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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Number: 777-25-0482 Original Issue: February 24, 2011 Revision 1: February 21, 2012 ATA System: 2521 5313 SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel - Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support Structure 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.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2011 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 1 of 61
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 2 of 61 BOEING SERVICE BULLETIN 777-25-0482
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 3 E. Compliance .............................................. 1 4 F. Approval ............................................... 1 4 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 6 J. References .............................................. 1 6
1. Existing Data .......................................... 1 6
2. Data supplied with this Service Bulletin ............................ 1 6
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 7
2. MATERIAL INFORMATION ........................................ 1 9 A. Material - Price and Availability ................................... 1 9 B. Industry Support Information .................................... 2 0 C. Parts Necessary For Each Airplane ................................. 2 0
1. Kits/Parts ............................................ 2 0
2. Parts and Materials Supplied by the Operator ........................ 2 4
3. Parts Modified and Reidentified ................................ 2 4
4. Parts Removed and Not Replaced .............................. 2 4 D. Parts Necessary to Change Spares ................................. 2 5 E. Special Tooling - Price and Availability ............................... 2 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 8 FIGURE 1: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL .......... 3 0 FIGURE 2: LEFT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION ....... 3 3 FIGURE 3: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 1] ......... 4 0 FIGURE 4: LEFT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 2] ......... 4 3 FIGURE 5: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE REMOVAL ......... 4 6 FIGURE 6: RIGHT SIDE LOWERED CEILING SUPPORT STRUCTURE INSTALLATION ....... 4 9 FIGURE 7: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 1] ......... 5 6 FIGURE 8: RIGHT SIDE TIE ROD AND ATTACH FITTING INSTALLATION [Group 2] ......... 5 9
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Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 3 of 61 BOEING SERVICE BULLETIN 777-25-0482
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Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 4 of 61 BOEING SERVICE BULLETIN 777-25-0482
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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Revision Transmittal SheetNumber: 777-25-0482Original Issue: February 24, 2011 Revision 1: February 21, 2012 ATA System: 2521 5313 SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel - Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support Structure This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION This revision is sent to incorporate changes found during the validation of this service bulletin.
As a part of a service bulletin validation program, this change was completed on airplane WD796 by Service Bulletin 777-25-0482 Original Issue before the release of Revision 01 of this service bulletin. The change completed on airplane WD796 by Service Bulletin 777-25-0482 Original Issue is equivalent to the release of Revision 01of this service bulletin. Airplane WD796 has the configuration of a Group 2 airplane.
These sections are changed:
1. Summary - Background - Validation statement added.
2. Summary - Manpower - Time for access and restoring access added.
3. Paragraph 1.C., Reason - Validation statement added.
4. Paragraph 1.G., Manpower - Time for access and restoring access added.
5. Paragraph 1.J.1, Existing Data - Standard Wiring Practices Manual (SWPM) and 777 Aircraft Maintenance Manual (AMM) references added.
6. Paragraph 2.C.1., Kits/Parts - Changed part number for 1 bolt.
7. Paragraph 3.A., General Information - Current general notes added.
8. Paragraph 3.B., Work Instructions - Instruction for Access and Restoring Access added.
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Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 5 of 61
9. Figures 3, and 4:
a. Changed part number for 1 bolt in Step Table.
b. Added information to relocate ground if required.
10. Figure 6:
a. Instruction is added to the Step Table regarding a possibly blocked ceiling panel insert.
11. Figures 7, and 8:
a. Changed part number for 1 bolt in Step Table.
b. Added information to relocate ground if required.
c. In Step 1 and Step 3 of Step Tables, changed More Data for Bushing to Far Side from Near Side.
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 February 24, 2011Original Issue:
February 21, 2012Revision 1:
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Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 6 of 61 BOEING SERVICE BULLETIN 777-25-0482
Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION SummaryNumber: 777-25-0482Original Issue: February 24, 2011 Revision 1: February 21, 2012 ATA System: 2521 5313 SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel - Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support Structure BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin provides instructions and a kit of parts to strengthen the structure which supports the forward lowered ceiling panels for some 777 model airplanes. If you do not do this service bulletin and a 9G forward load condition occurs, the forward lowered ceiling panels and support structure could become dislodged and injure personnel or interfere with emergency evacuation.
The possibility of a 9G forward load when landing is small. No operator has reported dislodged ceiling panels from such a load. The support structure was found to be under strength during the design review of a new section 41 lowered ceiling configuration.
Only airplanes incorporating the Overhead Space Utilization (OSU) option would have under strength structure.
The OSU option includes overhead stowage boxes in the ceiling inboard of left and right door 1. The under strength area supports lowered ceiling panels immediately aft of these overhead stowage boxes. This service bulletin provides for increasing strength by installing thicker structure and an additional load path on each side.
Boeing Service Related Problem (SRP) 777-SRP-25-0289 is related to this service bulletin. This SRP is described in Fleet Team Digest Article 777 FTD 25-09010.
As a part of a service bulletin validation program, this change was completed on airplane WD796 by Service Bulletin 777-25-0482 Original Issue before the release of Revision 01 of this service bulletin. The change completed on airplane WD796 by Service Bulletin 777-25-0482 Original Issue is equivalent to the release of Revision 01of this service bulletin. Airplane WD796 has the configuration of a Group 2 airplane.
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Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 7 of 61
ACTION (PRR 62224) In the forward lowered ceiling area, remove the forward overhead stowage bin modules and adjacent aft ceiling panel to expose the support structure for the lowered ceiling panels in section 41. Disconnect a tie rod and remove two C-channels and related brackets from both left and right side ceiling panel support structure. Install new support channel assemblies composed of C-channels having thicker cross sections. The new assemblies also include fittings for attaching two tie rods in place of fittings for attaching one tie rod. Add a new load path on each side by adding new fittings to the rails above the changed structure and adding new tie rods between the fittings on new support structure and the new fittings on the rails above. If a ground stud occupies a hole required for the new fitting, relocate the ground to an adjacent hole. Reconnect the existing tie rods.
EFFECTIVITY 777-200, -200LR and -300ER airplanes incorporating Overhead Space Utilization (OSU) option. 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 changes given in this service bulletin be done within 5 years after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of January 16, 2008. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER Elapsed HoursTotal Task HoursAirplanes
12.0022.50All
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 8 of 61 BOEING SERVICE BULLETIN 777-25-0482
BOEING SERVICE BULLETIN 777-25-0482 STA 248 STA 445 O
INSTALL ADDITIONAL TIE ROD
ATTACH FITTING ON UPPER RAIL
INSTALL ADDITIONAL TIE ROD
REMOVE T-MEMBER WITH SINGLE TIE ROD ATTACH FITTING. INSTALL
STRONGER T-MEMBER WITH DOUBLE TIE ROD ATTACH FITTING.
(LEFT SIDE SHOWN, RIGHT SIDE SIMILAR) 1974859 Original Issue: February 24, 2011 Revision 1: February 21, 2012 777-25-0482
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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Number: 777-25-0482 Original Issue: February 24, 2011 Revision 1: February 21, 2012 ATA System: 2521 5313 SUBJECT: EQUIPMENT/FURNISHINGS - Passenger Compartment - Lowered Ceiling Panel - Section 41 - Overhead Space Utilization (OSU) Ceiling - Change To Strengthen Support Structure BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
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. An equivalent change is on subsequent production airplanes. Refer to PRR 62224 for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 777-200 and 777-300ER Airplanes with Overhead Space Utilization (OSU) Option and line number from 423 through 494.
-1 777-200, 777-200LR, and 777-300ER Airplanes with Overhead Space Utilization (OSU) Option and line number from 497 through 751.
-2 Airplane Models:
777-200, 777-200LR, 777-300ER GroupVariable Number 2WC221 - WC222 1WC301 - WC306 2WC307 - WC308 1WC381 - WC388
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GroupVariable Number 2WC389 - WC395 2WC486 - WC493 2WC506 - WC508 2WC531 - WC536 2WC546 - WC548 2WC556 2WC566 - WC567 2WD001 - WD002 2WD011 - WD015 2WD031 - WD036 2WD066 - WD067 1WD501 - WD502 2WD503 - WD510 1WD521 - WD526 2WD527 - WD539 2WD546 - WD552 1WD561 2WD562 - WD573 2WD581 - WD591 2WD606 - WD609 2WD621 - WD632 2WD651 - WD661 2WD671 - WD675 2WD741 - WD750 2WD761 - WD770 2WD786 - WD788 2WD796 - WD804 2WD826 - WD830 2WD871 - WD875 2WD911 - WD912 2WD936 - WD939 2WD966
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Original Issue: February 24, 2011 777-25-0482Revision 1: February 21, 2012 12 of 61 BOEING SERVICE BULLETIN 777-25-0482