TO: Holders of 777 ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches. FROM: BAE SYSTEMS CAGE: 89954 ILS/Product Support 600 Main St. Johnson City, NY 13790-1888 USA Web: http://www.commercialsupport.biz SUBJECT: 233W3202-24-04, ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches Service Bulletin, Revision 2, dated Oct 02/2006. The subject Service Bulletin is attached to this letter of transmittal. This Service Bulletin authorizes the conversion of the following unit Part Numbers (PNs).

NOTE : This Service Bulletin was previously issued by The Boeing Company (CAGE: 81205).

Please direct any questions or comments to the above address. FROM TO 233W3202-6 233W3202-19 233W3202-7 233W3202-18 233W3202-11 233W3202-22 233W3202-12 233W3202-18 233W3202-13 233W3202-19

REVISION HISTORY Basic Issue Jun 27/2002 Revision 1 Sep 25/2003 Revision 2 Oct 02/2006
On August 13, 2004, BAE SYSTEMS acquired Boeing’s Commercial Electronics Unit.

BAE SYSTEMS PROPRIETARY INFORMATION This information is owned by BAE SYSTEMS and contains proprietary information of BAE SYSTEMS. This information is copyrighted by the owner and is licensed to the recipient. This information may not be disclosed to anyone other than the reci pient, or used for other than its intended purpose without express written consent of BAE SYSTEMS. COPYRIGHT 2006 BAE SYSTEMS. All rights reserved. EXPORT CONTROLLED DATA This document contains technical information, the export of which is governed by the U.S. Export Administration Regulations (EA R). This information must not be transferred to a foreign person without proper authorization of the U.S. Government. Violations m ay result in administrative, civil or criminal penalties.

# SERVICE BULLETIN
ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION This information is owned by BAE SYSTEMS and contains proprietary information of BAE SYSTEMS. This information is copyrighted by the owner and is licensed to the recipient. This information may not be disclosed to anyone other than the recipient, or us ed for other than its intended purpose without express written consent of BAE SYSTEMS. COPYRIGHT 2006 BAE SYSTEMS. All rights reserved. EXPORT CONTROLLED DATA This document contains technical information, the export of which is governed by the U.S. Export Administration Regulations (EA R). This information must not be transferred to a foreign person without proper authorization of the U.S. Government. Violations m ay result in administrative, civil or criminal penalties.

Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 1 of 16 1. PLANNING INFORMATION

. A. Effectivity

. This Service Bulletin is for the components that follow. An equivalent change is on subsequent production components. Part Number Name Used On 233W3202-6 Electrical Module Assembly 777 233W3202-7 Electrical Module Assembly 777 233W3202-11 Electrical Module Assembly 777 233W3202-12 Electrical Module Assembly 777 233W3202-13 Electrical Module Assembly 777 B. Concurrent Requirements

. The related airplane Service Bulletins are 777-24-0074 and 777-24-0077. C. Reason

. The change described in this Service Bulletin adds two new switches to the electrical panel assembly to control electrical power provided to the passenger cabin systems. Operators have reported numerous occurrences of smoke and fire in the passenger cabin. The electrical systems associated with the occurrences include the in-flight entertainment system, telephones, in-seat power systems, lighting and galley electrical systems. Two switches can be added to the electrical system flight deck control panel to remove power to these systems if smoke or flame occurs.Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 2 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page

D. Description

. This Service Bulletin authorizes the conversion of the following Electrical Module Assembly Part Numbers (PNs).

E. Compliance

. (1) Technical Compliance. Category 7 Do at customer convenience or option. (2) Program Compliance. There are no labor or material allowances. F. Approval

. This Service Bulletin has been reviewed by Boeing and the Federal Aviation Administration (FAA). The repairs and modifications herein comply with Federal Aviation Regulations (14CFR Part 25) and EASA/Joint Aviation Requirements (JAR-25) and are on record with the supplier as FAA approved for installation on model 777 aircraft. FROM TO 233W3202-6 233W3202-19 233W3202-7 233W3202-18 233W3202-11 233W3202-22 233W3202-12 233W3202-18 233W3202-13 233W3202-19Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 3 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page

G. Manpower

. (1) The following table shows an estimate of the man-hours necessary to make this change for each component. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with opera tor man-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: – Time to adjust to the workplace – Time to schedule the work – Time to examine the work – Time to cure the materials – Time to make the parts – Time to find the tools.

(2) If you are not able to perform this Service Bulletin, and want to accomplish this Service Bulletin, return the affected unit and a Purchase Order to one of the following addresses (include the number of this Service Bulletin). BAE SYSTEMS - Dallas Service Center 3131 Story Rd. W. Irving, TX 75038 OR BAE SYSTEMS - London Service Centre 21 Sutton Park Ave. Reading, England RG6 1LA OR BAE SYSTEMS - Asia Pacific Service Centre 18 Loyang Lane Singapore 508918 H. Weight and Balance

. Accomplishment of this Service Bulletin will cause the weight of the modules to increase by 0.70 pounds. I. Electrical Load Data

. Not Changed. TASK MAN-HOURS Accomplishment Instructions 1.25 Test 1.00 TOTAL FOR EACH COMPONENT 2.25Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 4 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page

J. Software Accomplishment Summary

. Not Applicable. K. References

. BAE SYSTEMS Document 362A4388 (Instrument Panel Electrical Module General Information) BAE SYSTEMS Document 362A4397 (Application of Stencils, Insignia, Silk Screen, Part Numbering and Identification Markings) Boeing Service Bulletin 777-24-0074 Boeing Service Bulletin 777-24-0077 Component Maintenance Manual (CMM) 24-22-17 GENERAL PRACTICES MANUAL , ACS 15520 L. Publications Affected

. CMM 24-22-17 M. Interchangeability or Intermixability of Parts

. None.Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 5 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page 2. MATERIAL INFORMATION

. A. Material - Price and Availability

. NOTE : Kit PN 005W3198-2 has been deleted in Revision 2 of this Service Bulletin.

B. Industry Support Information

. Warranty remedies are not available for the con figuration changes given in this Service Bulletin. PART NUMBER QTY NAME UNIT PRICE PKG QTY LEAD TIME DAYS 005W3198-21 1 Wire $12.00 (-) * 005W3198-22 1 Wire ** (-) * 005W3198-23 1 Label ** (-) * 005W3198-24 1 Label ** (-) * 09-530-0101 2 Switch $2223.00 (-) * 09-530-9501 2 Connector $95.00 (-) * 233W3202-402 1 Base Plate $625.00 (-) * 69B46200-13 3 Standoff $14.00 (-) * BACC47CN1S 9 Contact $10.00 (-) * BACS38K1I 20 Strap $10.00 (-) * BACS38K1B 10 Strap $10.00 (-) * BACS38K7H 6 Strap $10.00 (-) * BACT19B-T2 12 Tape, Identification $10.00 (-) * BACW10EC06C 6 Washer $10.00 (-) * D-436-45 2 Sleeve $10.00 (-) * D-436-46 4 Sleeve $10.00 (-) * M39029/22-192 30 Contact $10.00 (-) * NAS1387-2 2 Splice $10.00 (-) * NAS1387-3 4 Splice $10.00 (-) * S233W110-3043 1 Light Plate $9154.00 (-) * * BAE SYSTEMS will quote the lead time of these parts. Lead time is valid 90 days from date of quote. Pricing information is available at: http://www.commercialsupport.biz. ** Price not available at publication date. Contact Spare Parts Sales. Refer to http://www.commercialsupport.biz for contact information.Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 6 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page

C. Parts Necessary for Each Component

. For part ordering information, refer to Paragraph 2.A. (1) Material to be purchased.

NEW PART NUMBER QTY NAME EXISTING PART NUMBER NOTES

005W3198-21 1 Wire - - 005W3198-22 1 Wire - - 005W3198-23 1 Label - - 005W3198-24 1 Label - - 09-530-0101 2 Switch - - 09-530-9501 2 Connector - - 233W3202-402 1 Base Plate 233W3202-401 (a) (b) (c) 69B46200-13 3 Standoff 69B46200-11 (a) (b) (c) BACC47CN1S 9 Contact - (d) BACS38K1I 20 Strap - (d) BACS38K1B 10 Strap - (d) BACS38K7H 6 Strap - (d) BACT19B-T2 12 Tape, Identification - (d) BACW10EC06C 6 Washer - (d) D-436-45 2 Sleeve - D-436-46 4 Sleeve - M39029/22-192 30 Contact - (d) NAS1387-2 2 Splice - NAS1387-3 4 Splice - S233W110-3043 1 Light Plate S233W110-3002 (a) (b) (c) NOTES : (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. (d) There are more parts than are necessary.Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 7 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page (2) Material supplied by the operator.

(3) Parts modified and reidentified.

(4) Parts removed and not replaced. PART NUMBER/SPECIFICATION QTY NAME COMMENTS Type 222 or 242 1 oz. Sealant, Loctite Refer to Note NOTE : Loctite Corporation, 705 North Mountain Road, Newington, Connecticut 06111-1411.

EXISTING PART NUMBER QTY NAME NEW PART NUMBER NOTES 233W3202-6 - Electrical System Control Panel 233W3202-19 (a) (b) 233W3202-7 - Electrical System Control Panel 233W3202-18 (a) (b) 233W3202-11 - Electrical System Control Panel 233W3202-22 (a) 233W3202-12 - Electrical System Control Panel 233W3202-18 (a) (b) 233W3202-13 - Electrical System Control Panel 233W3202-19 (a) (b)

NOTES : (a) Make the change given in this Service Bulletin. (b) This part is used in production.

EXISTING PART NUMBER NAME QTY COMMENTS 233W3202-401 Base Plate 1 Refer to Note 69B46200-11 Standoff 3 Refer to Note S233W110-3002 Light Plate 1 Refer to Note NOTE : Keep the part if there are other uses for it.Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 8 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page

D. Parts Necessary to Change Spares

. None. E. Special Tooling Price and Availability

. None. F. Special Tooling Necessary to do Service Bulletin

. No special tools or equipment are necessary to do th e change in this Service Bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.K., References , can be necessary. Examine operator tool supply to make sure all necessary tools are available.Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 9 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page 3. ACCOMPLISHMENT INSTRUCTIONS

. A. General Notes

. (1) Manual titles are referred to by acronyms. Refer to Paragraph 1.K., 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, ot her than rivet and bolt edge margins, is plus or minus 0.03 inch (0.76 mm) – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch (1.27 mm) – Angular tolerance is plus or minus two degrees. (4) 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 can be used.

CAUTION : SUBASSEMBLIES OF THE EQUIPMENT CAN CONTAIN ESDS DEVICES (MICROCIRCUITS, SEMICONDUCTORS, AND FILM RESISTORS) THAT ARE SENSITIVE TO VOLTAGES MADE BY ELECTROSTATIC DISCHARGE. OBEY ESDS PRECAUTIONS WHEN YOU HANDLE SUBASSEMBLIES THAT HAVE THE ESD SYMBOL. THESE PRECAUTIONS ARE APPLICABLE TO THE FULL SUBASSEMBLY WHICH CONTAINS ESDS DEVICES. 

### ATTENTION
OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES WHEN ESDS SUBASSEMBLIES ARE NOT INSTALLED IN THE UNIT, THEY MUST BE KEPT OR MOVED IN MATERIALS THAT ARE ELECTRICALLY CONDUCTIVE, AND MUST NOT BE PUT IN NON-CONDUCTIVE PLASTIC BAGS. STATIC SHIELD BAGS, OR THEIR EQUIVALENT, ARE THE CORRECT PROTECTIVE MATERIALS TO KEEP OR MOVE SUBASSEMBLIES. REFER TO THE GENERAL PRACTICES MANUAL , CHAPTER 73-60-00, FOR SPECIAL PROCEDURES FOR ESDS SUBASSEMBLIES. B. Work Instructions

.

(1) Make the changes as shown in Figure 1 and Figure 2. (2) Install the new light plate PN S233W110-3043 on the changed panel. (3) Do a test of the changed panel as specified in CMM 24-22-17.Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 10 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page Install the New Power Control Switches (Sheet 1 of 5) Figure 1Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 11 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page Install the New Power Control Switches (Sheet 2 of 5) Figure 1Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 12 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page Install the New Power Control Switches (Sheet 3 of 5) Figure 1Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 13 

# SERVICE BULLETIN
ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page Install the New Power Control Switches (Sheet 4 of 5) Figure 1 STEP TASK NAME PART NUMBER QTY NOTES 1 Remove Components -- -- Remove all the components from the base plate. You can use standard industry practices and the procedures in BAE SYSTEMS Document 362A4388 2 Install Base plate 233W3202-402 1 Use the new base plate and put back the removed components. It is not necessary to install the standoffs for the J2/J3 connectors at this time 3 Install Switch 09-530-0101 2 4 Remove/ Reinstall Connector Bracket -- -- Remove the connector bracket. Change the orientation of the J2 and J3 reference designators. Refer to Figure 1, Sheet 3. Check the installed wires to see if any wires will be too short to get to the new connector locations. Change the wire routing or the wire length as necessary. Reinstall bracket, and change positions of J2 and J3 connectors to match locations and keying orientation as shown in Figure 1, Sheet 3 5 Install Standoff 69B46200-13 3 Use: Screw FH6C5CPL12BN 3 Use the saved screws Screw MS51957-27 3 Use the saved screws Washer BACW10EC06C 3Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 14 

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ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page Install the New Power Control Switches (Sheet 5 of 5) Figure 1 STEP TASK NAME PART NUMBER QTY NOTES 6 Install Wires -- -- Change the wire bundle as shown in Figure 2 Use: Strap BACS38K1I -- Quantities as required. Refer to Figure 2 to get the separation requirements. Separation code RM2 is brown, SY2 is purple, and all others are white. Refer to the REPAIRsection of CMM 24-22-17 for more data about wire separation Strap BACS38K1B -- Strap BACS38K7H --

7 Change Part Number -- 1 Change the part number of the panel from 233W3202-6 to 233W3202-19 or from 233W3202-7 to 233W3202-18 or from 233W3202-11 to 233W3202-22 or from 233W3202-12 to 233W3202-18 or from 233W3202-13 to 233W3202-19. Refer to BAE SYSTEMS Document 362A4397 for the necessary proceduresJun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 15 

# SERVICE BULLETIN
ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page Change the Module Wiring (Sheet 1 of 2) Figure 2Jun 27/2002 Revision 2, Oct 02/2006 

## 233W3202-24-04 Page 16 

# SERVICE BULLETIN
ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical Power Isolation Switches

BAE SYSTEMS PROPRIETARY INFORMATION/WARNING: EXPORT CONTROLLED – Subject to the restrictions on the first page Change the Module Wiring (Sheet 2 of 2) Figure 2 FLAG NOTE NAME PART NUMBER QTY NOTES 1 Wire 005W3198-21 -- 22 American Wire Gauge (AWG). Use this wire except when diagram shows “20” 2 Wire 005W3198-22 -- 20 AWG 3 Label 005W3198-23 1 M/W S14 4 Label 005W3198-24 1 M/W S15 5 Contact BACC47CN1S 8 6 Contact M39029/22-192 20 7 Splice NAS1387-2 2 SM20 and SM21 are new splices Sleeve D-436-45 2 Splice NAS1387-3 2 SM4 and SM5 are replaced Sleeve D-436-46 2 8 Splice NAS1387-3 2 SM1 and SM2 are replaced Sleeve D-436-46 2 9 Connector 09-530-9501 2 DS14 and DS15