

(4) CABIN SYSTEM CONTROL PANEL (CSCP)

P110 / D16 OEU ZONE 3 LEFT MAIN

BUS

C23441

P110 / E16 OEU ZONE 3 CENTER

MAIN BUS

C23443

P110 / F1 ZONE MGMT UNIT 1 C23415

P110 / F2 OEU ZONE 1 XFER BUS C23439

P110 / G2 OEU ZONE 3 XFER BUS C23447

P110 / H4 ZONE MGMT UNIT 3 C23419

P210 /C10 OEU ZONE 2 LEFT MAIN

BUS

C23414

P210 / D9 AREA CONTROL

PANELS

C23444

P210 / D10 OEU ZONE 2 CENTER

MAIN BUS

C23416

P210 / E10 OEU ZONE 2 RIGHT

MAIN BUS

C23418

P210 / E24 OEU ZONE 2 XFER BUS C23420

P210 / E25 ZONE MGMT UNIT 2 C23417

P210 / M05 PAX MASTER CALL LT C33628

P310 / E06

(if applicable)

LLAR SDM C23647

P310 / F06 PAX ADRS CTRL PRI C23632

P310 / F07 PAX ADRS CTRL SEC C23633

P310 / F08 PA DIR ACCESS C23637

P310 / F09 SDM COL 1 C23634

P310 / F10 SDM COL 2 C23635

P310 / F11 SDM COL 3 C23636

P310 / F12 CAB INTPH PRI C23638

P310 / F13 CAB INTPH SEC C23639

P310 / F14 CAB INTPH ZMUS C23640

Location

(Panel/Position)

Nomenclature Circuit Breaker
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c. Make sure the CSCP-CCP hardware part number that shows is 285W0863-6, the MMC part

number that shows is 285W0925-3, and the OPS software part number that shows is 230ABCE-01L-02. Make sure the database part number is correct.

d. Touch these selections on the CSCP:

(1) PREVIOUS MENU

(2) CABIN AREA CONTROL PANEL (CACP)

e. Make sure the CACP-CCP hardware part number that shows is 285W0863-6, the MMC part

number that shows is 285W0896-2, and the OPS software part number that shows is 2313-

BCE-01U-02. Make sure the database part number is correct.

f. Touch these selections on the CSCP:

(1) PREVIOUS MENU

(2) ZONE MANAGEMENT UNIT (ZMU)

g. Make sure the ZMU hardware part number that shows is correct and the OPS software part

number that shows is 2374-BCE-021-02. Make sure the database part number is correct.

h. Touch these selections on the CSCP:

(1) PREVIOUS MENU

(2) CABIN SYSTEM MANAGEMENT UNIT (CSMU)

i. Make sure the CSMU hardware part number that shows is correct and the OPS software

part number that shows is 2313-BCE-01T-03. Make sure the database part number is

correct.

j. Touch these selections on the CSCP:

(1) PREVIOUS MENU

(2) OVERHEAD ELECTRONICS UNIT (OEU)

k. Make sure the OEU hardware part number that shows is correct and the OPS software part

number that shows is 2310-BCE-01V-02. Make sure the database part number is correct.

l. If the airplane has core print capability, select PRINT PAGE and make sure the page prints.

Note: On Group 1 and Group 3 airplanes, after incorporation of this service bulletin, you will

no longer be able to print from the CSCP if that feature was previously available. A

subsequent service bulletin will install the necessary lavatory wiring to allow printing

from the CSCP.

m. Touch these selections on the CSCP:

(1) CABIN TESTS
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(2) START ALL TEST

n. Select CONTINUE TEST to do the All Test.

o. Make sure the ALL TEST COMPLETE screen or the ALL TEST FAULT REVIEW screen

shows.

p. If the ALL TEST FAULTS REVIEW screen shows, make sure there are no faults related to

the CSCP and CACPs.

(1) If the PANELS button is not active, there are no faults related to the CSCP or CACP.

(2) If the PANELS button is active, select it and then select CONTINUE to review the faults.

q. Select MAIN MENU.

26. Put the airplane back to a serviceable condition.
FIGURE 1: CACP REMOVAL

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FIGURE 1: CACP REMOVAL

(EXAMPLE)

ATTENDANT STATION

FWD

SEE A

SEE A

(GROUPS 1, 2 AND 3)

SEE A (GROUP 4)

SEE A (GROUPS 2, 3 AND 4)

SEE A (GROUP 1)

A

SEE B

3 (4 LOCATIONS)

4 (4 LOCATIONS)

5

B

2

(2 LOCATIONS) 4

3

1

1 (4 LOCATIONS)

AUTO-LOCK PIN

W44395

(SHEET 1 OF 2)
FIGURE 1: CACP REMOVAL

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for each CACP location. There are 3 CACPs on the

airplane.

CAUTION: DO NOT TOUCH THE CONECTOR PINS OR OTHER CONDUCTORS ON THE CACP. IF YOU

TOUCH THESE CONDUCTORS, ELECTROSTATIC DISCHARGE CAN CAUSE DAMAGE TO

THE CACP.

STEP TASK NAME PART NUMBER QTY NOTES

1

Remove Front Shroud

Assembly

476W2110-1( ) 1 Push a 1.5mm or smaller

allen wrench in the autolock pin holes to release

the auto-lock pins which

hold the front shroud in

its position.

2 Disconnect Electrical

Connector

-- 1 From the CACP.

3

Remove / Keep Bolt BACB30LK3-3 4

Washer NAS1149D0332J 4

Remove Cabin Area

Control Panel

285W0012-3 or

285W0012-4

1

4 Remove / Keep Bolt BACB30LH3-( ) 4 (a)

Bracket 476W2112-3 2

5 Remove Rear Shroud

Assembly

476W2111-1( ) 1

(a) Bolt length is different at each mounting location. Make sure the bolts are re-installed at the same

location.

(SHEET 2 OF 2)
FIGURE 2: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 1 AIRPLANES

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 2: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 1 AIRPLANES

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

found in subkit 280W5112-102.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 End Cap 324484 1 Refer to BSWPM 20-30-

16.

2

Tie Wrap - Brown 280W5112-10201 -- Use as necessary to tie

wires to wire bundle

W1011. Refer to

BSWPM 20-10-11.

1410-20

1606-20

P101 DISTRIBUTION INTEGRATION PANEL-DOOR 1

10

12

AP0421

AP0461

AP0461

D1300P

D1394P

D1301P

W6223

W6001

W6120

6

J

J

J

TB1011

TB1011

W1011

UA49

UB49

0012-20

2 1

DELETED WIRE OR FORMER ROUTING

W59579

ADDED WIRE

EXISTING WIRE OR IMPACTED WIRE

(SHEET 1 OF 1)
FIGURE 3: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 2 AIRPLANES

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 3: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 2 AIRPLANES

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

found in subkit 280W5112-102.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 End Cap 324484 1 Refer to BSWPM 20-30-

16.

2

Tie Wrap - Brown 280W5112-10201 -- Use as necessary to tie

wires to wire bundle

W1011. Refer to

BSWPM 20-10-11.

TB1011

AP0461

AP0421

P101

0012-20

J

W6120

D1396P J

D1301P

W6223 6710-20 10

12

DISTRIBUTION INTEGRATION PANEL-DOOR 1

UA49

1

2

REFERENCE: 777 WIRING DIAGRAM 23-33-12

W1011

W44403

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 4: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 4: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 3 AIRPLANES

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

found in subkit 280W5112-102.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 End Cap 324484 1 Refer to BSWPM 20-30-

16.

2

Tie Wrap - Brown 280W5112-10201 -- Use as necessary to tie

wires to wire bundle

W1011. Refer to

BSWPM 20-10-11.

AP0461

AP0421

P101

0012-20

J

W6120

D1394P J

D1301P

W6223 1410-20 10

12

DISTRIBUTION INTEGRATION PANEL-DOOR 1

UA49

TB1011

1

2

REFERENCE: 777 WIRING DIAGRAM 23-33-12

W1011

W44401

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 5: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P102 - GROUPS 2, 3 AND 4

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 5: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P102 - GROUPS 2, 3 AND 4

DISTRIBUTION INTEGRATION PANEL-DOOR 2

TB1021

TB1021

W6002 519-20 UB49

D1342P

AP0971

19

P102

UA49

J

REFERENCE: 777 WIRING DIAGRAM 23-33-13

W1021

W59587

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 6: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P103 - GROUP 4 AIRPLANES

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 6: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P103 - GROUP 4 AIRPLANES

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

found in subkit 280W5112-103 and 280W5112-105.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 End Cap 324484 1 Refer to BSWPM 20-30-

16.

2

Tie Wrap - Brown 280W5112-10503 -- Use as necessary to tie

wires to wire bundle

W1031. Refer to

BSWPM 20-10-11.

AP1701

P103

0022-20

J

W6121

D1370P J

D1353P

W6253 1727-20 27

22

DISTRIBUTION INTEGRATION PANEL-DOOR 3

UA49

TB1031

2

1

REFERENCE: 777 WIRING DIAGRAM 23-33-14

W1031

W59588

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 7: WIRE CHANGE - CACP 1 TO CCP - GROUPS 2 AND 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 7: WIRE CHANGE - CACP 1 TO CCP - GROUPS 2 AND 3 AIRPLANES

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

Parts are found in subkit 280W5112-104.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1

I.D. Tape 280W5112-10401 1 Use to replace existing

identification tape.

Text: D6625P M/W M23554

2

Tie Wrap - White 280W5112-10102 - Use as necessary to tie

wires to wire bundle W6087.

Refer to BSWPM 20-10-11.

M23064 CACP 1

(J1)

FLIGHT CREW REST

D6625P

D6625P

M23554 CCP

(J1)

REFERENCE: 777 WIRING DIAGRAM 23-33-12

2

1

W6087

W59589

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 8: WIRE CHANGE - CACP 2 TO CCP - GROUP 1 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 8: WIRE CHANGE - CACP 2 TO CCP - GROUP 1 AIRPLANES

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

Parts are found in subkit 280W5112-101.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1

I.D. Tape 280W5112-10101 1 Use to replace existing

identification tape.

Text: D6600P M/W M23555

2

Tie Wrap - White 280W5112-10102 - Use as necessary to tie

wires to wire bundle W0479.

Refer to BSWPM 20-10-11.

M23066 CACP 2

(J1)

CLOSET DOOR 2-LEFT

D6600P

D6600P

M23555 CCP

(J1)

REFERENCE: 777 WIRING DIAGRAM 23-33-13

2

1

W479

W59593

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 9: WIRE CHANGE - PURSER STATION - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 9: WIRE CHANGE - PURSER STATION - GROUP 2 AIRPLANES

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

Parts are found in subkit 280W5112-105

FLAG

NOTE NAME PART NUMBER QTY NOTES

1

I. D. Tape 280W5112-10501 1 Use to replace existing

identification tape.

Text: DM23555A M/W

M23555

2 Backshell

(DM23555BT)

557B071NF530S 1 Refer to BSWPM 20-25-

14.

3 Plug Connector

(DM23555B)

CDMA50P-K87 1

4 Contact M39029/64-369 4 Refer to BSWPM 20-90-

11.

DM23673D

32

409RK-22

11

PURSER STATION

DM23555B

43

40

42

DM23555A

13

39

14

M23066 CACP 2

(J1) DM23066A

M23555 CCP

(J2)

409B -22

409BK-22

409R -22

M23673 CMT

(J1)

REFERENCE: 777 WIRING DIAGRAMS 23-33-13, 23-36-41

4 (4 LOCATIONS)

2 3

1

11

5 6 7 8 9

10

W6943

W59594

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 2)
FIGURE 9: WIRE CHANGE - PURSER STATION - GROUP 2 AIRPLANES

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BOEING SERVICE BULLETIN 777-23-0142

5 Solder Sleeve with

Shield Ground

BACS13CT3B 1 Refer to BSWPM 20-10-

15.

6 Shield Terminator

Band

BACB42F3 1 Refer to BSWPM 20-25-

14 and Appendix B.

7 Shielding Tape,

Scotch No. 24

280W5112-10505 - Refer to Appendix B.

8 Insulation Tape,

Scotch No. 70

280W5112-10506 - Refer to Appendix B.

9 Insulation Tape,

Permacel P-421

280W5112-10507 - Refer to Appendix B.

10 I. D. Tape 280W5112-10504 1 Text: DM23555B M/W

M23555

11

Tie Wrap - Brown 280W5112-10503 - Use as necessary to tie

wires to wire bundle

W6943. Refer to

BSWPM 20-10-11.

FLAG

NOTE NAME PART NUMBER QTY NOTES

(SHEET 2 OF 2)
FIGURE 10: WIRE CHANGE - PURSER STATION - GROUP 4 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 10: WIRE CHANGE - PURSER STATION - GROUP 4 AIRPLANES

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

Parts are found in subkit 280W5112-105

FLAG

NOTE NAME PART NUMBER QTY NOTES

1

I. D. Tape 280W5112-10501 1 Use to replace existing

identification tape.

Text: DM23555A M/W

M23555

2 Backshell

(DM23555BT)

557B071NF530S 1 Refer to BSWPM 20-25-

14.

3 Plug Connector

(DM23555B)

CDMA50P-K87 1

4 Contact M39029/64-369 4

DM23673D

13

409RK-22

11

PURSER STATION

DM23555B

43

40

42

DM23555A

35

39

14

M23066 CACP 2

(J1) DM23066A

M23555 CCP

(J2)

409B -22

409BK-22

409R -22

M23673 CMT

(J1)

REFERENCE: 777 WIRING DIAGRAMS 23-33-13, 23-36-41

4 (4 LOCATIONS)

2 3

1

11

5 6 7 8 9

10

W6943

W59596

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 2)
FIGURE 10: WIRE CHANGE - PURSER STATION - GROUP 4 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

5 Solder Sleeve with

Shield Ground

BACS13CT3B 1 Refer to BSWPM 20-10-

15.

6 Shield Terminator

Band

BACB42F3 1 Refer to BSWPM 20-25-

14 and Appendix B.

7 Shielding Tape,

Scotch No. 24

280W5112-10505 - Refer to Appendix B.

8 Insulation Tape,

Scotch No. 70

280W5112-10506 - Refer to Appendix B.

9 Insulation Tape,

Permacel P-421

280W5112-10507 - Refer to Appendix B.

10 I. D. Tape 280W5112-10504 1 Text: DM23555B M/W

M23555

11

Tie Wrap - Brown 280W5112-10503 - Use as necessary to tie

wires to wire bundle

W6943. Refer to

BSWPM 20-10-11.

FLAG

NOTE NAME PART NUMBER QTY NOTES

(SHEET 2 OF 2)
FIGURE 11: WIRE CHANGE - AP0715 TO LAVATORY 2F-1L - GROUP 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 11: WIRE CHANGE - AP0715 TO LAVATORY 2F-1L - GROUP 3 AIRPLANES

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

Parts are found in subkit 280W5112-107

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 Pin Contact BACC47CN1S 4 Refer to BSWPM 20-61-00.

2 I. D. Tape 280W5112-10701 1 Use to replace existing

identification tape.

Text: D06331P M/W AP0715

POS 01 (W6002)

3 Solder Sleeve

With Pigtail

BACS13CT5C 2 Maximum pigtail length is 2

inches. Refer to BSWPM 20-

10-15.

4 Plug Connector

(D01607P)

BACC63CB12-

12S6

1 Refer to BSWPM 20-35-11 and

20-61-11.

5 Backshell

(D06107PQ)

S280W603-302 1 Refer to BSWPM 20-25-14.

6 Socket Contact BACC47CP1S 4 Refer to BSWPM 20-61-00.

7 Shield Terminator

Band

BACB42F3 2 Refer to BSWPM 20-25-14.

8 I. D. Tape 280W5112-10703 1 Text: D06107P M/W VENDOR

9 Tie Wrap (White) 280W5112-10702 1 Use as necessary to tie wires

to wire bundle W6023. Refer

to BSWPM 20-10-11.

1

2

3

4

(J12) J D6331P

(2F-1L)

11

7

10

D6107P

AP0715

W6023-402B-24

W6023-402R-24

W6023-402BK-24

W6023-402RK-24

M25049 LAVATORY

6

REFERENCE: 777 WIRING DIAGRAM 23-36-41

5

3

7

1 6

8

4

2

9 (4 LOCATIONS)

(4 LOCATIONS)

3

7

W59598

ADDED WIRE OR NEW ROUTING

(SHEET 1 OF 1)
FIGURE 12: CCP INSTALLATION AS CSCP

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FIGURE 12: CCP INSTALLATION AS CSCP

(EXAMPLE)

ATTENDANT STATION

FWD

SEE A (GROUP 1) SEE A (GROUPS 2, 3 AND 4)

A

SEE B

B 8 4

6

2

7

2

2

1

(4 LOCATIONS)

3

(4 LOCATIONS)

4

5

3

W59599

(SHEET 1 OF 3)
FIGURE 12: CCP INSTALLATION AS CSCP

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane. Parts are found in subkit 005W3210-

10 (Groups 1, 2, and 3) or 005W3210-11 (Group 4).

The CCP used as a CSCP is installed in a location used for a CACP before. The location of the CCP is shown

in the table below:

CAUTION: DO NOT TOUCH THE CONECTOR PINS OR OTHER CONDUCTORS ON THE CCP, DISK

DRIVE OR MASS MEMORY CARD. IF YOU TOUCH THESE CONDUCTORS,

ELECTROSTATIC DISCHARGE CAN CAUSE DAMAGE TO THE CCP, DISK DRIVE OR MASS

MEMORY CARD.

Group Location Monument CCP Equipment

Number

Group 1 Door 1 Left Lav 1F-2L M23554

Group 2 Door 2 Left Purser Station M23555

Group 3 Door 2 Left Lav 2F-1L M23555

Group 4 Door 2 Left Purser Station M23555

STEP TASK NAME PART NUMBER QTY NOTES

1 Install Rear Shroud

Assembly

476W2111-5G (a)

476W2111-5D (b)

1

2 Install / Kept Bracket 476W2112-3 2

Bolt BACB30LH3-( ) 4 (c)

3

Install Cabin Control

Panel

285W0863-6 1 Refer to AMM 777 23-

39-16/201.

Install / Kept Bolt BACB30LK3-3 4

Washer NAS1149D0332J 4

4 Remove Cover Plate 285W0904 2 From CCP.

5

Install Disk Drive 285W0895-1 1 Make sure the drive is

inserted fully before the

captive screws are

tightened. Refer to AMM

777 23-39-16/201.

6

Install Mass Memory

Card Assembly

(MMC 85)

285W0925-3 1 Make sure the card is

inserted fully before the

captive screws are

tightened. Refer to AMM

777 23-39-16/201.

7 Connect Electrical

Connector

-- 2 To the CCP.

(SHEET 2 OF 3)
FIGURE 12: CCP INSTALLATION AS CSCP

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8

Install Front Shroud

Assembly

476W2110-3G (a)

476W2110-3D (b)

1 Make sure the front

shroud and rear shroud

fit close together. Adjust

the auto-lock pins with a

1.5mm allen wrench if

necessary. Refer to

AMM 777 23-39-16/201.

(a) Groups 1, 2, and 3.

(b) Group 4

(c) Bolt length is different at each mounting location. Make sure the bolts are installed at the same

location they were removed from.

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 3 OF 3)
FIGURE 13: CCP INSTALLATION AS CACP

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FIGURE 13: CCP INSTALLATION AS CACP

(EXAMPLE)

ATTENDANT STATION

FWD

SEE A (GROUP 1)

SEE A (GROUPS 2, 3 AND 4)

A

SEE B

B

7 4

5

2

6

2

2

1

(4 LOCATIONS)

(4 LOCATIONS) 3

3

SEE A (GROUPS 2 AND 3)

SEE A (GROUP 1)

SEE A (GROUP 4)

W59600

(SHEET 1 OF 3)
FIGURE 13: CCP INSTALLATION AS CACP

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for each CACP location. There are 2 CACP locations

on the airplane. Parts are found in subkit 005W3210-12 (Groups 1, 2, and 3) or 005W3210-13 (Group 4).

The locations of the CACP CCPs are shown in the table below:

CAUTION: DO NOT TOUCH THE CONECTOR PINS OR OTHER CONDUCTORS ON THE CCP OR MASS

MEMORY CARD. IF YOU TOUCH THESE CONDUCTORS, ELECTROSTATIC DISCHARGE

CAN CAUSE DAMAGE TO THE CCP OR MASS MEMORY CARD.

Group Location Monument CCP Equipment

Number

Group 1 Door 2 Left Closet 2 M23555

Door 4 Right Lav 4F-R M23557

Group 2 Door 1 Left Flight Crew Rest M23554

Door 4 Right Galley A3 M23557

Group 3 Door 1 Left Flight Crew Rest M23554

Door 4 Right Galley A3 M23557

Group 4 Door 1 Right Galley F3 M23554

Door 4 Right Galley A3 M23557

STEP TASK NAME PART NUMBER QTY NOTES

1 Install Rear Shroud

Assembly

476W2111-4G (a)

476W2111-4D (b)

1

2 Install / Kept Bracket 476W2112-3 2

Bolt BACB30LH3-( ) 4 (c)

3

Install Cabin Control

Panel

285W0863-6 1 Refer to AMM 777 23-

39-16/201.

Install / Kept Bolt BACB30LK3-3 4

Washer NAS1149D0332J 4

4 Remove Cover Plate 285W0904 1 From the CCP.

5

Install Mass Memory

Card Assembly

(MMC 20)

285W0896-2 1 Make sure the card is

inserted fully before the

captive screws are

tightened. Refer to AMM

777 23-39-16/201.

6 Connect Electrical

Connector

-- 1 To the CCP.

7

Install Front Shroud

Assembly

476W2110-2G (a)

476W2110-2D (b)

1 Make sure the front

shroud and rear shroud

fit close together. Adjust

the auto-lock pins with a

1.5mm allen wrench if

necessary. Refer to

AMM 777 23-39-16/201.

(SHEET 2 OF 3)
FIGURE 13: CCP INSTALLATION AS CACP

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BOEING SERVICE BULLETIN 777-23-0142

(a) Groups 1, 2, and 3.

(b) Group 4

(c) Bolt length is different at each mounting location. Make sure the bolts are installed at the same

location they were removed from.

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 3 OF 3)
FIGURE 14: REMOVE CSCP - GROUP 1 AIRPLANES

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 14: REMOVE CSCP - GROUP 1 AIRPLANES

(4 LOCATIONS)

AUTO-LOCK PIN

PURSER STATION

(8 LOCATIONS) A 2

1

1

2

3

SEE A

FWD

W59601

(SHEET 1 OF 2)
FIGURE 14: REMOVE CSCP - GROUP 1 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1

Remove Bezel Assembly 476W2100-1G 1 Push a 1.5mm or smaller

allen wrench into the

auto-lock pin holes to

release the auto-lock

pins.

2 Remove / Keep Screw BACS12FA3K5 8

Close Out Panel 439W3217-264A 1

3

CAUTION: DO NOT TOUCH THE CONNECTOR PINS OR OTHER CONDUCTORS ON THE

CSCP. IF YOU TOUCH THESE CONDUCTORS, ELECTROSTATIC DISCHARGE CAN

CAUSE DAMAGE TO THE CSCP.

Remove Cabin System

Control Panel

(CSCP)

285W0011-4 or

285W0011-5

1 Refer to 777 AMM 20-

10-01/401.

(SHEET 2 OF 2)
FIGURE 15: WIRE CHANGE - PURSER STATION - GROUP 1 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 15: WIRE CHANGE - PURSER STATION - GROUP 1 AIRPLANES

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

found in subkit 280W5112-105.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 End Cap 324484 7 Refer to BSWPM 20-10-11 and

20-30-16.

Coil and stow wire bundle at

last clamp point.

2 Tie Wrap (Brown) 280W5112-10503 -- Use as necessary. Refer to

BSWPM 20-10-11.

M23062 CSCP 1

DM23062AA

DM23062AC

PURSER STATION

DM23062AC

DM23062AA

1

1

2

REFERENCE: 777 WIRING DIAGRAM 23-33-12

(3 LOCATIONS)

(4 LOCATIONS)

W6943

W59602

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 16: CLOSE OUT PANEL MODIFICATION - GROUP 1 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 16: CLOSE OUT PANEL MODIFICATION - GROUP 1 AIRPLANES

A

A

3 1

4

(4 LOCATIONS) CLOSE OUT PANEL

REFERENCE ONLY)

(SHOWN FOR

COVER PLATE

A-A

(4 LOCATIONS) 2 3

11.5466

0.50 0.50

14.2540

W59613

(SHEET 1 OF 2)
FIGURE 16: CLOSE OUT PANEL MODIFICATION - GROUP 1 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane. Parts are found in subkit 439W1403-

1B.

STEP TASK NAME PART NUMBER QTY NOTES

1 Locate Close Out Panel 439W3217-264A 1 Previously removed from the

purser station.

2 Drill Hole -- 4 Drill 0.562 to 0.565 inch

diameter holes. Locate holes to

match the holes in the

439W3278-144B cover plate.

Refer to BAC 5583, Method B

Process Data provided in

Appendix A.

3 Install Inserts SL2334-3A3 4 Refer to BAC 5583, Method B

Process Data provided in

Appendix A. Use Potting Compound BMS 5-28, Type

18, Class 2

--

4 Mark Close Out Panel -- 1 Mark the service bulletin

number on the non-decorative

surface of the close out panel.

Refer to BSOPM 20-50-10.

(SHEET 2 OF 2)
FIGURE 17: PURSER STATION MODIFICATION - GROUP 1 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 17: PURSER STATION MODIFICATION - GROUP 1 AIRPLANES

PURSER STATION

A 7 (8 LOCATIONS)

8

8

7

FWD

(4 LOCATIONS)

SEE B

SEE A

B

1

(2 LOCATIONS)

3

6

5

2

4 (8 LOCATIONS) (4 LOCATIONS)

W59615

(SHEET 1 OF 2)
FIGURE 17: PURSER STATION MODIFICATION - GROUP 1 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane. Parts are found in subkit 439W1403-

1B.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Screw NAS8203A9 2

Washer NAS1149D0332J 2

2 Loosen Captive Fastener -- 4

3 Remove Tray Assembly 476W0734-3 1

4 Remove Screw BACS12FA3K6 8

5 Remove Bracket Assembly 476W0733-1 1

6 Remove Placard BAC27WEL531 1 Text: M23062 CSCP

7 Install /

Modified

Close Out Panel 439W3217-264A 1

Install / Kept Screw BACS12FA3K5 8

8 Install Plate 439W3278-144B 1

Screw BACS12FA3K5 4

(SHEET 2 OF 2)
FIGURE 18: REMOVE CSCP - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 18: REMOVE CSCP - GROUP 2 AIRPLANES

PURSER STATION

(4 LOCATIONS)

AUTO-LOCK PIN

SEE A

A

1

2

1

W59616

FWD

(SHEET 1 OF 2)
FIGURE 18: REMOVE CSCP - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1

Remove Bezel Assembly 476W2100-1G 1 Push a 1.5mm or smaller

allen wrench into the

auto-lock pin holes to

release the auto-lock

pins.

2

CAUTION: DO NOT TOUCH THE CONNECTOR PINS OR OTHER CONDUCTORS ON THE

CSCP. IF YOU TOUCH THESE CONDUCTORS, ELECTROSTATIC DISCHARGE CAN

CAUSE DAMAGE TO THE CSCP.

Remove Cabin System

Control Panel

(CSCP)

285W0011-4 or

285W0011-5

1 Refer to 777 AMM 20-

10-01/401.

(SHEET 2 OF 2)
FIGURE 19: WIRE CHANGE - PURSER STATION - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 19: WIRE CHANGE - PURSER STATION - GROUP 2 AIRPLANES

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

found in subkit 280W5112-105.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 End Cap 324484 7 Refer to BSWPM 20-10-11 and

20-30-16.

Coil and stow wire bundle at

last clamp point.

2 Tie Wrap (Brown) 280W5112-10503 -- Use as necessary. Refer to

BSWPM 20-10-11.

M23062 CSCP 1

DM23062AA

DM23062AC

PURSER STATION

DM23062AC

DM23062AA

1

REFERENCE: 777 WIRING DIAGRAM 23-33-12

1

2

(3 LOCATIONS)

(4 LOCATIONS)

W6943

W59618

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 20: PURSER STATION MODIFICATION - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 20: PURSER STATION MODIFICATION - GROUP 2 AIRPLANES

#

FWD

SEE B

SEE A

PURSER STATION

A

3

7

6

5

2

1

4 1

(4 LOCATIONS)

W59619

(SHEET 1 OF 4)
FIGURE 20: PURSER STATION MODIFICATION - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

A

A

B

8 9

12

15

14

16

(4 LOCATIONS)

8 9

(4 LOCATIONS) 10

13

1.25 1.25

10

(4 LOCATIONS)

11

0.65

0.42

A-A

11

W59620

(SHEET 2 OF 4)
FIGURE 20: PURSER STATION MODIFICATION - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane. Parts are found in subkit 439W1403-

3B.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Screw NAS8203A9 2

Washer NAS1149D0332J 2

2 Loosen Captive Fastener -- 4

3 Remove Tray Assembly 476W0734-3 1

4 Remove Screw BACS12FA3K6 3

Remove Tray Support

Assembly

476W2732-7 1

5 Remove Screw BACS12FA3K6 3

Remove Tray Support

Assembly

476W2732-9 1

6 Remove Screw BACS12FA3K6 3

Remove Tray Support

Assembly

476W2732-11 1

7 Remove Placard BAC27WEL531 1 Text: M23062 CSCP

8 Remove /

Keep

Screw BACS12FA3K6 4

Remove Cover 439W3271-41B 1

9 Install Cover 439W3271-47B 1

Install / Kept Screw BACS12FA3K6 4

10 Drill Hole -- 4 Drill 0.2190 to 0.2300 diameter

holes. Drill two holes in top

angle 476W2126-4 and two

holes in bottom angle

476W2126-5 in the locations

shown. Holes will match the

holes in the 439W3278-145B

plate. If necessary, remove

angles from purser station to

prevent damage.

11 Mark Angle 476W2126-4 and

476W2126-5

2 Mark the service bulletin

number on the non-decorative

surface of the 476W2126-4

and 476W2126-5 angles.

Refer to BSOPM 20-50-10.

12 Install Clip-on Nut BACN10YD1G 2 Install over each hole on

bottom angle 439W2126-5.

13 Install Clip-on Nut BACN10YD3G 2 Install over each hole on top

angle 439W2126-4.

(SHEET 3 OF 4)
FIGURE 20: PURSER STATION MODIFICATION - GROUP 2 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

14 Install Plate 439W3278-145B 1

15 Install Screw BACS12FA3K6 2 Install in the bottom holes.

16 Install Screw BACS12FA3K7 2 Install in the top holes

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 4 OF 4)
FIGURE 21: REMOVE CSCP - GROUP 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 21: REMOVE CSCP - GROUP 3 AIRPLANES

(4 LOCATIONS)

AUTO-LOCK PIN

PURSER STATION

A (8 LOCATIONS)

SEE A

3

2

4

3

1

2 1

W45791

FWD

(SHEET 1 OF 2)
FIGURE 21: REMOVE CSCP - GROUP 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1

Remove Bezel Assembly 476W2100-1G 1 Push a 1.5mm or smaller

allen wrench into the

auto-lock pin holes to

release the auto-lock

pins.

2

Disconnect Wire Bundle -- 2 From S33045 Light

Switch and L23101 Call

Light on the close out

panel. Refer to WDM

33-22-31 and 23-42-21.

3 Remove / Keep Screw BACS12FA3K5 8

Close Out Panel 439W3217-126A 1

4

CAUTION: DO NOT TOUCH THE CONNECTOR PINS OR OTHER CONDUCTORS ON THE

CSCP. IF YOU TOUCH THESE CONDUCTORS, ELECTROSTATIC DISCHARGE CAN

CAUSE DAMAGE TO THE CSCP.

Remove Cabin System

Control Panel

(CSCP)

285W0011-3,

285W0011-4 or

285W0011-5

1 Refer to 777 AMM 20-

10-01/401.

(SHEET 2 OF 2)
FIGURE 22: WIRE CHANGE - PURSER STATION - GROUP 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 22: WIRE CHANGE - PURSER STATION - GROUP 3 AIRPLANES

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

found in subkit 280W5112-105.

FLAG

NOTE NAME PART NUMBER QTY NOTES

1 End Cap 324484 7 Refer to BSWPM 20-10-11 and

20-30-16.

Coil and stow wire bundle at

last clamp point.

2 Tie Wrap (Brown) 280W5112-10503 -- Use as necessary. Refer to

BSWPM 20-10-11.

M23062 CSCP 1

DM23062AA

DM23062AC

PURSER STATION

DM23062AC

DM23062AA

1

REFERENCE: 777 WIRING DIAGRAM 23-33-12

1

2

(3 LOCATIONS)

(4 LOCATIONS)

W6943

W45796

ADDED WIRE OR NEW ROUTING

EXISTING WIRE

DELETED WIRE OR FORMER ROUTING

(SHEET 1 OF 1)
FIGURE 23: CLOSE OUT PANEL MODIFICATION - GROUP 3 AIRPLANES

November 25, 2003

777-23-0142

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 23: CLOSE OUT PANEL MODIFICATION - GROUP 3 AIRPLANES

A

A

1

3 (4 LOCATIONS)

CLOSE OUT PANEL

REFERENCE ONLY)

(SHOWN FOR

COVER PLATE

A-A

(4 LOCATIONS) 2 3

11.5466

0.50

14.2540

4

0.50

FWD

UP

W45826

(SHEET 1 OF 2)
FIGURE 23: CLOSE OUT PANEL MODIFICATION - GROUP 3 AIRPLANES

November 25, 2003

777-23-0142

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane. Parts are found in subkit 439W1403-

2B.

STEP TASK NAME PART NUMBER QTY NOTES

1 Locate Close Out Panel 439W3217-126A 1 Previously removed from the

purser station.

2 Drill Hole -- 4 Drill 0.562 to 0.565 inch

diameter holes. Locate holes to

match the holes in the

439W3278-144B cover plate.

Refer to BAC 5583, Method B

Process Data provided in

Appendix A.

3 Install Inserts SL2334-3A3 4 Refer to BAC 5583, Method B

Process Data provided in

Appendix A. Use Potting Compound BMS 5-28, Type

18, Class 2

--

4 Mark Close Out Panel -- 1 Mark the service bulletin

number on the non-decorative

surface of the close out panel.

Refer to BSOPM 20-50-10.

(SHEET 2 OF 2)
FIGURE 24: PURSER STATION MODIFICATION - GROUP 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 24: PURSER STATION MODIFICATION - GROUP 3 AIRPLANES

PURSER STATION

(8 LOCATIONS)

A

A

11

A 9

9

FWD

(4 LOCATIONS)

SEE B

SEE A

B

1

(2 LOCATIONS)

3

6

5

2

4 (8 LOCATIONS) (4 LOCATIONS)

10

10 11

W46015

(SHEET 1 OF 3)
FIGURE 24: PURSER STATION MODIFICATION - GROUP 3 AIRPLANES

November 25, 2003

777-23-0142

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane. Parts are found in subkit 439W1403-

2B.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove Screw NAS8203A9 2

Washer NAS1149D0332J 2

2 Loosen Captive Fastener -- 4

3 Remove Tray Assembly 476W0734-3 1

4 Remove Screw BACS12FA3K5 8

5 Remove Bracket Assembly 476W0733-1 1

6 Remove Placard BAC27WEL531 1 Text: M23062 CSCP

7 Remove Cover 439W3271-28A 1

Remove /

Keep

Screw BACS12FA3K5 4

8 Install Cover 439W3271-16B 1

Install / Kept Screw BACS12FA3K5 4

9 Install /

Modified

Close Out Panel 439W3217-126A 1

Install / Kept Screw BACS12FA3K5 8

7 8

A-A

W46022

(SHEET 2 OF 3)
FIGURE 24: PURSER STATION MODIFICATION - GROUP 3 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

10 Connect Wire Bundle -- 2 To S33045 Light Switch and

L23101 Call Light on the close

out panel. Refer to WDM 33-

22-31 and 23-42-21.

11 Install Plate 439W3278-144B 1

Screw BACS12FA3K5 4

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 3 OF 3)
FIGURE 25: REMOVE CSCP AND TRAY ASSEMBLY - GROUP 4 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

FIGURE 25: REMOVE CSCP AND TRAY ASSEMBLY - GROUP 4 AIRPLANES

A

10

3

2

1

(4 LOCATIONS) 2

1 (4 LOCATIONS)

AUTO-LOCK PIN

CONTROL CENTER

A-4 GALLEY VIDEO

SEE A

SEE B

B 4

8

5

5

6

5

7

(4 LOCATIONS)

SEE C

FWD

UP

W46250

(SHEET 1 OF 3)
FIGURE 25: REMOVE CSCP AND TRAY ASSEMBLY - GROUP 4 AIRPLANES

November 25, 2003

777-23-0142

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BOEING SERVICE BULLETIN 777-23-0142

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

numbers shown below are the number of parts necessary for the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

1

Remove Bezel Assembly 476W2100-1D 1 Push a 1.5mm or smaller

allen wrench into the

auto-lock pin holes to

release the auto-lock

pins.

2

Remove Screw BACS12ER3K14GR 4

Close Out Panel 476W3107-7A 1

3

CAUTION: DO NOT TOUCH THE CONNECTOR PINS OR OTHER CONDUCTORS ON THE

CSCP. IF YOU TOUCH THESE CONDUCTORS, ELECTROSTATIC DISCHARGE CAN

CAUSE DAMAGE TO THE CSCP.

Remove Cabin System

Control Panel

(CSCP)

285W0011-4 or

285W0011-5

1 Refer to 777 AMM 20-

10-01/401.

10

(4 LOCATIONS) 9

C

FWD

INBD

W46263

(SHEET 2 OF 3)
FIGURE 25: REMOVE CSCP AND TRAY ASSEMBLY - GROUP 4 AIRPLANES

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

4 Remove Screw NAS8203A6 2

Washer NAS1149D0332J 2

5 Remove Screw NAS1352N06-11 4

Screw NAS1352N06-17 2

Nut BACN10YR06CD 6

6 Remove Connector,

DM23062

-- 1 From tray assembly

7 Loosen Captive Fastener -- 4

8 Remove Tray Assembly 476W0734-4 1

9 Remove Bolt BACB30NM4K9 4

Washer NAS1149D0432 4

10 Remove Shell Assembly 476W3007-1 1

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 3 OF 3)
APPENDIX A: PROCESS DATA - POTTING INSERTS AND EDGES INTO SANDWICH PANELS

(BAC5583)

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

APPENDIX A: PROCESS DATA - POTTING INSERTS AND EDGES INTO SANDWICH PANELS (BAC5583)

Note: THE PROCESS INFORMATION THAT IS SUPPLIED WITH THIS SERVICE BULLETIN IN

SHORTENED FORM WAS UP-TO-DATE WHEN THIS SERVICE BULLETIN WAS PREPARED. THIS

PROCESS INFORMATION SUPPLIED WILL NOT BE KEPT UP-TO-DATE. FOR MORE

INFORMATION, REFER TO THE APPLICABLE BAC PROCESS AND MATERIALS SPECIFICATIONS.

1. METHOD B - WET POTTING OF INSERTS

A. Hole Preparation - Blind Inserts

1. Locate and drill a hole in the panel to size as specified in the service bulletin instructions or by

manufacturer's recommendation.

2. The hole depth shall be greater than the insert length, so the inserts do not come in contact with

the opposite face.

3. The presence of honeycomb core in the bottom of a blind hole is permitted if honeycomb core is

not crushed into the bottom of the hole or does not interfere with the flush seating of the insert,

thereby preventing the flow of the potting compound.

4. Core materials may be removed from the bottom of a blind hole, provided the process does not

cause skin damage or permanent dimpling on a decorative surface.

5. Finish cutting may be accomplished with a hand cutter mounted in a drill motor to bring the hole

to the proper depth or to remove interfering core materials, provided hole dimensions remain

within tolerance.

6. Insert holes shall be free of face sheet material including burrs or loose skin, and other material

which would interfere with proper seating of the insert or prevent the flow of potting around the

insert.

WARNING: IF COMPRESSED AIR IS USED, USE WITH EFFECTIVE CHIP GUARDING AND

PERSONAL PROTECTIVE EQUIPMENT

7. Remove loose particles, including dust from the hole using a suitable method such as

compressed air of less than 30 PSI.

CAUTION: HANDLING INSERTS WITH BARE HANDS MAY RESULT IN CONTAMINATION THAT

COULD REDUCE THE ADHESION OF THE POTTING COMPOUND TO THE INSERTBONDING SURFACE.

8. Do not clean inserts unless they are contaminated with oil, grease, or similar bond inhibiting

substances or particles which would prevent proper bonding of the insert. Solvent clean in

accordance with BSOPM 20-30-03. Gauze moistened with an approved solvent may be used.

Gloves may be worn when potting inserts.

B. Installation of Blind Inserts

1. Inspect holes for proper size and quality.

2. Prefill holes with enough potting compound to make sure that when insert is installed the bottom

of the insert will be immersed into the potting.
APPENDIX A: PROCESS DATA - POTTING INSERTS AND EDGES INTO SANDWICH PANELS

(BAC5583)

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

3. Before the initial gel time is achieved, push insert into the hole by applying even pressure across

the insert tab until it is flush with the surface. See Detail A.1.

4. Inject potting compound into one hole of the insert tab until approximately a 0.25 inch

uninterrupted stream of potting compound comes out of the opposite hole.

5. Inject potting compound into the opposite insert tab hole until approximately a 0.25 inch

uninterrupted stream of potting compound comes out of the other hole.

6. Examine the insert to make sure that it is flush (+0.02/-0.00 inch) with the panel surface and that

surfaces are clean of potting compound.

7. Remove the excess potting compound. Solvent clean as specified in BSOPM 20-30-03. An

approved solvent may be used on fiberglass or paperbase laminate surfaces for removing traces

of potting material. Decorative laminate surfaces may be protected from contamination by

masking tape, and solvent cleaned if needed.

8. Alignment tabs, protective tape, etc. shall be removed after extruded potting is firm to the touch.

Tab removal must not disturb the seating of the insert.

9. Cure the potting compound as specified in Table 1, cure schedule.

2. PREPARATION OF POTTING COMPOUND

A. Blend curing agents into resin in accordance with the manufacturer’s recommendations. The work life

of the mixed potting compound is shown in Table 1.

Table 1

COMPOUND MAXIMUM WORK

LIFE OF POTTING

COMPOUND (a)

CURE SCHEDULE

MINIMUM INITIAL

CURE

MIMIMUM FULL

CURE

BMS 5-28,

TYPE 18,

CLASS 2

3 to 9 minutes at

room temperature

3 hours at room

temperature

7 days at room

temperature or

5 hours at 125

degrees F

(a) Sometimes called pot life. Material should be in place before it reacts and

gets hot. Material left in container may become too thick for intended use.

Large quantities, such as quart or pint, may get hot faster.

TYPICAL BLIND INSERT INSTALLATION

DETAIL A.1

POTTING PORTS

INSERT

PANEL

POTTING COMPOUND

TAB

W46277
APPENDIX B: TERMINATION OF SHIELDS TO BACKSHELL USING SHIELDING TAPE

November 25, 2003

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BOEING SERVICE BULLETIN 777-23-0142

APPENDIX B: TERMINATION OF SHIELDS TO BACKSHELL USING SHIELDING TAPE

1. Assemble the backshell on the connector as shown in BSWPM 20-25-14.

2. Wind a continuous length of Scotch 24 shielding tape or equivalent around the area of the exposed shield

and the backshell.

A. Start to wind the shielding tape individually around each cable where the shield is exposed. Make

sure that the shielding tape is wound against every cable shield in the bundle. Refer to Detail B.1.

B. After each cable is wound, wind the shielding tape twice around the entire bundle to safety the area

where the shield is exposed.

C. Continue to wind the shielding tape around the bundle forward to the backshell. Make sure the wrap

has a 50% overlap. Keep the shielding tape tension moderate and constant. Refer to Detail B.2.

D. When the shielding tape reaches the backshell, wind the tape onto the banding area as shown in

Detail B.3. Make two (2) complete wraps around the banding area. Make sure that the edge of the

wraps align with the rear face of the backshell.

E. Continue to wind the shielding tape rearward to the location where the winding of the shield tape

started. Maintain a 50% overlap of the shielding tape. Refer to Detail B.4.

F. At the location of the start of the shield tape wrap, wind the shielding tape once around the bundle to

complete the wrap. Refer to Detail B.5.

3. Wind Scotch 70 insulation tape or equivalent over the end of the shielding tape. Make spiral wraps with

50% overlap while winding the Scotch 70 insulation tape. Make sure the tape wrap extends 0.5 inch

beyond each end of the outer jacket opening. Refer to Detail B.6.

4. Install lacing tape over the Scotch 70 insulation tape at approximately the mid-point of the wrap. Refer to

Detail B.6.

5. Install metal clamp band on the termination platform of the backshell. Refer to Detail B.7.

6. Wrap the backshell termination platform with 3 to 5 layers of 0.5 inch wide Scotch 70 or Arlon 912-10X12

insulation tape.

7. Put Permacel P-421 tape or equivalent over the insulation tape. Make spiral wraps with 50% overlap.

Refer to Detail B.8.

8. Install lacing tape over the end of the last wrap of Permacel P-421 for the closing step.
APPENDIX B: TERMINATION OF SHIELDS TO BACKSHELL USING SHIELDING TAPE

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SCOTCH 24 SHIELD TAPE

DETAIL B.1

DETAIL B.2

DETAIL B.3

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SCOTCH 70 INSULATION TAPE

DETAIL B.6

DETAIL B.5

DETAIL B.4

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PERMACEL P-421 TAPE

METAL BAND CLAMP

DETAIL B.8

DETAIL B.7

0.10 INCH MAXIMUM GAP

SCOTCH 70 TAPE

EXTENSION

0.5 INCH MAXIMUM

W49335
APPENDIX C: Cost Benefit Analysis

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APPENDIX C: Cost Benefit Analysis

Boeing did a cost benefit analysis on the changes given in this service bulletin. The data that follows was used

to do the analysis. Operators can use the data to do their own cost benefit analysis. The "Before the Change"

data are estimated average fleet data based on in-service experience. The "After the Change" data are

projected based on available fleet and engineering data.

— Part Name:Cabin System Control Panel (CSCP), Part Number: 285W0011-3, -4, -5

— Part Name:Cabin Area Control Panel (CACP), Part Number: 285W0012-3, -4

— Part Name:Cabin Control Panel (CCP), Part Number: 285W0863-X

Assumptions / Comments:

This analysis uses available in-service fleet data for three years, 1/1/1999 to 12/ 31/2002.

There are two panels considered in the Before the Change configuration; 285W0011-3,-4,-5 & 285W0012-3,-4.

Airline experience will vary depending on which dash number is installed in their aircraft and on their own

operation environment.

Data showed that the average time to remove and replace the Before the Change parts is approximately 3

hours. Data is not available for the After the Change configuration. We have assumed time to remove and

replace has not changed.

The part number for the After the Change configuration has been upgraded six times. Available data does not

differentiate between dash numbers, therefore the data shown is cumulative for all dash numbers associated

with 285W0863.

Analysis Inputs Before the Change After the Change

CSCP CACP CCP

Delays/ 100 Revenue Departures 0.000150 0.000340 0.000000

Cancellations / 100 Revenue Departures 0.000000 0.000000 0.000000

Airturnbacks / 100 Revenue Departures 0.000000 0.000000 0.000000

Diversions / 100 Revenue Departures 0.000000 0.000000 0.000000

MTBUR (flight hours) 8,420 21,285 30,615

MTBF (flight hours) 27,803 22,988 76,537

Fuel Factor (weight in pounds) 0.0 0.0 0.0

Line Maintenance Hours / Removal 3.0 3.0 3.0

Line Maint Hours / Maint Action (non-removal) 0.0 0.0 0.0

Maint Actions / 1000 flt hrs (non-removal) 0.177000 0.175000 0.017500

Sched Maint Hours / 1000 flt hrs 0.000000 0.000000 0.000000

Shop Labor Hours - Repair & Test 0.0 0.0 0.0

Shop Labor Hours - Test 0.0 0.0 0.0

Shop Material Cost / Failure $0 $0 $0
Table of Contents

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Table of Contents

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 13

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 20

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 22

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

FIGURE 1: CACP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 2: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 1 AIRPLANES

35

FIGURE 3: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 2 AIRPLANES

36

FIGURE 4: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P101 - GROUP 3 AIRPLANES

37

FIGURE 5: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P102 - GROUPS 2, 3 AND 4 .

38

FIGURE 6: WIRE CHANGES - DISTRIBUTION INTEGRATION PANEL P103 - GROUP 4 AIRPLANES

39

FIGURE 7: WIRE CHANGE - CACP 1 TO CCP - GROUPS 2 AND 3 AIRPLANES . . . . . . . . . 40
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FIGURE 8: WIRE CHANGE - CACP 2 TO CCP - GROUP 1 AIRPLANES . . . . . . . . . . . . . . 41

FIGURE 9: WIRE CHANGE - PURSER STATION - GROUP 2 AIRPLANES . . . . . . . . . . . . . 42

FIGURE 10: WIRE CHANGE - PURSER STATION - GROUP 4 AIRPLANES . . . . . . . . . . . . . 44

FIGURE 11: WIRE CHANGE - AP0715 TO LAVATORY 2F-1L - GROUP 3 AIRPLANES . . . . . . . 46

FIGURE 12: CCP INSTALLATION AS CSCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

FIGURE 13: CCP INSTALLATION AS CACP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

FIGURE 14: REMOVE CSCP - GROUP 1 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 53

FIGURE 15: WIRE CHANGE - PURSER STATION - GROUP 1 AIRPLANES . . . . . . . . . . . . . 55

FIGURE 16: CLOSE OUT PANEL MODIFICATION - GROUP 1 AIRPLANES . . . . . . . . . . . . . 56

FIGURE 17: PURSER STATION MODIFICATION - GROUP 1 AIRPLANES. . . . . . . . . . . . . . 58

FIGURE 18: REMOVE CSCP - GROUP 2 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 60

FIGURE 19: WIRE CHANGE - PURSER STATION - GROUP 2 AIRPLANES . . . . . . . . . . . . . 62

FIGURE 20: PURSER STATION MODIFICATION - GROUP 2 AIRPLANES. . . . . . . . . . . . . . 63

FIGURE 21: REMOVE CSCP - GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 67

FIGURE 22: WIRE CHANGE - PURSER STATION - GROUP 3 AIRPLANES . . . . . . . . . . . . . 69

FIGURE 23: CLOSE OUT PANEL MODIFICATION - GROUP 3 AIRPLANES . . . . . . . . . . . . . 70

FIGURE 24: PURSER STATION MODIFICATION - GROUP 3 AIRPLANES. . . . . . . . . . . . . . 72

FIGURE 25: REMOVE CSCP AND TRAY ASSEMBLY - GROUP 4 AIRPLANES . . . . . . . . . . . 75

APPENDIX A: PROCESS DATA - POTTING INSERTS AND EDGES INTO SANDWICH PANELS

(BAC5583) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

APPENDIX B: TERMINATION OF SHIELDS TO BACKSHELL USING SHIELDING TAPE. . . . . . . 80

APPENDIX C: Cost Benefit Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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Commercial

Airplane

Group 777

Service Bulletin

Number: 777-23-0142 Evaluation Form

Date: November 25, 2003

ATA System: 2339

MDN

SUBJECT: COMMUNICATIONS - Passenger Address and Entertainment - Cabin Management

System - Cabin Services System Hardware and Software Change

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) 4 3 2 1 (poor)

Please rate the quality of the illustrations: (good) 4 3 2 1 (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 Airplanes Group

P.O. Box 3707, Mail Code 2H-36

Seattle, WA 98124-2207 USA
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