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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Number: 777-25-0621 Original Issue: December 10, 2014 Revision 2: February 28, 2020 ATA System: 2510 2581 SUBJECT: EQUIPMENT/FURNISHINGS - Flight Compartment - Overhead Panel Support Structure BMS 8-39 Urethane Foam Insulation Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2014 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 1 of 88
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 2 of 88 BOEING SERVICE BULLETIN 777-25-0621
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION13
A. Effectivity13
1. Airplanes13
2. Spares Affected15
B. Concurrent Requirements15
C. Reason15
D. Description16
E. Compliance17
F. Approval19
G. Manpower20
H. Weight and Balance Changes22
I. Electrical Load Data22
J. References22
1. Existing Data:22
2. Data Supplied with this Service Bulletin:23
3. Installation Drawings Used in the Preparation of this Service Bulletin:23
K. Publications Affected23
L. Interchangeability and Intermixability of Parts24
M. Software Accomplishment Summary24
2. MATERIAL INFORMATION25
A. Material - Price and Availability25
B. Industry Support Information25
C. Parts Necessary for Each Airplane25
1. Kits/Parts25
2. Parts and Materials Supplied by the Operator27
3. Parts Modified and Reidentified27
4. Parts Removed and Not Replaced28
D. Parts Necessary to Change Spares28
E. Special Tooling - Price and Availability28
F. Special Tooling Necessary to do this Service Bulletin28
3. ACCOMPLISHMENT INSTRUCTIONS29
A. GENERAL INFORMATION29
B. WORK INSTRUCTIONS31
FIGURE 1: FLIGHT COMPARTMENT - OVERHEAD PANEL - OPEN ACCESS [Group 1, Configuration 1]
.45
FIGURE 2: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE, BMS 8-39
URETHANE FOAM INSULATION REPLACEMENT [Group 1, Configuration 1]50
FIGURE 3: FLIGHT COMPARTMENT - OVERHEAD PANEL - CLOSE ACCESS [Group 1, Configuration
1-2, 4]53
FIGURE 4: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE - REMOVAL [Group
1, Configuration 1-2, 4]58
FIGURE 5: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE - INSTALLATION
[Group 1, Configuration 1-2, 4]61
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 3 of 88 BOEING SERVICE BULLETIN 777-25-0621
FIGURE 6: FLIGHT COMPARTMENT - OVERHEAD PANEL - OPEN ACCESS [Group 1, Configuration 2,
4]64
FIGURE 7: FLIGHT COMPARTMENT - DRIPSHIELD, BMS 8-39 URETHANE FOAM INSULATION -
GENERAL VISUAL INSPECTION [Group 1, Configuration 1-2]67
FIGURE 8: FLIGHT COMPARTMENT - DRIPSHIELD, BMS 8-39 URETHANE FOAM INSULATION -
REPLACEMENT [Group 1, Configuration 1-2]69
FIGURE 9: FLIGHT COMPARTMENT - OVERHEAD PANEL - CLOSE ACCESS [Group 1, Configuration
2, 4]71
FIGURE 10: FLIGHT COMPARTMENT - OVERHEAD PANEL - MORE ACCESS [Group 1, Configuration 2,
4]74
FIGURE 11: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE, BMS 8-39 URETHANE FOAM INSULATION DETAILED INSPECTION [Group 1, Configuration 2, 4] . 77 FIGURE 12: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE, BMS 8-39
URETHANE FOAM INSULATION REPLACEMENT [Group 1, Configuration 2, 4]79
APPENDIX A: PART DEMAND INTENT82
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: OVERHEAD PANEL SUPPORT STRUCTURE BMS 8-39 URETHANE FOAM INSULATION REPLACEMENT AND GENERAL VISUAL INSPECTION OF THE DRIPSHIELD [Group 1, Configuration 1] . . . 83 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: DETAILED INSPECTION
OF THE OVERHEAD PANEL SUPPORT STRUCTURE AND GENERAL VISUAL INSPECTION OF THE DRIPSHIELD FOR BMS 8-39 URETHANE FOAM INSULATION [Group 1, Configuration
2]84
APPENDIX D: TYPICAL INSTALLATIONS OF BMS 8-39 URETHANE FOAM INSULATION INSTALLED ON
THE DRIPSHIELD86
APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 3: DETAILED INSPECTION OF THE OVERHEAD PANEL SUPPORT STRUCTURE FOR BMS 8-39 URETHANE FOAM
INSULATION [Group 1, Configuration 4]88
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 4 of 88 BOEING SERVICE BULLETIN 777-25-0621
Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Revision Transmittal SheetNumber: 777-25-0621Original Issue: December 10, 2014 Revision 2: February 28, 2020 ATA System: 2510 2581 SUBJECT: EQUIPMENT/FURNISHINGS - Flight Compartment - Overhead Panel Support Structure BMS 8-39 Urethane Foam Insulation Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2018-14-02 is related to this service bulletin.
Effects of this Revision on airplanes on which the Original Issue or Revision 1 was previously done:
ActionConditionGroup
1. Do a Detailed Inspection for BMS 8-39 urethane foam on the overhead panel support structure.
2. Do a General Visual Inspection (GVI) for BMS 8- 39 urethane foam on the dripshield.
3. Replace any BMS 8-39 urethane foam found with BMS 8-371 foam.
4. Do functional tests.
Airplanes that have accomplished the Original Issue of this service bulletin only.
1, Configuration 2
1. None.Airplanes that have accomplished Revision 1 of this service bulletin only.
1, Configuration 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 5 of 88
ActionConditionGroup
1. Do a Detailed Inspection for BMS 8-39 urethane foam on the overhead panel support structure.
2. Replace any BMS 8-39 urethane foam found with BMS 8-371 foam.
3. Do functional tests.
Airplanes that have accomplished both the Original Issue and Revision 1 of this service bulletin.
1, Configuration 4 See Paragraph 1.D., Description for more information.
REASON FOR REVISION This revision is sent to:
1. Provide alternative materials and quantities.
2. Include instructions to remove ducting to access the BMS 8-39 urethane foam on the overhead panel support structure.
3. Provide additional work requirements for airplanes that have accomplished the Original Issue of this service bulletin and may not have removed BMS 8-39 urethane foam insulation completely from the overhead panel support structure.
4. Provide additional tests to verify the functionality of equipment affected by the removal of the overhead panel support structure.
These sections were changed:
1. Summary, Background: Changed information.
2. Summary, Action: Added group/configuration applicability.
3. Summary, Compliance: Added FAA AD information.
4. Summary, Illustration: Added group/configuration applicability.
5. Paragraph 1.A., Effectivity: Added group/configuration applicability.
6. Paragraph 1.C., Reason: Background: Added reason for revision statement.
7. Paragraph 1.D., Description: Added group/configuration applicability.
8. Paragraph 1.E., Compliance: Added FAA AD information and new compliance tables.
9. Paragraph 1.F., Approval: Added AMOC paragraph.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 6 of 88 BOEING SERVICE BULLETIN 777-25-0621
10. Paragraph 1.G., Manpower: Updated manpower information.
11. Paragraph 1.J., References: Updated references.
12. Paragraph 2.A., Material - Price and Availability: Updated footnotes.
13. Paragraph 2.C.1., Kits/Parts: Changed existing part number for self-locking nut.
14. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added material dimensions and added group/configuration applicability.
15. Paragraph 3.A., General Information: Added notes for Detailed Inspection and temporary protection.
16. Paragraph 3.B., Work Instructions: Updated instructions for Group 1, Configuration 1 and 2. Created new instructions for Group 1, Configuration 3 and 4.
17. Figure 1 through 9: Added applicability.
18. Figure 1 and 3: Changed AMM reference in step 4.
19. Figure 2: Changed service bulletin number in step 4.
20. Created new Figure 10.
21. Appendix B and C: Updated information.
22. Created new Appendix E.
The data given in Information Notice 777-25-0621 IN 01 is included in this revision.
The data given in Information Notice 777-25-0621 IN 02 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY December 10, 2014Original Issue:
August 04, 2017Revision 1:
February 28, 2020Revision 2:
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Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 7 of 88 BOEING SERVICE BULLETIN 777-25-0621
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 8 of 88 BOEING SERVICE BULLETIN 777-25-0621
BLANK PAGE
Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION SummaryNumber: 777-25-0621Original Issue: December 10, 2014 Revision 2: February 28, 2020 ATA System: 2510 2581 SUBJECT: EQUIPMENT/FURNISHINGS - Flight Compartment - Overhead Panel Support Structure BMS 8-39 Urethane Foam Insulation Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS DOCUMENT IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of this service bulletin will make sure that the risk of fire in the flight compartment from aging BMS 8-39 urethane foam insulation is decreased. Degraded BMS 8-39 urethane foam insulation on the overhead panel support structure can be an unacceptable fuel source for a fire if exposed to an ignition source. If this service bulletin is not done, degraded BMS 8-39 urethane foam insulation could result in an increased risk of a fire.
BMS 8-39 flexible urethane foam insulation has self-extinguishing and physical properties that degrade with age and large parts fabricated from this material present an unacceptable fuel source. BMS 8-39 urethane foam insulation fire retardants are mixed into, but are not chemically connected with, the remaining components of the foam insulation. This condition will cause the fire retardant properties to have decreased effectiveness. The concern is hidden areas where fire cannot easily be detected and suppressed.
BMS 8-39 urethane foam insulation in the flight compartment and other areas of the airplanes was replaced in production from line number 507 and Boeing Service Bulletin 777-25-0362 was released to instruct foam insulation replacement for in-service airplanes. However, Boeing has recently found some additional BMS 8-39 urethane foam insulation on the overhead panel support structure in the flight compartment, that was not included in Boeing Service Bulletin 777-25-0362.
Since the release of the Original Issue of this service bulletin, BMS 8-39 urethane foam insulation was found on the dripshield above the overhead panel. All BMS 8-39 urethane foam insulation on the overhead panel and if installed on the dripshield, must be removed and replaced with BMS 8-371 polyvinylidene fluoride foam insulation. This service bulletin gives instructions to remove BMS 8-39 urethane foam insulation and install BMS 8-371 polyvinylidene fluoride foam insulation on the overhead panel support structure in the flight compartment.
BMS 8-371 polyvinylidene fluoride foam insulation has better fire retardant properties that stay effective with age.
Boeing Service Related Problem (SRP) 777-SRP-25-0346 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 25-14003 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 9 of 88
As a part of a service bulletin validation program, this change was completed on airplane WB509 by Service Bulletin 777-25-0621 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane WB509 is equivalent to accomplishing Revision 1 of this service bulletin. Airplane WB509 has the configuration of a Group 1, Configuration 3 airplane.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Group 1, Configuration 1:
Remove the overhead panel support structure and replace the BMS 8-39 urethane foam with BMS 8-371 foam.
Inspect for BMS 8-39 urethane foam on the dripshield and replace any found with BMS 8-371 foam. Reinstall the overhead panel support structure and do functional tests.
Group 1, Configuration 2:
Inspect for BMS 8-39 urethane foam on the overhead panel support structure and the dripshield. If any BMS 8-39 urethane foam is found, remove the overhead panel support structure. Replace any BMS 8-39 urethane foam found on the overhead panel support structure or the dripshield with BMS 8-371 foam. Reinstall the overhead panel support structure and do functional tests.
Group 1, Configuration 3:
Do functional tests.
Group 1, Configuration 4:
Inspect for BMS 8-39 urethane foam on the overhead panel support structure. If any BMS 8-39 urethane foam is found, remove the overhead panel support structure. Replace any BMS 8-39 urethane foam found on the overhead panel support structure with BMS 8-371 foam. Reinstall the overhead panel support structure and do functional tests.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 10 of 88 BOEING SERVICE BULLETIN 777-25-0621
EFFECTIVITY 777-200/200LR/300/300ER Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2018-14-02 is related to this service bulletin.
The effective date of the AD 2018-14-02 is August 13, 2018.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX A of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 2: February 28, 2020 11 of 88 BOEING SERVICE BULLETIN 777-25-0621
BOEING SERVICE BULLETIN 777-25-0621 GROUP 1, CONFIGURATION 1:
REMOVE THE OVERHEAD PANEL SUPPORT STRUCTURE AND REPLACE THE BMS 8-39 URETHANE FOAM WITH BMS 8-371 FOAM. INSPECT FOR BMS 8-39 URETHANE FOAM ON THE DRIPSHIELD AND REPLACE ANY FOUND WITH BMS 8-371 FOAM.
REINSTALL THE OVERHEAD PANEL SUPPORT STRUCTURE AND DO FUNCTIONAL TESTS.
GROUP 1, CONFIGURATION 2:
INSPECT FOR BMS 8-39 FOAM ON THE OVERHEAD PANEL SUPPORT STRUCTURE AND THE DRIPSHIELD. IF ANY BMS 8-39
FOAM IS FOUND, REMOVE THE OVERHEAD PANEL SUPPORT STRUCTURE. REPLACE ANY BMS 8-39 FOAM FOUND ON THE
OVERHEAD PANEL SUPPORT STRUCTURE OR THE DRIPSHIELD WITH BMS 8-371 FOAM. REINSTALL THE OVERHEAD PANEL SUPPORT STRUCTURE AND DO FUNCTIONAL TESTS.
FLIGHT COMPARTMENT GROUP 1, CONFIGURATION 3: DO FUNCTIONAL TESTS.
GROUP 1, CONFIGURATION 4:
INSPECT FOR BMS 8-39 FOAM ON THE OVERHEAD PANEL SUPPORT STRUCTURE. IF ANY BMS 8-39 FOAM IS FOUND, REMOVE THE OVERHEAD PANEL SUPPORT STRUCTURE.
REPLACE ANY BMS 8-39 FOAM FOUND ON THE OVERHEAD PANEL SUPPORT STRUCTURE WITH BMS 8-371 FOAM
REINSTALL THE OVERHEAD PANEL SUPPORT STRUCTURE AND DO FUNCTIONAL TESTS.
OVERHEAD PANEL SUPPORT STRUCTURE 2376182 (WIRE BUNDLES AND MODULES NOT SHOWN) Original Issue: December 10, 2014 Revision 2: February 28, 2020 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 777-25-0621 Work - See page 1 for details. 12 of 88