Date: 201312
Location: ZZZ.Airport, US
Aircraft: B777 Undifferentiated or Other Model
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Other N/A
Aircraft component: Instrument and Control Panels
Reporter organization: Air Carrier
Reporter function: Captain
Human factors: Communication Breakdown; Training / Qualification
Anomaly: Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Maintenance; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Flight Crew
When detected: In-flight
Result: General Maintenance Action
Contributing factors: Incorrect / Not Installed / Unavailable Part; Procedure; Manuals; Chart Or Publication
Primary problem: Ambiguous

Narrative: The safety issue with the event was I had trouble breaking safety wire and lifting plactic cover. Safety wire appeared improperly twisted on both sides plastic cap which increased the wire size on the breakaway side preventing a quick disconnect of the drive. Because of the double twist holding the plastic cover down could not break wire; loosened enough to get finger under cap to disconnect drive according to ECL procedure. It appeared the other drive cap was safety wired the same way; could twist under the cap. Other plastic caps looked to be wired in the same way. Might warrant random inspections to see if capped switches are improperly safety wired preventing a quicker disconnect. The safety wire should prevent a quick inadvertant improper disconnect; but the way this was wired; I could not break the wire to open the cap and disconnect the switch in accordance with the procedure.I have reviewed the action items below; but in the reports I did not see the Bulletin attached to the response report. Recently I have been looking at the aircraft I fly. Most recently the one attached to this report; and the issue is still there. I am seeing a thicker silver gauge safety wire; not copper; and double twists on both sides of the plastic drive cover eyelet; presenting the same issue that I faced when I could not break the safety wire and open the drive cover in a timely manner; and overall could not break it at all only open it enough over 5-7 minutes to get a partial finger on the switch to slightly touch it enough to trip the generator drive.I would like to know if a bulletin was created as it appears below; what was the corrective action to get this implemented on the B777 fleet if not inspections on other fleets. Action Item Response:  Typically .020 inch copper wire is twisted one strand to hold selector shields in place and can easily be broken when the shield must be opened to gain access to the selector. This is the design; to break away in an emergency. The language in the AMM is vague and does not directly address the maintenance practice. The installation of breakaway wire is covered in normal training of technicians though; like common basic knowledge. If this is being found as a problem then an bulletin should be developed and briefed to the technicians.Action Item Response:  I am still working on the process. The language for Safetying General resides initially in the EDOCS General Processes Manual; GPM; as GNMM 1-00-12-001. I'll let you know when I have submitted it.




Synopsis: A B777 Captain repeatedly requested that the Generator Drive Disconnect switch safety cover breakaway wire be copper which is easily broken to permit drive disconnect. He is currently seeing thick silver wire; very difficult to break.