Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-24A0119

Original Issue: November 11, 2011

ATA System: 2421 5383

SUBJECT: ELECTRICAL POWER - Power and Regulation - Inspection and if Necessary, Repair

of Clamps, Power Feeder Cable, Insulation Blanket and Aft Pressure Bulkhead

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

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2011 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Unpublished Work - All Rights Reserved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

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4.0
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BLANK PAGE
Table of Contents

Summary ...................................................... 5

1. PLANNING INFORMATION ........................................ 9

A. Effectivity ................................................ 9

1. Airplanes ............................................. 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1. Existing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. Data supplied with this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Installation Drawings Used in the Preparation of this Service Bulletin . . . . . . . . . . . . 17

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

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

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 20

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

FIGURE 1: ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIGURE 2: INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FIGURE 3: REPLACEMENT AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

APPENDIX A: CONDUCTIVITY TEST EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

APPENDIX B: INDIRECT CONDUCTIVITY EDDY CURRENT INSPECTION . . . . . . . . . . . . . . . . 39

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Summary Number: 777-24A0119

Original Issue: November 11, 2011

ATA System: 2421 5383

SUBJECT: ELECTRICAL POWER - Power and Regulation - Inspection and if Necessary, Repair

of Clamps, Power Feeder Cable, Insulation Blanket and Aft Pressure Bulkhead

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Accomplishment of this service bulletin will prevent failure of the clamp at station 2150 between stringer 3R and

4R, and within the section 48 flammable fluid leakage zone. If not incorporated, a failed clamp can result in wire

chafing and potential electrical arcing which might cause a fire in section 48 which is identified as flammable

fluid leakage zone, or heat damage to the Auxiliary Power Unit (APU) power feeder cable, insulation blankets

and/or pressure bulkhead at station 2150.

An operator has reported failure of the clamp at station 2150 and between stringer 3R and 4R in the forward

section of the aft pressure bulkhead. The chafing caused by the failed clamp resulted in heat damage to the

APU power feeder cables, insulation blankets, and the pressure bulkhead adjacent to the clamp.

This service bulletin gives the instructions to do a Detailed Inspection of the clamps at station 2150 and in the

48 section aft of the pressure bulkhead. If non-TA clamps, or damage to the cable, blankets and the pressure

bulkhead are found, this service bulletin gives procedures to replace the existing non-TA clamps with the TA

clamps, and to repair the cable, the blanket and the pressure bulkhead if required.

Boeing Service Related Problem (SRP) 777-SRP-24-0139 is related to this service bulletin. This SRP is described

in Fleet Team Digest Article 777 FTD 24-10003.

ACTION (PRR 62777-84S)

Gain access to the APU power feeder cable between stringer 3R and 4R at station 2150.

Gain access to the APU power feeder cable in the 48 section.

Do a Detailed Inspection of the clamps on the APU power feeder cable. Replace the existing non-TA clamps

with the TA clamps.

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Do a General Visual Inspection of the APU power feeder cable for cable damage. Repair damaged cable if

found.

Do a General Visual Inspection of the insulation blanket adjacent to the clamp at station 2150 and between

stringer 3R and 4R. Repair damaged insulation blanket if found.

Do a test to determine damage to the aft pressure bulkhead and structure. Contact Boeing for repair instructions

if damage is found.

Close access.

EFFECTIVITY

777-200, 777-200LR, 777-300, 777-300ER, and 777F 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 recommends that the change given in this service bulletin be done within 48 months of the original issue

of this service bulletin.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of July 22, 2010. Please refer to Paragraph

2.B., Industry Support Information.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Number: 777-24A0119

Original Issue: November 11, 2011

ATA System: 2421 5383

SUBJECT: ELECTRICAL POWER - Power and Regulation - Inspection and if Necessary, Repair

of Clamps, Power Feeder Cable, Insulation Blanket and Aft Pressure Bulkhead

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and

Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent

production airplanes. Refer to PRR 62777-84S for data about this change.

GROUP CONFIGURATION DESCRIPTION

1 - Freighter Airplanes

2 - Passenger Airplanes

Airplane Models:

777-200, 777-200LR, 777-300, 777-300ER, 777F

Variable Number Group

WA001 - WA017 2

WA076 - WA079 2

WA086 - WA093 2

WA101 - WA104 2

WA116 - WA119 2

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Variable Number Group

WA131 - WA137 2

WA171 - WA175 2

WA196 - WA198 2

WA206 - WA212 2

WA221 - WA223 2

WA231 - WA232 2

WA241 - WA250 2

WA261 - WA266 2

WA281 - WA283 2

WA301 - WA304 2

WB001 - WB021 2

WB031 - WB042 2

WB044 - WB046 2

WB051 - WB088 2

WB101 - WB106 2

WB121 - WB125 2

WB131 - WB148 2

WB151 - WB155 2

WB161 - WB177 2

WB181 - WB194 2

WB201 - WB215 2

WB231 - WB247 2

WB271 - WB273 2

WB276 - WB286 2

WB291 - WB302 2

WB306 - WB307 2

WB311 - WB337 2

WB341 - WB342 2

WB366 - WB368 2

WB371 - WB388 2

WB406 2

WB411 - WB413 2

WB416 - WB439 2

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Variable Number Group

WB446 - WB453 2

WB476 2

WB481 - WB484 2

WB501 - WB512 2

WB531 - WB537 2

WB551 - WB554 2

WB591 - WB597 2

WB601 - WB606 2

WB611 - WB622 2

WB631 - WB638 2

WB646 - WB649 2

WC051 - WC073 2

WC101 - WC104 2

WC111 - WC120 2

WC221 - WC224 2

WC241 - WC243 2

WC281 - WC290 2

WC301 - WC308 2

WC361 - WC364 2

WC371 - WC374 2

WC381 - WC395 2

WC441 2

WC446 - WC449 2

WC456 - WC459 2

WC486 - WC493 2

WC506 - WC508 2

WC521 - WC522 2

WC531 - WC536 2

WC546 - WC548 2

WC556 2

WC566 - WC567 2

WC571 - WC574 2

WC581 2

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Variable Number Group

WD001 - WD002 2

WD011 - WD018 2

WD031 - WD036 2

WD046 - WD055 2

WD066 - WD075 2

WD081 - WD088 2

WD091 2

WD096 2

WD101 - WD105 2

WD111 2

WD501 - WD513 2

WD521 - WD541 2

WD546 - WD554 2

WD561 - WD573 2

WD581 - WD599 2

WD606 - WD609 2

WD621 - WD632 2

WD651 - WD665 2

WD671 - WD677 2

WD691 - WD709 2

WD741 - WD752 2

WD761 - WD771 2

WD786 - WD788 2

WD796 - WD817 2

WD826 - WD837 2

WD846 - WD863 2

WD871 - WD885 2

WD911 - WD915 2

WD921 - WD922 2

WD936 - WD939 2

WD946 - WD953 2

WD966 - WD970 2

WD981 - WD982 2

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Variable Number Group

WD986 - WD987 2

WD996 2

WE001 - WE004 2

WE011 - WE012 2

WE021 - WE026 2

WE031 - WE034 2

WE051 - WE053 2

WE071 2

WE081 - WE082 2

WE126 - WE135 2

WE151 2

WE176 - WE177 2

WE186 2

WF001 - WF004 1

WF016 - WF020 1

WF031 - WF032 1

WF046 - WF055 1

WF076 - WF077 1

WF081 - WF088 1

WF096 - WF100 1

WF106 - WF107 1

WF111 - WF112 1

WF121 - WF122 1

WF131 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

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C. Reason

Accomplishment of this service bulletin will prevent failure of the clamp at station 2150 between stringer

3R and 4R, and within the section 48 flammable fluid leakage zone. If not incorporated, a failed clamp

can result in wire chafing and potential electrical arcing which might cause a fire in section 48 which

is identified as flammable fluid leakage zone, or heat damage to the Auxiliary Power Unit (APU) power

feeder cable, insulation blankets and/or pressure bulkhead at station 2150.

An operator has reported failure of the clamp at station 2150 and between stringer 3R and 4R in the

forward section of the aft pressure bulkhead. The chafing caused by the failed clamp resulted in heat

damage to the APU power feeder cables, insulation blankets, and the pressure bulkhead adjacent to

the clamp.

This service bulletin gives the instructions to do a Detailed Inspection of the clamps at station 2150

and in the 48 section aft of the pressure bulkhead. If non-TA clamps, or damage to the cable, blankets

and the pressure bulkhead are found, this service bulletin gives procedures to replace the existing

non-TA clamps with the TA clamps, and to repair the cable, the blanket and the pressure bulkhead if

required.

Boeing Service Related Problem (SRP) 777-SRP-24-0139 is related to this service bulletin. This SRP

is described in Fleet Team Digest Article 777 FTD 24-10003.

D. Description

Gain access to the APU power feeder cable between stringer 3R and 4R at station 2150.

Gain access to the APU power feeder cable in the 48 section.

Do a Detailed Inspection of the clamps on the APU power feeder cable. Replace the existing non-TA

clamps with the TA clamps.

Do a General Visual Inspection of the APU power feeder cable for cable damage. Repair damaged

cable if found.

Do a General Visual Inspection of the insulation blanket adjacent to the clamp at station 2150 and

between stringer 3R and 4R. Repair damaged insulation blanket if found.

Do a test to determine damage to the aft pressure bulkhead and structure. Contact Boeing for repair

instructions if damage is found.

Close access.

The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

777F 312, 314

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Group 2:

Affected Maintenance Zones

Model Zone

777-200, 777-200LR, 777-300, 312, 314

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.

Boeing recommends that the change given in this service bulletin be done within 48 months of the

original issue of this service bulletin.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (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 0.50 0.50

Figure 1 1 0.50 0.50

Figure 2 1 3.25 3.25

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Group 1:

Task Number of Persons Task Hours Elapsed Hours

Figure 3 1 2.50(a) 2.50(a)

Test (If required) (b) (b)

Close Access 1 1.00 1.00

TOTAL FOR EACH AIRPLANE 7.75 7.75

(a) Estimate assumes no repair is required to APU power feeder cable or insulation

blankets. If repair is required more time may be required

(b) Estimate assumes no test time is required. If testing is required more time will

be required.

Group 2:

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 1 1 0.25 0.25

Figure 2 1 3.25 3.25

Figure 3 1 2.50(a) 2.50(a)

Test (If required) (b) (b)

Close Access 1 0.75 0.75

TOTAL FOR EACH AIRPLANE 7.25 7.25

(a) Estimate assumes no repair is required to APU power feeder cable or insulation

blankets. If repair is required more time may be required.

(b) Estimate assumes no test time is required. If testing is required more time will

be required.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data

a. Engineering Change Memo PRR 62777-84S

b. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-13, 20-10-19

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c. 777 Aircraft Maintenance Manual (AMM) 20-10-22, 24-22-00, 25-21-06, 25-21-07, 25-59-01,

25-80-00, 52-48-05, 52-48-06

d. 777 Fleet Team Digest (FTD) 24-10003

e. 777 Non-Destructive Testing (NDT) Manual Part 6, 51-00-08

f. Service Related Problem (SRP) 777-SRP-24-0139

2. Data supplied with this Service Bulletin

None.

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

Drawing Number Title

WIRE BUNDLE INSTL - R.S. UPR SWL W/AFT PRESS BLKHD

(STA 2150 - 2414) & FW BLKHD (FWD)

288W4800

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications:

None.

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 affects FCS but no new DTIs are necessary.

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

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BLANK PAGE
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

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

2. Fax to (206) 662-7145

Group 1-2:

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

the original issue

date of this Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name Date QTY

APU Power Feeder July 01, 2011 10 149 $500.00

Clamp Replacement

005W3505-1

August 01, 10 149 $500.00

2011

APU Power Feeder

Clamp Replacement

005W3505-1

August 29, 10 149 $500.00

2011

APU Power Feeder

Clamp Replacement

005W3505-1

September 27, 10 149 $500.00

2011

APU Power Feeder

Clamp Replacement

005W3505-1

October 25, 9 149 $500.00

2011

APU Power Feeder

Clamp Replacement

005W3505-1

B. Industry Support Information

Boeing warranty remedies are available for 777 airplanes in warranty as of July 22, 2010. For task hour

reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Commercial

Airplanes Group - Warranties. The kits for airplanes in warranty as of that date will be supplied at no

charge. Send a purchase order for the kits to Boeing Spares. Please refer to this service bulletin number

and reference the airplane number in your purchase order.

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.

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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.

Group 1-2:

Kit 005W3505

Existing Part Notes

Number

New Part Number QTY Name

-1

TOPKIT - APU

Power Feeder

Clamp Replacement

005W3505-1 -

TA027063-22P 25 CLAMP (a)

TA027063-24P 25 CLAMP (a)

(a) There are more parts than are necessary

2. Parts and Materials Supplied by the Operator

None.

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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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

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

OTHER ELECTRICAL DAMAGE.

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

definition of the acronyms.

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

3. The work instructions are divided into work packages. Task Hours and Elapsed Hours

for each package are given in Paragraph 1.G., Manpower. You can do each work

package independently.

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 and fasteners are in Structural Repair

Manual (SRM) Chapter 51

– Torque limits to tighten nuts and bolts are in SRM Chapter 51

5. 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.

6. The necessary conditions for selection of clamp type and size are included in SWPM

20-10-12. If any wire bundle support clamp specified in this service bulletin does not

make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted

procedure to select a clamp that fits correctly.

7. If the length of any fastener specified in this service bulletin does not meet installation

standards given in SRM Chapter 51, then a fastener of the same specification, or

an approved substitute, with a length which meets the installation standards given

in SRM Chapter 51 may be used. In addition, washers may be installed for fastener

grip length in accordance with SRM Chapter 51.

8. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

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9. A Special Detailed Inspection is defined as: An intensive examination of a specific

item,installation, or assembly to detect damage, failure, or irregularity. The

examination is likely to make extensive use of specialized Inspection techniques

and/or equipment. Intricate cleaning and substantial access or disassembly procedure

may be required.

10. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

11. 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.

12. Refer to Appendix A for heat damage inspection referencing example.

13. The instructions in Paragraph 3.B., Work Instructions and the figures can include

operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated

Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing

Index contain data on versions of the tools or test equipment that you can use. It is

permitted to use replaced tools. It is not permitted to use superseded tools.

14. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

15. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

16. This service bulletin includes functional test procedures for the systems changed by

this service bulletin. More functional tests can possibly be necessary in accordance

with standard maintenance practices because of interruption to other airplane systems.

B. WORK INSTRUCTIONS

1. Remove electrical power from the airplane. Refer to 777 AMM 24-22-00 as an accepted procedure.

2. Group 1:

Gain access to the APU power feeder cable at station 2150 and between stringer 3R and 4R in

accordance with Figure 1. Open the access door in the aft bulkhead cargo center panel. Refer to

777 AMM 25-59-01 as an accepted procedure.

Group 2:

Gain access to the APU power feeder cable at station 2150 and between stringer 3R and 4R in

accordance with Figure 1. Open the ceiling panel of the aft A2 and A3 galley. Refer to 777 AMM

25-21-06 and 777 AMM 25-21-07 as an accepted procedure.

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Group 1-2:

Gain access to the APU power feeder cable in the 48 section in accordance with Figure 1. Open

the access door 311BL and 313AL. Refer to 777 AMM 52-48-05 and 777 AMM 52-48-06 as an

accepted procedure.

3. Do a Detailed Inspection of the clamps on the APU power feeder cable at station 2150, and in the

48 section in accordance with Figure 2.

a. If TA027063 clamps are used, do steps 10, 11 and 12.

b. If non-TA027063 clamps are used, proceed to step 4.

4. Do a General Visual Inspection of the APU power feeder cables in accordance with Figure 2.

a. If no damage to the cable is found, do steps 8, 10, 11 and 12.

b. If damage to the cable is found, proceed to step 5.

5. Do a General Visual Inspection of the insulation blanket adjacent to the clamp at station 2150 and

between stringer 3R and 4R for possible heat damages in accordance with Figure 2.

a. If no heat damage to the insulation blanket is found, do steps 7, 8, 10, 11 and 12.

b. If heat damage to the insulation blanket is found, proceed to step 6.

6. Do a heat damage inspection on the pressure bulkhead and structure in accordance with the

instructions below.

a. Perform a detailed inspection of the Section 47 and 48 fuselage structure within 42 inches of

the APU feeder clamp. This includes the skin, stringers, and end fittings on either side of

station 2150, the aft pressure dome web, radial stiffeners, intermediate stiffeners, the station

2150 inner chord, outer chord, failsafe chord (Y-chord), doublers, triplers, circumferential tear

straps and web. Inspect for the following indications of heat damage:

(1) Primer discoloration

(2) Structural deterioration

b. If visual indications of heat damage are found, do steps 6.c through 6.f.

c. Remove loose paint, dirt and sealant from the surface of the inspection area. Refer to 777

AMM 20-10-22 as an accepted procedure.

NOTE: 1. Do not remove the finishes to perform conductivity.

2. Do not use abrasive materials to remove paint, dirt and sealant.

d. With a felt tipped marker, create a 1.00 inch by 1.00 inch grid across the skin locations thought

to be heat damaged and number the grid. For all other structure mark the part into 1.00 inch

sections. Refer to Appendix A, Grid Creation Example, as an accepted procedure.

e. Do a Special Detailed Inspection of the aluminum part for heat damage.

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(1) If space is not restrictive, do the Inspection for Heat Damage to Aluminum Structure, refer

to 777 NDT Part 6, 51-00-08 as an accepted procedure and proceed to step 6.f.

(2) If space is restrictive, standard conductivity probes may not fit in the tight areas, such as

the failsafe chord (Y-chord). If the manufacturer of the conductivity test equipment cannot

provide a probe to fit into the area of interest, refer to Appendix B, Indirect Conductivity

Eddy Current Inspection, as an accepted procedure.

NOTE: 1. Conductivity is very sensitive on materials with a clad layer. Do not remove the

primer on any parts. Measure the conductivity of all parts through the primer.

2. Because the stringer end fittings common to station 2150 are small, measure a

similar end fitting away from the damage that is similar in size and gage. Be sure to

measure the conductivity of the fitting in three locations, near the tension bolts, at

the neck of the fitting and near the stringer attachment fasteners.

3. The baseline conductivity values should be measured away from the area thought

to be heat damaged. These values should be measured on the same part and gage.

4. Measure the undamaged area at two to three locations and take average value

as the baseline conductivity.

5. Record conductivity of each box in the grid created in a spreadsheet. Refer to

Appendix A, Conductivity Table for Skin and Other Structure Example as an accepted

procedure.

f. Do analysis of the inspection results.

(1) If any areas deviate greater than 1% International Annealed Copper Standard (IACS)

from the baseline conductivity reading (for example: the baseline percent IACS is 34,

IACS measurement less than 33 or more than 35 is deviation), do steps 6.f.(1).(a),

6.f.(1).(b), 6.f.(1).(c), 7, 8, 9, 10, 11 and 12.

(a) Contact Boeing for repair instruction

(b) Provide the following to Boeing:

1) Measured conductivity values for all structure listed in 6.a that is within 21 inches

of the areas showing evidence of discoloration or deterioration due to the fire.

2) Detailed digital photos of the structure marked with the grid.

3) Dimensions of the heat damage and distances to surrounding structure, such

as radial stiffeners, intermediate stiffeners, circumferential tear straps, doublers,

triplers and the station 2150 failsafe chord (Y-Chord).

(c) Do the repair in accordance to the instruction from Boeing.

(2) If no damage to the pressure bulkhead is determined, do steps 7, 8, 9, 10, 11 and 12.

7. Do the repair for APU power feeder cable in accordance with Figure 3.

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8. Do the replacement of the existing non-TA027063 clamps with TA027063 clamps in accordance

with Figure 3.

9. Do the repair for insulation blanket in accordance with Figure 3.

10. Group 1:

Close access. Refer to 777 AMM 25-59-01, Main Deck Cargo Compartment Lining Panels, as an

accepted procedure.

Group 2:

Close access. Refer to 777 AMM 25-21-06, Main Ceiling Panel and 777 AMM 25-21-07, Lowered

Ceiling Panel, as an accepted procedure.

Group 1-2:

Close access. Refer to 777 AMM 52-48-05, Service Access Door and 777 AMM 52-48-06, Controls

Bay Access Door, as an accepted procedure.

11. Restore the electrical power to the airplane. Refer to 777 AMM 24-22-00 as an accepted procedure.

12. Put the airplane back to a serviceable condition.

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FIGURE 1: ACCESS

(SHEET 1 OF 2)

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Step Task Name Identification Qty More Data

1 Locate Access Panel - -

2 Locate Access Door - -

FIGURE 1: ACCESS

(SHEET 2 OF 2)

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FIGURE 2: INSPECTION

(SHEET 1 OF 5)

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FIGURE 2: INSPECTION

(SHEET 2 OF 5)

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FIGURE 2: INSPECTION

(SHEET 3 OF 5)

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FIGURE 2: INSPECTION

(SHEET 4 OF 5)

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Step Task Name Identification Qty More Data

Do a Detailed Inspection of the clamps.1 Inspect CLAMPS - -

Note: The color of

the clamp cushion

material for

TA027063 is brown,

any other color is

considered nonTA027063 clamps.

If non-TA027063

clamps are used, do

a General Visual Inspection of the APU

power feeder cable

for damage.

APU Power Feeder W7850 1

Cable

2 Inspect

If APU power feeder

cable is damaged,

do a General Visual

Inspection of the insulation blanket for

heat damage.

3 Inspect Insulation Blanket - -

FIGURE 2: INSPECTION

(SHEET 5 OF 5)

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FIGURE 3: REPLACEMENT AND REPAIR

(SHEET 1 OF 5)

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FIGURE 3: REPLACEMENT AND REPAIR

(SHEET 2 OF 5)

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FIGURE 3: REPLACEMENT AND REPAIR

(SHEET 3 OF 5)

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FIGURE 3: REPLACEMENT AND REPAIR

(SHEET 4 OF 5)

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Step Task Name Identification Qty More Data

If non-TA027063

clamps are found,

refer to SWPM 20-

10-12 as an accepted procedure. See

the extra parts table

for different clamp

size, if necessary.

1 Install (New) CLAMP TA027063-22P 23

If damage is found,

refer to SWPM 20-

10-13 as an accepted procedure.

APU Power Feeder W7850 1

Cable

2 Repair

If damage is found,

refer to 777 AMM

25-80-00 as an accepted procedure.

3 Repair Insulation Blanket - 1

The parts shown in the table below are provided as extra parts for this figure.

Name Identification Qty More Data

CLAMP TA027063-22P 2

Use TA027063-24P clamps if required.CLAMP TA027063-24P 25

FIGURE 3: REPLACEMENT AND REPAIR

(SHEET 5 OF 5)

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APPENDIX A: CONDUCTIVITY TEST EXAMPLES

(SHEET 1 OF 1)

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1. Purpose

Use this indirect conductivity eddy current procedure to evaluate aluminum structure for heat damage when

a standard probe of conductivity instrument will not fit into the an area with limited clearance.

This eddy current procedure uses an impedance plane display instrument. It is not considered as accurate

as a standard conductivity instrument.

2. Equipment

a. Instrument

Use an impedance plane display eddy current instrument that operates at a frequency range of 100

kHz to 500 kHz. A Hocking Phasec 2200 eddy current instrument was used to help prepare this

procedure.

b. Probes

Use a shielded differential type probe with outer diameter of approximately 0.125 inch (3.2mm) that

operates from 100 to 500 kHz. An NDT Engineering Inc (Olympus) MP-30 probe is an example of a

suitable probe.

NOTE: Use a probe that is not sensitive to hand pressure.

c. Reference Standard

Use two certified conductivity standards with values as follows:

(1) One standard should have a conductivity value between 34 - 43% IACS (34 - 36 preferred).

(2) One standard with a conductivity value between 26 - 29.5% IACS.

3. Preparation for Inspection

a. Get access to the areas in step 6 of Work Instructions, paragraph 3.B where visual inspections indicated

potential heat damage.

b. Remove all dirt and grease from the inspection areas that the probe will touch.

4. Instrument Calibration

a. Connect the probe to the instrument.

b. Set the instrument frequency to 150 kHz.

c. Put the probe on the conductivity reference standard with the highest conductivity.

d. Balance the instrument as specified by the manufacturer's instructions.

APPENDIX B: INDIRECT CONDUCTIVITY EDDY CURRENT INSPECTION

(SHEET 1 OF 3)

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e. Set the balance point at approximately 20% of full screen height and 60% full screen width. Refer to

Appendix B, Calibration Screen Display Example, Point 1, as an accepted procedure.

f. Set the lift-off (phase) so that the signal moves horizontally from right to left when the probe is lifted off

the reference standard. Refer to Appendix B, Calibration Screen Display Example, as an accepted

procedure.

g. Put the probe on the conductivity reference standard with the lowest conductivity.

h. Adjust the instrument gain to set the signal at 80%FSH (60% full screen height separation between

the two signals). Refer to Appendix B, Calibration Screen Display Example, Point 2, as an accepted

procedure.

i. Do steps 4.c through 4.h in Appendix B again to make sure that there is a 60% full screen height

separation between the two signals.

NOTE: Change probes or increase the instrument frequency if you can not get the 60% full screen

height separation between the two signals.

j. The conductivity of the part can be estimated by extrapolating the vertical position of the signal as

compared to the two known conductivity standards.

5. Inspection Procedure

a. Put the probe on the high conductivity standard and balance the instrument again.

b. Put the probe on the suspect structure (e.g. failsafe chord (Y-chord)) at a location away from the possible

damage and quickly read the vertical height of the signal. Record this instrument reading.

c. Move the probe towards the damage to see if there is a change in signal height. Heat damage will

cause the signal to decrease in height (indicating increased conductivity). If there are no changes to

the signal height, there is no heat damage to the Y-chord.

d. If there is a change in the signal height, take careful readings to estimate the conductivity values. Before

each reading, put the probe on the high conductivity standard and balance the instrument before putting

the probe back on to the part. The conductivity of the part can be estimated by extrapolating the vertical

position of the signal as compared to the two known conductivity standards.

NOTE: It is very important to have the conductivity standards the same temperature as the part to be

examined. Put the standards near the inspection part before starting the calibration to make

sure they are the same temperature. Holding the probe on the standard or part for too long

can cause the probe tip to get warm and the reading to change. Make sure that the instrument

reads the correct value on the test standard before taking a reading on the part. Balance the

instrument often on the high conductivity standard and take the readings quickly.

e. Record conductivity of each box in the grid created in a spreadsheet. Refer to Appendix A, Conductivity

Table for Skin and Other Structure Example, as an accepted procedure.

6. Inspection Results

APPENDIX B: INDIRECT CONDUCTIVITY EDDY CURRENT INSPECTION

(SHEET 2 OF 3)

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Proceed to step 6.f of Work Instruction, paragraph 3.B.

APPENDIX B: INDIRECT CONDUCTIVITY EDDY CURRENT INSPECTION

(SHEET 3 OF 3)

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ALERT ALERT