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.

ECCN: 9E991

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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Unpublished Work - All Rights Reserved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

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

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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

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BLANK PAGE
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

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BLANK PAGE
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.

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No compliance time is given.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

Airplanes Total Task Hours Elapsed Hours

Group 1 6.25 6.25

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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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.

GROUP CONFIGURATION DESCRIPTION

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

Variable Number Group

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 1

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Variable Number Group

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 1

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BOEING SERVICE BULLETIN 777-24-0102
Variable Number Group

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 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

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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

Model Zone

777-200, 777-200LR, 777-300, 117, 118

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.

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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:

Task Number of Persons Task-Hours Elapsed Hours

Open Access 1 0.25 0.25

FIGURE 1 1 2.50 2.50

FIGURE 2 1 3.00 3.00

Test 1 0.25 0.25

Close Access 1 0.25 0.25

TOTAL FOR EACH AIRPLANE 6.25 6.25

H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

(Pounds)

Airplane

Group 1 + 0.1 + 46.7

I. Electrical Load Data

Not changed.

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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:

Drawing Number Title

284W8038 RECEPTACLE INSTL - EXTERNAL POWER

284W8050 SUPPORT - GROUND POWER CABLE, EXT POWER RECEPTACLE

K. Publications Affected

1. Publications:

Publication Chapter-Section

777 Aircraft Maintenance Manual 24-41

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.

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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)

Kit Number Name

External Power Receptacle Foreign 25 $134.00

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

Top Kit 2

005W3337-1 1

ALL

KIT 005W3337-1

NOTES

Existing Part

Name Number

Figure

New Part Number

2

QTY

284W8050-13 2 SHIELD

BACN10YR3CD 4 NUT

BACS12GU3K40 4 SCREW, CAP

NAS1149F0332P 8 WASHER

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BOEING SERVICE BULLETIN 777-24-0102
2. Parts and Materials Supplied by the Operator:

Part Number / Specification QTY Name Notes

BMS 5-95, Type 1, Class B 6 ounces Sealant (a)

(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.

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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.

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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.

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BOEING SERVICE BULLETIN 777-24-0102
FIGURE 1: EXTERNAL POWER RECEPTACLE - CONDUCTOR GUARD REMOVAL AND WIRE

DISCONNECTION

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-24-0102
FIGURE 1: EXTERNAL POWER RECEPTACLE - CONDUCTOR GUARD REMOVAL AND WIRE

DISCONNECTION

(SHEET 2 OF 3)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Remove / Keep FASTENERS - 12

2 Remove / Keep FLOOR PANEL ASSY 284W8165-14 1

3 Remove / Keep NUT - 6

Remove / Keep WASHER - 6

Remove / Keep CONDUCTOR GUARD - 2

4 Remove / Keep NUT - 8

Remove / Keep LOCK WASHER - 8

Remove / Keep WASHER - 8

Disconnect WIRE - 8 (a)

5 Remove / Keep NUT - 4

Remove / Keep LOCK WASHER - 4

Remove / Keep WASHER - 4

Disconnect WIRE - 4 (b)

6 Remove / Keep INSULATOR SUPPORT - 2

Remove / Keep NUT - 4

Remove / Keep WASHER - 8

Remove SCREW - 4

(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)

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BOEING SERVICE BULLETIN 777-24-0102
FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR

GUARD INSTALLATION

(SHEET 1 OF 4)

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BOEING SERVICE BULLETIN 777-24-0102
FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR

GUARD INSTALLATION

(SHEET 2 OF 4)

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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.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Install (New) SCREW, CAP BACS12GU3K40 4 (a)

Install (Kept) WASHER - 8 (a)

Install (Kept) NUT - 4 (a)

Install (Kept) INSULATOR SUPPORT - 2 (a)

2 Install (New) SHIELD 284W8050-13 2 (b) (g)

FIGURE 2: EXTERNAL POWER RECEPTACLE - FOREIGN OBJECT DEBRIS SHIELD AND CONDUCTOR

GUARD INSTALLATION

(SHEET 3 OF 4)

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BOEING SERVICE BULLETIN 777-24-0102
STEP TASK NAME IDENTIFICATION QTY MORE DATA

3 Connect WIRE - 8 (c)

Install (Kept) WASHER - 8 (c)

Install (Kept) LOCK WASHER - 8 (c)

Install (Kept) NUT - 8 (c)

Measure RESISTANCE - - (d)

4 Connect WIRE - 4 (e)

Install (Kept) WASHER - 4 (e)

Install (Kept) LOCK WASHER - 4 (e)

Install (Kept) NUT - 4 (e)

Measure RESISTANCE - - (f)

5 Install (Kept) CONDUCTOR GUARD - 2

Install (Kept) WASHER - 6

Install (Kept) NUT - 6

6 Install (New) WASHER NAS1149F0332P 8

Install (New) NUT BACN10YR3CD 4

7 Install (Kept) FLOOR PANEL ASSY 284W8165-14 1

Install (Kept) FASTENERS - 12

(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)

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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

Analysis Inputs Before the Change After the Change

Delays / 100 Unit Revenue Departures .00035 .00000

Cancellations / 100 Unit Revenue Departures .00000 .00000

Air Turnbacks / 100 Unit Revenue Departures .00000 .00000

Diversions / 100 Unit Revenue Departures .00000 .00000

MTBUR (unit flight hours) 58,322 91,128

MTBF (unit flight hours) 58,322 91,128

Fuel Factor (weight in pounds) - +.1

Line Maintenance Labor Hours per Removal 3.25 3.25

Line Maintenance Labor Hours per Maintenance Action (non-re- 2.5 2.5

movals)

Maintenance Actions / 1000 Unit Flight Hours .0055 .0055

Scheduled Maintenance Hours / 1000 Unit Flight Hours .000 .000

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 Not applicable Not applicable

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)

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BOEING SERVICE BULLETIN 777-24-0102