### Commercial **Airplanes** 

# 777 Service Bulletin **Number: 777-24-0102** Original Issue: July 12, 2007 Revision 1: June 17, 2010 ATA System: 2441 **SUBJECT:** ELECTRICAL POWER - External Power Receptacle - Foreign Object Debris Shield Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 1 of 28 3.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 2 of 28 **BOEING SERVICE BULLETIN 777-24-0102**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 16 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 18 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 18 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FIGURE 1: EXTERNAL POWER RECEPTACLE - CONDUCTOR GUARD REMOVAL AND WIRE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR GUARD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 APPENDIX A: COST BENEFIT ANALYSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 3 of 28 **BOEING SERVICE BULLETIN 777-24-0102**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 4 of 28 **BOEING SERVICE BULLETIN 777-24-0102**

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### Commercial **Airplanes** 

# 777 Service Bulletin **Revision Transmittal Sheet Number: 777-24-0102**  Original Issue: July 12, 2007 Revision 1: June 17, 2010 ATA System: 2441 **SUBJECT:** ELECTRICAL POWER - External Power Receptacle - Foreign Object Debris Shield Change This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. Airplanes WC488, WD606, WD674 and WD675 were added to Group 1 of this service bulletin effectivity. **REASON FOR REVISION** This revision is sent to add airplanes WC488, WD606, WD674 and WD675 to Group 1 of this service bulletin. Airplanes WC488, WD606, WD674 and WD675 did not get Foreign Object Debris (FOD) shields installed over the primary and secondary external power receptacles during production. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. These sections were changed: 1. In Summary, Compliance and Paragraph 1.E., Compliance, added Federal Aviation Administration (FAA) Airworthiness Directive (AD) data. 2. In Summary, Background and Paragraph 1.C., Reason, added Cost Benefit Analysis text. 3. In Paragraph 1.D., Description, added Affected Maintenance Zones tables. 4. In APPENDIX A, added Cost Benefit Analysis table. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** July 12, 2007 Original Issue: June 17, 2010 Revision 1:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 5 of 28BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 6 of 28 **BOEING SERVICE BULLETIN 777-24-0102**

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### Commercial **Airplanes** 

# 777 Service Bulletin **Summary Number: 777-24-0102**  Original Issue: July 12, 2007 Revision 1: June 17, 2010 ATA System: 2441 **SUBJECT:** ELECTRICAL POWER - External Power Receptacle - Foreign Object Debris Shield Change **CONCURRENT REQUIREMENTS** None. **BACKGROUND** This service bulletin gives instructions to install rubber Foreign Object Debris (FOD) shields over the primary and secondary external power receptacles in the forward equipment bay. The FOD shield will be installed over the neutral power feeders attached to the rear of the primary and secondary external power receptacles. If this service bulletin is not accomplished, the primary and secondary external power receptacles will remain exposed to migrating FOD, which could result in a fire event. There have been a number of occurrences of overheating or arcing at the 777 external power receptacle. On one occasion, a fire event occurred in the factory on an airplane at the secondary external power receptacle location. An investigation showed that FOD caused overheating of the power receptacle, which resulted in arcing. On another occasion, a washer was found inside the external power receptacle during the check of an in-production airplane. Accomplishment of this service bulletin will make sure that the primary and secondary external power receptacles at the P30 panel are protected from FOD which could result in arcing. Boeing did a cost benefit analysis on the changes given in this service bulletin. Refer to Appendix A for the analysis. **ACTION** In the main equipment center, install rubber FOD shields over the neutral power feeders attached to the rear of the primary and secondary external power receptacles at approximately station 350. Do a functional test. **EFFECTIVITY** 777-200, 777-200LR, 777-300, 777-300ER Airplanes. Refer to Paragraph 1.A.1 Airplanes, for the list of affected airplanes. **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 7 of 28No compliance time is given. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **MANPOWER Elapsed Hours**  **Total Task Hours Airplanes**  6.25 6.25 Group 1
**MATERIAL INFORMATION** Boeing Supplied Kits/Parts. Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 8 of 28 **BOEING SERVICE BULLETIN 777-24-0102**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 9 of 28 **BOEING SERVICE BULLETIN 777-24-0102**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 10 of 28 **BOEING SERVICE BULLETIN 777-24-0102**

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### Commercial **Airplanes** 

# 777 Service Bulletin **Number: 777-24-0102** Original Issue: July 12, 2007 Revision 1: June 17, 2010 ATA System: 2441 **SUBJECT:** ELECTRICAL POWER - External Power Receptacle - Foreign Object Debris Shield Change **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data. This service bulletin is for the airplanes shown below.
**DESCRIPTION CONFIGURATION**  **GROUP** 777-200, -200LR, -300, -300ER airplanes that require rubber Foreign Object Debris (FOD) shields. - 1

Airplane Models: 777-200, 777-200LR, 777-300, 777-300ER **Group Variable Number**  1 WA001 - WA017 1 WA076 - WA080 1 WA086 - WA093 1 WA101 - WA104 1 WA116 - WA119 1 WA131 - WA137 1 WA171 - WA175 1 WA196 - WA198 1 WA206 - WA212 1 WA221 - WA223

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 11 of 28**Group Variable Number**  1 WA231 - WA232 1 WA241 - WA250 1 WA261 - WA266 1 WA281 - WA282 1 WA301 - WA304 1 WB001 - WB021 1 WB031 - WB046 1 WB051 - WB088 1 WB101 - WB106 1 WB121 - WB125 1 WB131 - WB141 1 WB151 - WB155 1 WB161 - WB177 1 WB181 - WB194 1 WB201 - WB215 1 WB231 - WB247 1 WB271 - WB273 1 WB276 - WB286 1 WB291 - WB302 1 WB306 - WB307 1 WB311 - WB337 1 WB341 - WB342 1 WB366 - WB368 1 WB371 - WB388 1 WB406 1 WB411 - WB413 1 WB416 - WB437 1 WB446 - WB453 1 WB476 1 WB481 - WB484 1 WB501 - WB511 1 WB531 - WB537 1 WB551 - WB554

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 12 of 28 **BOEING SERVICE BULLETIN 777-24-0102 Group**  **Variable Number** 1 WB591 - WB597 1 WB601 - WB606 1 WB611 - WB622 1 WB631 - WB638 1 WB646 - WB649 1 WC051 - WC073 1 WC101 - WC104 1 WC111 - WC116 1 WC241 - WC243 1 WC281 - WC290 1 WC301 - WC308 1 WC361 - WC364 1 WC371 - WC374 1 WC381 - WC390 1 WC441 1 WC446 - WC448 1 WC456 - WC458 1 WC486 - WC488 1 WD001 - WD002 1 WD501 - WD504 1 WD521 - WD532 1 WD561 - WD563 1 WD581 - WD586 1 WD606 1 WD621 - WD624 1 WD651 - WD652 1 WD671 - WD675 2. Spares Affected None. **B. Concurrent Requirements** None.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 13 of 28 **BOEING SERVICE BULLETIN 777-24-0102 C. Reason**  This service bulletin gives instructions to install rubber Foreign Object Debris (FOD) shields over the primary and secondary external power receptacles in the forward equipment bay. The FOD shield will be installed over the neutral power feeders attached to the rear of the primary and secondary external power receptacles. If this service bulletin is not accomplished, the primary and secondary external power receptacles will remain exposed to migrating FOD, which could result in a fire event. There have been a number of occurrences of overheating or arcing at the 777 external power receptacle. On one occasion, a fire event occurred in the factory on an airplane at the secondary external power receptacle location. An investigation showed that FOD caused overheating of the power receptacle, which resulted in arcing. On another occasion, a washer was found inside the external power receptacle during the check of an in-production airplane. Accomplishment of this service bulletin will make sure that the primary and secondary external power receptacles at the P30 panel are protected from FOD which could result in arcing. Revision 1 is sent to add airplanes WC488, WD606, WD674 and WD675 to Group 1 of this service bulletin. Airplanes WC488, WD606, WD674 and WD675 did not get FOD shields installed over the primary and secondary external power receptacles during production. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. Boeing did a cost benefit analysis on the changes given in this service bulletin. Refer to Appendix A for the analysis. **D. Description** In the main equipment center, install rubber FOD shields over the neutral power feeders attached to the rear of the primary and secondary external power receptacles at approximately station 350. Do a functional test. Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 117, 118 777-200, 777-200LR, 777-300, 777-300ER **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. No compliance time is given.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 14 of 28 **BOEING SERVICE BULLETIN 777-24-0102 F. Approval**  This service bulletin was examined by the FAA. The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. **G. Manpower** The table below shows an estimate of the task hours necessary to do this 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 inspect the work — Time to cure the materials — Time to make the parts — Time to find the tools. **Group 1: Elapsed Hours**  **Task-Hours Number of Persons**  **Task** 0.25 0.25 1 Open Access 2.50 2.50 1 FIGURE 1 3.00 3.00 1 FIGURE 2 0.25 0.25 1 Test 0.25 0.25 1 Close Access 6.25 6.25 TOTAL FOR EACH AIRPLANE **H. Weight and Balance Changes Change in Moment**  **(Pound-Inches) Change in Weight**  **(Pounds) Airplane** 
+ 46.7 + 0.1 Group 1
**I. Electrical Load Data** Not changed.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 15 of 28 **BOEING SERVICE BULLETIN 777-24-0102 J. References**  1. Existing Data: a. 777 Aircraft Maintenance Manual (AMM) 06-41-00, 24-22-00, 24-41-04 b. 777 Wiring Diagram Manual (WDM) 24-41-11, 24-41-31 c. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-19, 20-20-00 d. Boeing Drawing 012W6100 2. Data supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  RECEPTACLE INSTL - EXTERNAL POWER 284W8038 SUPPORT - GROUND POWER CABLE, EXT POWER RECEPTACLE 284W8050
**K. Publications Affected** 1. Publications: **Chapter-Section Publication**  24-41 777 Aircraft Maintenance Manual 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary. **L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 16 of 28 **BOEING SERVICE BULLETIN 777-24-0102 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the parts shown in Paragraph 2.C., Parts Necessary for Each Airplane as shown below. If there is a limit to the quantity (QTY) of available parts, a supply sequence is given by Spares. More parts become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.
**Unit Price thru DEC 31/07**  **ROLT (Weeks)**  **Name Kit Number**  $134.00 25 External Power Receptacle Foreign Object Debris Shield 005W3337-1
**B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **C. Parts Necessary For Each Airplane** 1. Kits/Parts: To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. **NOTE:** One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane. **Figure Kit 2**  **Top Kit** 1 005W3337-1
**ALL**
**KIT 005W3337-1**

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

**New Part Number 2**  **QTY** SHIELD 2 284W8050-13 NUT 4 BACN10YR3CD SCREW, CAP 4 BACS12GU3K40 WASHER 8 NAS1149F0332P

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 17 of 28 **BOEING SERVICE BULLETIN 777-24-0102**2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number / Specification**  (a) Sealant 6 ounces BMS 5-95, Type 1, Class B (a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
3. Parts Modified and Reidentified: None. 4. Parts Removed and Not Replaced: None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **F. Special Tooling Necessary to do this Service Bulletin** No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 18 of 28 **BOEING SERVICE BULLETIN 777-24-0102 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. The instructions identified in Paragraph 3.B., Work Instructions and the Figure(s) give the recommended sequence of steps. The sequence of steps to do this service bulletin can be changed. 2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 3. Obey all of the warnings and cautions given in the specified manual sections. 4. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches. – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch. – Angular tolerance is plus or minus 2 degrees. – Hole dimensions for standard solid rivets are in 777 SRM, Chapter 51. – Torque limits to tighten nuts and bolts are in 777 SRM, Chapter 51. 5. Use the approved fastener and process material substitutions in accordance with 777 SRM, Chapter 51. Alternate fasteners are listed in 777 SRM Chapter 51 and Boeing Drawing 012W6100. 6. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. 7. If the length of any fastener specified in this service bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. 8. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 19 of 28 **BOEING SERVICE BULLETIN 777-24-0102 B. WORK INSTRUCTIONS**  1. Remove electrical power from the airplane. Refer to 777 AMM 24-22-00 as an accepted procedure. 2. Get access to the Main Equipment Center. Open the access door 117AL. Refer to 777 AMM 06-41-00 as an accepted procedure. Remove the floor panel to get access to the back of the External Power and Gate Link Panel (P30) in accordance with FIGURE 1. 3. Remove the Primary and Secondary External Power Receptacle Conductor Guards, mounting hardware and wires in accordance with FIGURE 1. 4. Install the rubber Foreign Object Debris (FOD) shields in accordance with FIGURE 2. 5. Do the functional test that follows: a. Apply power to the airplane using the Primary External Power Receptacle. Refer to 777 AMM 24-22-00 as an accepted procedure. b. In the Flight Deck, press the Primary External Power switch on the P5 panel. Make sure that the Primary External Power supplies power to the airplane. c. Press the Primary External Power switch on the P5 panel. Make sure that power is removed from the airplane. d. Apply power to the airplane using the Secondary External Power Receptacle. Refer to 777 AMM 24-22-00 as an accepted procedure. e. In the Flight Deck, press the Secondary External Power switch on the P5 panel. Make sure that the Secondary Primary External Power supplies power to the airplane. f. Press the Secondary External Power switch on the P5 panel. Make sure that power is removed from the airplane. 6. Put the airplane back to a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1: June 17, 2010 20 of 28 **BOEING SERVICE BULLETIN 777-24-0102 FIGURE 1: EXTERNAL POWER RECEPTACLE - CONDUCTOR GUARD REMOVAL AND WIRE**  **DISCONNECTION (SHEET 1 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 21 of 28 **BOEING SERVICE BULLETIN 777-24-0102 FIGURE 1: EXTERNAL POWER RECEPTACLE - CONDUCTOR GUARD REMOVAL AND WIRE**  **DISCONNECTION (SHEET 2 OF 3)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 22 of 28 **BOEING SERVICE BULLETIN 777-24-0102**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 this figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  12
- FASTENERS Remove / Keep 1 1 284W8165-14 FLOOR PANEL ASSY Remove / Keep 2 6
- NUT Remove / Keep 3 6
- WASHER Remove / Keep 2
- CONDUCTOR GUARD Remove / Keep 8
- NUT Remove / Keep 4 8
- LOCK WASHER Remove / Keep 8
- WASHER Remove / Keep (a) 8
- WIRE Disconnect 4
- NUT Remove / Keep 5 4
- LOCK WASHER Remove / Keep 4
- WASHER Remove / Keep (b) 4
- WIRE Disconnect 2
- INSULATOR SUPPORT Remove / Keep 6 4
- NUT Remove / Keep 8
- WASHER Remove / Keep 4
- SCREW Remove (a) Attach an identification tag to the large electrical leads attached to studs 'A', 'B', 'C' and 'N' at DP30A and DP30B, and disconnect. Refer to 777 WDM 24-41-11 and 777 WDM 24-41-31. (b) Attach an identification tag to the small electrical leads attached to studs 'E' and 'F' at DP30A and DP30B, and disconnect. Refer to 777 WDM 24-41-11 and 777 WDM 24-41-31.

**FIGURE 1: EXTERNAL POWER RECEPTACLE - CONDUCTOR GUARD REMOVAL AND WIRE DISCONNECTION**  **(SHEET 3 OF 3)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 23 of 28 **BOEING SERVICE BULLETIN 777-24-0102 FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR**  **GUARD INSTALLATION (SHEET 1 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 24 of 28 **BOEING SERVICE BULLETIN 777-24-0102 FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR**  **GUARD INSTALLATION (SHEET 2 OF 4)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 25 of 28 **BOEING SERVICE BULLETIN 777-24-0102**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 this figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  (a) 4 BACS12GU3K40 SCREW, CAP Install (New) 1 (a) 8
- WASHER Install (Kept) (a) 4
- NUT Install (Kept) (a) 2
- INSULATOR SUPPORT Install (Kept) (b) (g) 2 284W8050-13 SHIELD Install (New) 2

**FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR GUARD INSTALLATION**  **(SHEET 3 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 26 of 28 **BOEING SERVICE BULLETIN 777-24-0102 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (c) 8
- WIRE Connect 3 (c) 8
- WASHER Install (Kept) (c) 8
- LOCK WASHER Install (Kept) (c) 8
- NUT Install (Kept) (d)

- - RESISTANCE Measure (e) 4
- WIRE Connect 4 (e) 4
- WASHER Install (Kept) (e) 4
- LOCK WASHER Install (Kept) (e) 4
- NUT Install (Kept) (f)

- - RESISTANCE Measure 2
- CONDUCTOR GUARD Install (Kept) 5 6
- WASHER Install (Kept) 6
- NUT Install (Kept) 8 NAS1149F0332P WASHER Install (New) 6 4 BACN10YR3CD NUT Install (New) 1 284W8165-14 FLOOR PANEL ASSY Install (Kept) 7 12
- FASTENERS Install (Kept) (a) Install the fasteners wet with BMS5-95 sealant. Remove the unwanted compound after assembly. (b) Move wire identified for connection to terminal 'N' through the large hole on the outboard side of the shield with the shield's mounting tabs pointing inboard before connecting wire to stud. (c) Connect identified wires to studs 'A', 'B', 'C' and 'N'. Refer to 777 WDM 24-41-11 and 777 WDM 24-41- 31. Torque nut. Refer to 777 AMM 24-41-04 as an accepted procedure. (d) Measure the resistance from each stud to the associated wire lug. Refer to SWPM 20-20-00 as an accepted procedure. If the resistance is more than 0.0005 ohms, carefully do step 3 again to make sure that the parts are clean. (e) Connect identified wires to studs 'E' and 'F'. Refer to 777 WDM 24-41-11 and 777 WDM 24-41-31. Torque nut. Refer to 777 AMM 24-41-04 as an accepted procedure. (f) Measure the resistance from each stud to the associated wire lug. Refer to SWPM 20-20-00 as an accepted procedure. If the resistance is more than 0.0005 ohms, carefully do step 4 again to make sure that the parts are clean. (g) After the conductor guard is installed, move the shield down the wire until the mounting tabs are on the mounting screws. Tighten the self-locking nuts until the shield is tightly installed. Do not tighten the nuts too much to the point that the shield material is twisted. Make sure that the bottom of the shield is as near as possible to the conductor guard.

**FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR GUARD INSTALLATION**  **(SHEET 4 OF 4)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 27 of 28 **BOEING SERVICE BULLETIN 777-24-0102**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. Please refer to ModEvaluator to prepare a cost benefit analysis for this service bulletin. ModEvaluator is a tool that quantifies the impact of the change to your operation and can be accessed on MyBoeingFleet.com. • Part Name: AC External Power Receptacle (Primary & Secondary) • Part Number: MS90362-3 **After the Change Before the Change**  **Analysis Inputs** .00000 .00035 Delays / 100 Unit Revenue Departures .00000 .00000 Cancellations / 100 Unit Revenue Departures .00000 .00000 Air Turnbacks / 100 Unit Revenue Departures .00000 .00000 Diversions / 100 Unit Revenue Departures 91,128 58,322 MTBUR (unit flight hours) 91,128 58,322 MTBF (unit flight hours) +.1
- Fuel Factor (weight in pounds) 3.25 3.25 Line Maintenance Labor Hours per Removal 2.5 2.5 Line Maintenance Labor Hours per Maintenance Action (non-re- movals) .0055 .0055 Maintenance Actions / 1000 Unit Flight Hours .000 .000 Scheduled Maintenance Hours / 1000 Unit Flight Hours Not applicable Not applicable Shop Labor Hours per Repair (includes Test) Not applicable Not applicable Shop Labor Hours per Test Not applicable Not applicable Shop Material Cost per Failure Assumptions / Comments: Before the Change: The above figures represent the service experience from a sample of operators over a recent three year period. The schedule interruption rates shown above may be understated due to the fact that Foreign Object Debris (FOD) related events are not typically charged against the airplane. After the Change: The design improvements detailed in this bulletin are anticipated to eliminate the FOD induced failures of the receptacle.

**APPENDIX A: COST BENEFIT ANALYSIS (SHEET 1 OF 1)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 12, 2007 777-24-0102 Revision 1 June 17, 2010 28 of 28 **BOEING SERVICE BULLETIN 777-24-0102**