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 recipient,

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 (EAR).

This information must not be transferred to a foreign person without proper authorization of the U.S. Government. Violations may

result in administrative, civil or criminal penalties.

ELECTRICAL POWER - Electrical Module Assembly - Install the Passenger Compartment Electrical 

SERVICE BULLETIN

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 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 (EAR).

This information must not be transferred to a foreign person without proper authorization of the U.S. Government. Violations may

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

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233W3202-24-04

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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 233W3202-19
Jun 27/2002

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233W3202-24-04

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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 operator man-hour data if necessary. The 

estimate does not include lost time. These are some examples of lost time:

– Time to adjust to the workplace

– Time to schedule the work

– Time to examine the work

– Time to cure the materials

– Time to make the parts

– Time to find the tools.

(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 2.25
Jun 27/2002

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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

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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 configuration 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

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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.
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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

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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 the 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

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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, other 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

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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 1
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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 1
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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 1
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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 3
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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 REPAIR section 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 procedures
Jun 27/2002

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

Change the Module Wiring (Sheet 1 of 2)

Figure 2
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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