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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Number: 777-25-0621 Original Issue: December 10, 2014 Revision 1: August 04, 2017 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Unpublished Work.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 1: August 04, 2017 1 of 65
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 1: August 04, 2017 2 of 65 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 Requirements16
C. Reason16
D. Description17
E. Compliance17
F. Approval19
G. Manpower19
H. Weight and Balance Changes20
I. Electrical Load Data20
J. References20
1. Existing Data:20
2. Data Supplied with this Service Bulletin:21
3. Installation Drawings Used in the Preparation of this Service Bulletin:21
K. Publications Affected21
L. Interchangeability and Intermixability of Parts21
M. Software Accomplishment Summary21
2. MATERIAL INFORMATION23
A. Material - Price and Availability23
B. Industry Support Information24
C. Parts Necessary for Each Airplane24
1. Kits/Parts24
2. Parts and Materials Supplied by the Operator25
3. Parts Modified and Reidentified25
4. Parts Removed and Not Replaced26
D. Parts Necessary to Change Spares26
E. Special Tooling - Price and Availability26
F. Special Tooling Necessary to do this Service Bulletin26
3. ACCOMPLISHMENT INSTRUCTIONS27
A. GENERAL INFORMATION27
B. WORK INSTRUCTIONS28
FIGURE 1: FLIGHT COMPARTMENT - OVERHEAD PANEL - OPEN ACCESS32
FIGURE 2: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE, BMS 8-39
URETHANE FOAM INSULATION REPLACEMENT [Group 1, Configuration 1]37
FIGURE 3: FLIGHT COMPARTMENT - OVERHEAD PANEL - CLOSE ACCESS40
FIGURE 4: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE - REMOVAL . 45 FIGURE 5: FLIGHT COMPARTMENT - OVERHEAD PANEL SUPPORT STRUCTURE - INSTALLATION
.48
FIGURE 6: FLIGHT COMPARTMENT - OVERHEAD PANEL - OPEN ACCESS [Group 1, Configuration 2]
.51
FIGURE 7: FLIGHT COMPARTMENT - DRIPSHIELD, BMS 8-39 URETHANE FOAM INSULATION -
GENERAL VISUAL INSPECTION54
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 1: August 04, 2017 3 of 65 BOEING SERVICE BULLETIN 777-25-0621
FIGURE 8: FLIGHT COMPARTMENT - DRIPSHIELD, BMS 8-39 URETHANE FOAM INSULATION -
REPLACEMENT56
FIGURE 9: FLIGHT COMPARTMENT - OVERHEAD PANEL - CLOSE ACCESS [Group 1, Configuration
2]58
APPENDIX A: PART DEMAND INTENT61
APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: OVERHEAD PANEL SUPPORT STRUCTURE BMS 3-89 URETHANE FOAM INSULATION INSPECTION AND
REPLACEMENT [Group 1, Configuration 1]62
APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 2: GENERAL VISUAL
INSPECTION OF THE DRIPSHIELD, ABOVE THE OVERHEAD PANEL SUPPORT
STRUCTURE, FOR BMS 8-39 FOAM INSULATION [Group 1, Configuration 2]63
APPENDIX D: TYPICAL INSTALLATIONS OF BMS 8-39 URETHANE FOAM INSULATION INSTALLED ON
THE DRIPSHIELD64
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 1: August 04, 2017 4 of 65 BOEING SERVICE BULLETIN 777-25-0621
Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Revision Transmittal SheetNumber: 777-25-0621Original Issue: December 10, 2014 Revision 1: August 04, 2017 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 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.
Effects of this Revision on airplanes on which the Original issue was previously done:
ActionConditionGroup Do a General Visual Inspection (GVI) for BMS 8-39 urethane foam insulation on the dripshield, above the overhead panel support structure. If found replace with BMS 8-371 polyvinylidene fluoride foam insulation.
Airplanes that have replaced BMS 8-39 urethane foam insulation with BMS 8-371 polyvinylidene fluoride foam insulation on the overhead panel support structure.
REASON FOR REVISION This revision is sent to incorporate results from the service bulletin validation. The validation found that foam insulation replacement could not be done without the removal of the overhead panel support structure from the flight compartment ceiling. Removal and installation instructions are added to this service bulletin. This revision also adds work instructions which includes tests of modules and a General Visual Inspection (GVI) of the dripshield for BMS 8-39 urethane foam insulation.
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 by Service Bulletin 777-25-0621 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WB509 has the configuration of a Group 1 airplane.
These sections were changed:
1. Summary, Background: Changed to add service bulletin validation information. Summary Evaluation Table changed to add AD related.
2. Summary, Action: Added applicability. Changed and added instructions.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 1: August 04, 2017 5 of 65
3. Summary, Compliance: Added possible FAA AD activity for this service bulletin.
4. Summary, Illustration: Added information.
5. Paragraph 1.C., Reason: Added validation information and Revision 1 information.
6. Paragraph 1.D., Description: Added applicability. Changed and added instructions. Added Revision 1 information.
7. Paragraph 1.E., Compliance: Added information and tables.
8. Paragraph 1.G., Manpower: Added applicability. Changed to show information for Part 1, 2, 3 and 4.
9. Paragraph 1.J.1., Existing Data: Added 777 Aircraft Maintenance Manual (AMM), Standard Overhaul Practices Manual (SOPM) and Standard Wiring Practices Manual (SWPM) references.
10. Paragraph 1.J.3., Installation Drawings Used in Preparation of this Service Bulletin: Added drawing.
11. Paragraph 1.K.1., Publications: Added Illustrated Parts Catalog (IPC) references. Added affected section of the Aircraft Maintenance Manual (AMM).
12. Paragraph 2.A., Material - Price and Availability: Added applicability. Changed ROLT, Pricing and added self-locking nut part number BACN11AG4.
13. Paragraph 2.C.1., Kits/Parts: Added applicability. Added part.
14. Paragraph 2.C.2., Parts and Materials Supplied by the Operator: Added material.
15. Paragraph 2.C.3., Parts Modified and Reidentified: Added applicability. Changed information.
16. Paragraph 3.A., General Information: Added notes.
17. Paragraph 3.B., Work Instructions: Changed to put instructions into Parts 1, 2, 3 and 4.
18. Figure 1: Changed figure title. Changed module titles and added AMM reference. Added instructions to remove modules and to disconnect electrical connectors and wiring.
19. Figure 2: Changed figure title and added applicability. Changed illustration. Added more instruction to better describe foam insulation bonding procedure. Changed step table and footnote (c).
20. Figure 3: Changed figure title. Changed module title and added AMM reference. Added instructions to add modules and to connect electrical connectors and wiring.
21. Figure 4 thru Figure 9: Added New Figures
22. Appendix B, Appendix C and Appendix D: Added New Appendices.
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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 1: August 04, 2017 6 of 65 BOEING SERVICE BULLETIN 777-25-0621
REVISION HISTORY December 10, 2014Original Issue:
August 04, 2017Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 1: August 04, 2017 7 of 65 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 1: August 04, 2017 8 of 65 BOEING SERVICE BULLETIN 777-25-0621
BLANK PAGE
Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION SummaryNumber: 777-25-0621Original Issue: December 10, 2014 Revision 1: August 04, 2017 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 1: August 04, 2017 9 of 65
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 by Service Bulletin 777-25-0621 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane WB509 has the configuration of a Group 1 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:
Replace BMS 8-39 urethane foam insulation with BMS 8-371 polyvinylidene fluoride foam insulation on the overhead panel support structure in the flight compartment. Do a General Visual Inspection of the dripshield, above the overhead panel support structure, for BMS 8-39 urethane foam insulation and do corrective actions.
Group 1, Configuration 2:
Do a General Visual Inspection of the dripshield, above the overhead panel support structure, for BMS 8-39 urethane foam insulation and do corrective actions.
Do the tests of the modules in the overhead panel.
EFFECTIVITY 777-200/200LR/300/300ER 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.
Refer to Paragraph 1.E., Compliance.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 10, 2014 777-25-0621Revision 1: August 04, 2017 10 of 65 BOEING SERVICE BULLETIN 777-25-0621
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 1: August 04, 2017 11 of 65 BOEING SERVICE BULLETIN 777-25-0621
BOEING SERVICE BULLETIN 777-25-0621 GROUP 1, CONFIGURATION 1:
REPLACE BMS 8-39 URETHANE FOAM INSULATION WITH BMS 8-371 POLYVINYLDENE FLUORIDE
FOAM INSULATION ON THE OVERHEAD PANEL SUPPORT STRUCTURE.
DO A GENERAL VISUAL INSPECTION OF THE
DRIPSHIELD, ABOVE THE OVERHEAD PANEL SUPPORT STRUCTURE, FOR BMS 8-39 URETHANE
FOAM INSULATION AND DO CORRECTIVE ACTIONS. TEST MODULES.
GROUP 1, CONFIGURATION 2:
DO A GENERAL VISUAL INSPECTION OF THE
DRIPSHIELD, ABOVE THE OVERHEAD PANEL SUPPORT STRUCTURE, FOR BMS 8-39 URETHANE
FOAM INSULATION AND DO CORRECTIVE FLIGHT COMPARTMENT ACTIONS. TEST MODULES.
OVERHEAD PANEL SUPPORT STRUCTURE 2376182 (WIRE BUNDLES AND MODULES NOT SHOWN) Original Issue: December 10, 2014 Revision 1: August 04, 2017 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 777-25-0621 Work - See page 1 for details. 12 of 65