Alert Service Bulletin B787-81205-SB540004-00 PYLON - General - Pylon

Structures - Fuel Leak Path Seal Installation

Publication: B787-81205-SB540004-00 Issue 002, 03 Dec 2015

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2014 Boeing. Unpublished Work. All rights reserved.

Treatment of this data module and its content is governed by contract with Boeing. Rights to use this data module 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.

EXPORT CONTROLLED

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.

ECCN: 9E991

The applicability information below is referenced at the lower left of each page to indicate the page applicability.

These references are valid for this print copy only.

PM Applicability (Publication Module applicability)

787-8 Airplanes. Refer to Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1., Effectivity for the

list of affected airplanes.

TITLE PAGE B787-81205-SB540004-00

Issue 002, 03 Dec 2015

Page 1 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

3.0

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Table of Contents

Page

Revision Transmittal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

A. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

9. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Installation Requirement Modules Used in the Preparation of this Service Bulletin: . . . 23

11. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

12. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 24

13. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . 40

C. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

D. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 41

ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Task 1 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group

1: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Task 2 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION

[Group 1: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

TABLE OF CONTENTS B787-81205-SB540004-00

Issue 002, 03 Dec 2015

Page 2 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Task 3 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group

2: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Task 4 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION

[Group 2: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Task 5 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]. . . 109

Task 6 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]. . 125

Task 7 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]. . . 141

Task 8 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]. . 156

Task 9 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group

5: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Task 10 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION

[Group 5: ]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Task 11 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]. . 197

Task 12 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]. . 210

Appendix A – INPUT SURVEY [Group 1-6:]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

TABLE OF CONTENTS B787-81205-SB540004-00

Issue 002, 03 Dec 2015

Page 3 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

List of Illustrations

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

Description

Group 1-6:

Table 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00

ICN Used In

ICN-B787-A-000061-A-81205-07439-A-01-1 B787-A-54-00-0004-00A-931C-D Issue 003

ICN-B787-A-000061-A-81205-07440-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07441-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07442-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07443-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07444-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07445-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07446-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07447-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07448-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07449-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07450-A-01-1 B787-A-54-00-0004-01A-933B-D Issue 003

B787-A-54-00-0004-01A-933B-D Issue 003

B787-A-54-00-0004-02A-933B-D Issue 003

B787-A-54-00-0004-03A-933B-D Issue 003

B787-A-54-00-0004-04A-933B-D Issue 003

B787-A-54-00-0004-05A-933B-D Issue 003

B787-A-54-00-0004-06A-933B-D Issue 003

B787-A-54-00-0004-07A-933B-D Issue 003

B787-A-54-00-0004-08A-933B-D Issue 003

B787-A-54-00-0004-09A-933B-D Issue 003

B787-A-54-00-0004-10A-933B-D Issue 003

B787-A-54-00-0004-11A-933B-D Issue 003

B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07451-A-01-1

Applicable To: B787-A-54-00-0004-00A-00AA-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 4 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00

ICN Used In

ICN-B787-A-000061-A-81205-07452-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07453-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07454-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07455-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07456-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07457-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07458-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07459-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07460-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07461-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07462-A-01-1 B787-A-54-00-0004-02A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07463-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07464-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07465-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07466-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07467-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07468-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07469-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07470-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07471-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07472-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07473-A-01-1 B787-A-54-00-0004-03A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07474-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07475-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07476-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07477-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07478-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07479-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07480-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07481-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

Applicable To: B787-A-54-00-0004-00A-00AA-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 5 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00

ICN Used In

ICN-B787-A-000061-A-81205-07482-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07483-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07484-A-01-1 B787-A-54-00-0004-04A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07485-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07486-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07487-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07488-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07489-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07490-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07491-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07492-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07493-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07494-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07495-A-01-1 B787-A-54-00-0004-05A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07496-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07497-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07498-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07499-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07500-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07501-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07502-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07503-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07504-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07505-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07506-A-01-1 B787-A-54-00-0004-06A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07507-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07508-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07509-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07510-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07511-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

Applicable To: B787-A-54-00-0004-00A-00AA-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 6 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00

ICN Used In

ICN-B787-A-000061-A-81205-07512-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07513-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07514-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07515-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07516-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07517-A-01-1 B787-A-54-00-0004-07A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07518-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07519-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07520-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07521-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07522-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07523-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07524-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07525-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07526-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07527-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07528-A-01-1 B787-A-54-00-0004-08A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07529-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07530-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07531-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07532-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07533-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07534-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07535-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07536-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07537-A-01-1 B787-A-54-00-0004-09A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07538-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07539-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07540-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07541-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

Applicable To: B787-A-54-00-0004-00A-00AA-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 7 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00

ICN Used In

ICN-B787-A-000061-A-81205-07542-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07543-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07544-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07545-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07546-A-01-1 B787-A-54-00-0004-10A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07547-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07548-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07549-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07550-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07551-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07552-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07553-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07554-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07555-A-01-1 B787-A-54-00-0004-11A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07556-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07557-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07558-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07559-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07560-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07561-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07562-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-11000-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07564-A-01-1 B787-A-54-00-0004-12A-933B-D Issue 003

ICN-B787-A-000061-A-81205-07008-A-01-1 B787-A-54-00-0004-0AA-931D-D Issue 003

Applicable To: B787-A-54-00-0004-00A-00AA-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 8 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

List of Effective Data Modules

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

Description

Group 1-6:

Table 1 List of Effective Data Modules - Alert Service Bulletin B787-81205-SB540004-00

Data Module – Information Name Issue Issue Status Issue Date

B787-A-54-00-0004-00A-00AA-D – List of Illustrations 003 Changed 2015-12-03

B787-A-54-00-0004-00A-00SA-D – List of Effective Data Modules 003 Changed 2015-12-03

B787-A-54-00-0004-00A-931B-D – Revision Transmittal Information 001 New 2015-12-03

B787-A-54-00-0004-00A-931C-D – Summary 003 Changed 2015-12-03

B787-A-54-00-0004-00A-932A-D – PLANNING INFORMATION 003 Changed 2015-12-03

B787-A-54-00-0004-00A-934A-D – MATERIAL INFORMATION 003 Changed 2015-12-03

B787-A-54-00-0004-00A-933A-D – ACCOMPLISHMENT INSTRUCTIONS 003 Changed 2015-12-03

B787-A-54-00-0004-01A-933B-D – Task 1 – LEFT ROLLS ROYCE ENGINE 003 Changed 2015-12-03

INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ]

B787-A-54-00-0004-02A-933B-D – Task 2 – RIGHT ROLLS ROYCE EN- 003 Changed 2015-12-03

GINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group

1: ]

B787-A-54-00-0004-03A-933B-D – Task 3 – LEFT ROLLS ROYCE ENGINE 003 Changed 2015-12-03

INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ]

B787-A-54-00-0004-04A-933B-D – Task 4 – RIGHT ROLLS ROYCE EN- 003 Changed 2015-12-03

GINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group

2: ]

B787-A-54-00-0004-05A-933B-D – Task 5 – LEFT GE ENGINE INBOARD 003 Changed 2015-12-03

AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]

B787-A-54-00-0004-06A-933B-D – Task 6 – RIGHT GE ENGINE INBOARD 003 Changed 2015-12-03

AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]

B787-A-54-00-0004-07A-933B-D – Task 7 – LEFT GE ENGINE INBOARD 003 Changed 2015-12-03

AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]

Applicable To: B787-A-54-00-0004-00A-00SA-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 9 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 List of Effective Data Modules - Alert Service Bulletin B787-81205-SB540004-00

Data Module – Information Name Issue Issue Status Issue Date

B787-A-54-00-0004-08A-933B-D – Task 8 – RIGHT GE ENGINE INBOARD 003 Changed 2015-12-03

AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]

B787-A-54-00-0004-09A-933B-D – Task 9 – LEFT ROLLS ROYCE ENGINE 003 Changed 2015-12-03

INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ]

B787-A-54-00-0004-10A-933B-D – Task 10 – RIGHT ROLLS ROYCE 003 Changed 2015-12-03

ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group

5: ]

B787-A-54-00-0004-11A-933B-D – Task 11 – LEFT GE ENGINE INBOARD 003 Changed 2015-12-03

AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]

B787-A-54-00-0004-12A-933B-D – Task 12 – RIGHT GE ENGINE IN- 003 Changed 2015-12-03

BOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]

B787-A-54-00-0004-0AA-931D-D – Appendix A – INPUT SURVEY [Group 003 Changed 2015-12-03

1-6:]

Applicable To: B787-A-54-00-0004-00A-00SA-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 10 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Revision Transmittal Information

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SB B787-A-54-00-0004-00A-932A-D Issue 003, Airplanes

Paragraph 1.A.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Compliance

Paragraph 5.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Material - Price and Availability

Paragraph 1.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Kits/Parts

Paragraph 3.A.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Parts and Materials Supplied by the Operator

Paragraph 3.B.

Alert Service Bulletin

B787-81205-SB540004-00 – Task 1 – LEFT ROLLS

SB B787-A-54-00-0004-01A-933B-D Issue 003

ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 1: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 2 – RIGHT ROLLS

SB B787-A-54-00-0004-02A-933B-D Issue 003

ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 1: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 12 – RIGHT GE

SB B787-A-54-00-0004-12A-933B-D Issue 003

ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 6: ]

Description

Group 1-6:

This revision includes all pages of the service bulletin.

Applicable To: B787-A-54-00-0004-00A-931B-D

Model 787 Issue 001, 03 Dec 2015

See Applicability of this data module

Page 11 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD is related to this

service bulletin.

Effects of this revision on Airplanes on which Issue 001 was previously done:

None

2. REASON FOR REVISION

This issue is sent to remove airplanes ZD001-ZD009 and ZA151 from the list of airplanes affected by this

service bulletin. These airplanes, which are affected by the Issue 001 of this service bulletin, will receive

the intent of the change contained in this service bulletin in production.

In addition, this issue clarifies instructions as a result of feedback reported by operators after incorporation

of the Issue 001 of this service bulletin on their fleet.

These sections were changed:

1. Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1.A., Airplanes - Removed airplanes

ZD001-ZD009 and ZA151 from the list of airplanes affected by this service bulletin.

2. Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 5., Compliance - Added reference of

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD to the compliance section of this service bulletin.

3. Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 1., Material - Price and Availability - Updated the Price and Availability data for the Top Kits.

4. Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 3.A., Kits/Parts - Added Washer

NAS1149V0363M to the list of parts required for this change and clarified the name of all Sub Kits.

5. Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 3.B., Parts and Materials Supplied by

the Operator - Added new footnote for BMS 1-68 Silicone Foam Rubber Sealant to direct operators to

the task table for more information on its usage.

6. Data Module Task 1, SB B787-A-54-00-0004-01A-933B-D - Re-Sequenced the numbers of the footnotes

to match correct steps in Task table.

7. Data Module Task 2, SB B787-A-54-00-0004-02A-933B-D - Re-Sequenced the numbers of the footnotes

and the reference in the More Data Column to match correct steps in Task table.

8. Data Module Task 12, SB B787-A-54-00-0004-12A-933B-D - Corrected an error with a circle note in

figure 8 of Task 12. Circle Note 18 called out in the SB is an error and should be Circle Note 17

Change marks are added, except in Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1.A.,

Airplanes and format changes, to show the location of all content changes.

3. REVISION HISTORY

Table 1 

Issue 1: October 24, 2014

Issue 2: December 03, 2015

Applicable To: B787-A-54-00-0004-00A-931B-D

Model 787 End of data module Issue 001, 03 Dec 2015

See Applicability of this data module

Page 12 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Summary

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SB B787-A-54-00-0004-00A-932A-D Issue 003, Spares Affected

Paragraph 1.B.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Compliance

Paragraph 5.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Weight and Balance Changes

Paragraph 8.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Electrical Load Data

Paragraph 9.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Publications Affected

Paragraph 11.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Kits/Parts

Paragraph 3.A.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Parts and Materials Supplied by the Operator

Paragraph 3.B.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Special Tooling Necessary to do this Service Bulletin

Paragraph 6.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Effectivity

Paragraph 1.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Industry Support Information

Paragraph 2.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Manpower

Paragraph 7.

SB B787-A-54-00-0004-00A-934A-D Issue 003, Material - Price and Availability

Paragraph 1.

Applicable To: B787-A-54-00-0004-00A-931C-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 13 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Description

Group 1-6:

1. CONCURRENT REQUIREMENTS

None.

2. BACKGROUND

This Service Bulletin gives instructions to install a Seal Dam at the inboard and outboard corners of the aft

pylon compartment. An earlier failure on a flexible coupling installed in the leading edge led to a leakage of

fuel into this cavity. If the change given in this service bulletin is not accomplished, an un-intended drain

path would exist which could result in fuel leaking onto the hot exhaust portion of an engine and a consequent

fire.

During operations, one operator discovered fuel leaking onto the hot exhaust portion of the engine. The fuel

leakage was as a result of a failure of a flexible coupling installation in the wing leading edge. During an investigation, it was determined that the pylon to wing interface design did not address drain paths for potential

low flow leakage rates. This caused the un-intended leak path from the leading edge through the pylons

and onto the hot exhaust part of the engines.

Boeing Service Related Problem (SRP) 787-SRP-54-0144 is related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane ZA117 by Service

Bulletin 787-54A0004 VC 1 before Issue 001 of this service bulletin. The change completed on airplane

ZA117 by Service Bulletin 787-54A0004 VC 1 is equivalent to Issue 001 of this service bulletin. Airplane

ZA117 has the configuration of a Group 2 airplane.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

Table 1 

Planning Data Affected Data Module Reference

Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 1.B., Spares AffectedSpares Affected No

Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 5., ComplianceAD Related Yes

Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 8., Weight and Balance ChangesWeight and Balance Changed Yes

Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 9., Electrical Load DataElectrical Load Changed No

Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 11., Publications AffectedPublications Affected Yes

Data Module SB B787-A-54-00-0004-00A-932AD, Paragraph 11., Publications AffectedAirplane Flight Operations Affected (Flight Crew No

Operations Manual and/or FAA Approved Airplane Flight Manual)

Data Module SB B787-A-54-00-0004-00A-934AD, Paragraph 3.A., Kits/PartsKits/Parts Required Yes

Applicable To: B787-A-54-00-0004-00A-931C-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 14 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Planning Data Affected Data Module Reference

Data Module SB B787-A-54-00-0004-00A-934AD, Paragraph 3.B., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material Yes

Data Module SB B787-A-54-00-0004-00A-934AD, Paragraph 6., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

3. ACTION

(CN-AA39164L)

Remove the left and right inboard and outboard pylon underwing panels and install new Seal Dams in the

inboard and outboard corners of the Aft Pylon frame. Install the left and right inboard and outboard underwing

panels.

4. EFFECTIVITY

787-8 Airplanes. Refer to Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 1., Effectivity for

the list of affected airplanes.

5. COMPLIANCE

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD is related to this

service bulletin.

Boeing recommends that the change given in this service bulletin be done within 60 months after the Issue

001 date of this service bulletin.

6. INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are available for airplanes in warranty as of December 20, 2012. Please refer to

Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 2., Industry Support Information. The warranty

remedies will expire eight years from the original release date of this service bulletin.

7. MANPOWER

Refer to Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 7., Manpower.

8. MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

Refer to Data Module SB B787-A-54-00-0004-00A-934A-D, Paragraph 1., Material - Price and Availability.

Operators are encouraged to complete the survey provided in the Appendix of this service bulletin to help

Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Applicable To: B787-A-54-00-0004-00A-931C-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 15 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07439-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-00A-931C-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 16 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

PLANNING INFORMATION

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN PARAGRAPH 1., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED

Alert:

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

HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

References

Reference Title

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

SOPM 20-50-01 BOLT AND NUT INSTALLATION

SOPM 20-50-12 APPLICATION OF ADHESIVES

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

SOPM 20-50-19 GENERAL SEALING

SWPM 20-10-11 Standard Wiring Practices Manual

SWPM 20-10-12 Standard Wiring Practices Manual

SWPM 20-10-19 Standard Wiring Practices Manual

Description

Group 1-6:

1. Effectivity

A. Airplanes

This service bulletin is applicable to 787-8 Airplanes, line numbers 6-125, 127-132, 134-138,140-145,

147-168, 170-180, 182-196. in 6 Group(s). The Variable Numbers and Group information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to

CN-AA39164 for data about this change.

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 17 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

GROUP CONFIGURATION DESCRIPTION

787 Airplanes with Rolls Royce Engine that have a non trimmed one

piece Bulb Seal Retainer configuration.

1 -

787 Airplanes with Rolls Royce Engine that have a non trimmed two

piece Bulb Seal Retainer configuration.

2 -

787 Airplanes with GE Engine that have a non trimmed one piece

Bulb Seal Retainer configuration.

3 -

787 Airplanes with GE Engine that have a non trimmed two piece Bulb

Seal Retainer configuration.

4 -

787 Airplanes with Rolls Royce Engine that have a trimmed Bulb Seal

Retainer configuration.

5 -

787 Airplanes with GE Engine that have a trimmed Bulb Seal Retainer

configuration.

6 -

Airplane Models: 787-8

Table 2 

Variable Number Group

ZA006 3

ZA100-ZA103 1

ZA104-ZA105 2

ZA116-ZA123 2

ZA124 5

ZA135 2

ZA136 5

ZA175-ZA177 3

ZA178-ZA187 4

ZA188-ZA189 6

ZA215-ZA217 4

ZA218-ZA220 6

ZA230-ZA243 4

ZA244-ZA245 6

ZA260-ZA264 4

ZA265-ZA268 6

ZA270-ZA274 2

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 18 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

Variable Number Group

ZA275 5

ZA285-ZA294 4

ZA295 6

ZA317-ZA320 4

ZA321 6

ZA327 4

ZA334 6

ZA380-ZA387 4

ZA388-ZA389 6

ZA430-ZA435 4

ZA436-ZA437 6

ZA445-ZA446 2

ZA447-ZA448 5

ZA450-ZA453 2

ZA454-ZA456 5

ZA460-ZA471 4

ZA472-ZA474 6

ZA506-ZA515 2

ZA516 5

ZA536-ZA540 2

ZA541-ZA542 5

ZA560-ZA563 4

ZA564-ZA565 6

ZA576-ZA577 2

ZA578-ZA580 5

ZA586 4

ZA588 5

ZA610-ZA612 6

ZA650 2

ZA651 5

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 19 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

Variable Number Group

ZA655-ZA657 6

ZA695 6

ZA778-ZA779 5

ZD002 1

B. Spares Affected

None.

2. Concurrent Requirements

None.

3. Reason

This Service Bulletin gives instructions to install a Seal Dam at the inboard and outboard corners of the aft

pylon compartment. An earlier failure on a flexible coupling installed in the leading edge led to a leakage

of fuel into this cavity. If the change given in this service bulletin is not accomplished, an un-intended drain

path would exist which could result in fuel leaking onto the hot exhaust portion of an engine and a consequent

fire.

During operations, one operator discovered fuel leaking onto the hot exhaust portion of the engine. The

fuel leakage was as a result of a failure of a flexible coupling installation in the wing leading edge. During

an investigation, it was determined that the pylon to wing interface design did not address drain paths for

potential low flow leakage rates. This caused the un-intended leak path from the leading edge through the

pylons and onto the hot exhaust part of the engines.

Boeing Service Related Problem (SRP) 787-SRP-54-0144 is related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane ZA117 by Service

Bulletin 787-54A0004 VC 1 before Issue 001 of this service bulletin. The change completed on airplane

ZA117 by Service Bulletin 787-54A0004 VC 1 is equivalent to Issue 001 of this service bulletin. Airplane

ZA117 has the configuration of a Group 2 airplane.

Issue 002 is sent to remove airplanes ZD001-ZD009 and ZA151 from the list of airplanes affected by this

service bulletin. These airplanes will receive the intent of the change contained in this service bulletin in

production. In addition, this issue clarifies instructions as a result of feedback reported by operators after

incorporation of the Issue 001 of this service bulletin on their fleet.

4. Description

Remove the left and right inboard and outboard pylon underwing panels and install new Seal Dams in the

inboard and outboard corners of the Aft Pylon frame. Install the left and right inboard and outboard underwing

panels.

Effects of this revision on Airplanes on which Issue 001 was previously done:

None

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 20 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

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

Table 3 

Affected Maintenance Zones

Model Zone

787-8 434, 444

5. Compliance

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD, is related to this

service bulletin.

Boeing recommends that the change given in this service bulletin be done within 60 months after the Issue

001 date of this service bulletin.

6. 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.

7. 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:

Table 4 

Number of Per- Task Hours Elapsed Hours

sons

Task

Work Package A 2 11.00 5.50

Work Package B 2 11.00 5.50

TOTAL FOR EACH AIRPLANE 22.00 11.00

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 21 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Group 2:

Table 5 

Number of Per- Task Hours Elapsed Hours

sons

Task

Work Package C 2 9.00 4.50

Work Package D 2 9.00 4.50

TOTAL FOR EACH AIRPLANE 18.00 9.00

Group 5:

Table 6 

Number of Per- Task Hours Elapsed Hours

sons

Task

Work Package E 2 6.50 3.25

Work Package F 2 6.50 3.25

TOTAL FOR EACH AIRPLANE 13.00 6.50

Group 3:

Table 7 

Number of Per- Task Hours Elapsed Hours

sons

Task

Work Package G 2 11.00 5.50

Work Package H 2 11.00 5.50

TOTAL FOR EACH AIRPLANE 22.00 11.00

Group 4:

Table 8 

Number of Per- Task Hours Elapsed Hours

sons

Task

Work Package I 2 9.00 4.50

Work Package J 2 9.00 4.50

TOTAL FOR EACH AIRPLANE 18.00 9.00

Group 6:

Table 9 

Number of Per- Task Hours Elapsed Hours

sons

Task

Work Package K 2 6.50 3.25

Work Package L 2 6.50 3.25

TOTAL FOR EACH AIRPLANE 13.00 6.50

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 22 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Group 1-6:

8. Weight and Balance Changes

Table 10 

Change in Moment

(Pound-Inches)

Change in Weight

(Pounds)

Airplane

All Airplanes + 1.5 + 1,313.0

9. Electrical Load Data

Not changed.

10. References

A. Existing Data:

1. Change Notice CN-AA39164C and CN-AA39164L

2. Standard Overhaul Practices Manual (SOPM) SOPM 20-11-03, SOPM 20-30-03, SOPM 20-50-

01, SOPM 20-50-12, SOPM 20-50-18, SOPM 20-50-19

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

4. Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2015-NM-051-AD is related

to this service bulletin.

B. Data Supplied with this Service Bulletin:

None.

C. Installation Requirement Modules Used in the Preparation of this Service Bulletin:

Table 11 

Requirement Mod- Title

ule

715Z3201-17 UNDERWING FAIRING INSTALLATION REWORK

715Z3201-18 UNDERWING FAIRING INSTALLATION REWORK

715Z3201-21 UNDERWING FAIRING INSTALLATION REWORK

715Z3201-22 UNDERWING FAIRING INSTALLATION REWORK

715Z3201-23 UNDERWING FAIRINGS - RECONCILIATION IRM

715Z3201-24 UNDERWING FAIRINGS - RECONCILIATION IRM

715Z3201-25 UNDERWING FAIRING INSTALLATION

715Z3201-26 UNDERWING FAIRING INSTALLATION

715Z3201-29 UNDERWING FAIRINGS - RECONCILIATION IRM

715Z3201-30 UNDERWING FAIRINGS - RECONCILIATION IRM

715Z3201-55 UNDERWING FAIRING INSTALLATION

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 23 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 11 

Requirement Mod- Title

ule

715Z3201-56 UNDERWING FAIRING INSTALLATION

715Z3201-57 UNDERWING FAIRING INSTALLATION

715Z3201-58 UNDERWING FAIRING INSTALLATION

The Requirements Modules above were used to prepare this service bulletin. The Requirements

Modules are not necessary to make the specified changes, and are not supplied with this service bulletin.

The Requirements Modules may not be applicable to all airplane configurations or operators.

11. Publications Affected

Table 12 

Publication Chapter-Section

787 Maintenance Manual 54-64

787 Illustrated Parts Data 54-62, ZA4-31, ZA4-41

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 does not affect FCS, therefore DTIs are not necessary.

12. Interchangeability and Intermixability of Parts

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

13. Software Accomplishment Summary

Not Affected.

Applicable To: B787-A-54-00-0004-00A-932A-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 24 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

MATERIAL INFORMATION

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SB B787-A-54-00-0004-00A-933A-D Issue 003, Step 2. Work Instructions

SB B787-A-54-00-0004-00A-932A-D Issue 003, References

Paragraph 10.

Description

Group 1-6:

1. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 3., 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

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.

Group 1:

Table 1 

Unit Price as of the

Issue 001 date of

this Service Bulletin (US Dollars)

ROLT as of the Issue 001 date of this

Service Bulletin

(Calendar Days)

Kit Number Name Date QTY

PYLON FUEL October 14, 2014 13 286 14,490.00

LEAKAGE SEAL

INSTALLATION

036Z0136-5

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 25 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Group 2:

Table 2 

Unit Price as of the

Issue 001 date of

this Service Bulletin (US Dollars)

ROLT as of the Issue 001 date of this

Service Bulletin

(Calendar Days)

Kit Number Name Date QTY

PYLON FUEL October 14, 2014 40 216 8,586.00

LEAKAGE SEAL

INSTALLATION

036Z0136-6

Group 3:

Table 3 

Unit Price as of the

Issue 001 date of

this Service Bulletin (US Dollars)

ROLT as of the Issue 001 date of this

Service Bulletin

(Calendar Days)

Kit Number Name Date QTY

PYLON FUEL October 14, 2014 6 286 14,490.00

LEAKAGE SEAL

INSTALLATION

036Z0136-7

Group 4:

Table 4 

Unit Price as of the

Issue 001 date of

this Service Bulletin (US Dollars)

ROLT as of the Issue 001 date of this

Service Bulletin

(Calendar Days)

Kit Number Name Date QTY

PYLON FUEL December 18, 2014 78 216 8,586.00

LEAKAGE SEAL

INSTALLATION

036Z0136-8

Group 5:

Table 5 

Unit Price as of the

Issue 001 date of

this Service Bulletin (US Dollars)

ROLT as of the Issue 001 date of this

Service Bulletin

(Calendar Days)

Kit Number Name Date QTY

PYLON FUEL September 19, 2014 18 204 5,272.00

LEAKAGE SEAL

INSTALLATION

036Z0136-9

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 26 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Group 6:

Table 6 

Unit Price as of the

Issue 001 date of

this Service Bulletin (US Dollars)

ROLT as of the Issue 001 date of this

Service Bulletin

(Calendar Days)

Kit Number Name Date QTY

PYLON FUEL September 19, 2014 30 204 5,272.00

LEAKAGE SEAL

INSTALLATION

036Z0136-10

Group 1-6:

Operators are encouraged to complete the survey provided in the Appendix of this service bulletin to help

Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

2. Industry Support Information

Boeing warranty remedies are available for 787 airplanes in warranty as of December 20, 2012. For task

hour reimbursement for airplanes in warranty as of that date, send a warranty claim to Boeing Fleet Support

Contracts - Warranty. 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 Material Management. Please refer to this service bulletin number

and reference the airplane variable numbers in your purchase order. The warranty remedies will expire eight

years from the original release date of this service bulletin.

3. Parts Necessary for Each Airplane

A. Kits/Parts:

To get the kits/parts shown below, refer to Paragraph 1., Material - Price and Availability.

NOTE: One top kit and the items shown in Paragraph 3.B., Parts and Materials Supplied by the Operator, are necessary for each airplane. 

Table 7 

Kit 036Z0136

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7 -8 -9 -10

SERVICE BULLETIN TOP KIT -

PYLON FUEL

LEAKAGE SEAL

INSTALLATION

036Z0136-5 - . . . . .

SERVICE BULLETIN TOP KIT -

PYLON FUEL

LEAKAGE SEAL

INSTALLATION

036Z0136-6 . - . . . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 27 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 7 

Kit 036Z0136

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7 -8 -9 -10

SERVICE BULLETIN TOP KIT -

PYLON FUEL

LEAKAGE SEAL

INSTALLATION

036Z0136-7 . . - . . .

SERVICE BULLETIN TOP KIT -

PYLON FUEL

LEAKAGE SEAL

INSTALLATION

036Z0136-8 . . . - . .

SERVICE BULLETIN TOP KIT -

PYLON FUEL

LEAKAGE SEAL

INSTALLATION

036Z0136-9 . . . . - .

SERVICE BULLETIN TOP KIT -

PYLON FUEL

LEAKAGE SEAL

INSTALLATION

036Z0136-10 . . . . . -

This Kit

is used

on the

Inboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-1 . . 1 . . .

This Kit

is used

on the

Inboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-2 . . 1 . . .

This Kit

is used

on the

Inboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-3 . . . 1 . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 28 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 7 

Kit 036Z0136

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7 -8 -9 -10

This Kit

is used

on the

Inboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-4 . . . 1 . .

This Kit

is used

on the

Outboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-5 . . 1 . . .

This Kit

is used

on the

Outboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-6 . . 1 . . .

This Kit

is used

on the

Outboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-7 . . . 1 . .

This Kit

is used

on the

Outboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-8 . . . 1 . .

This Kit

is used

on the

Inboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-9 . . . . . 1

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 29 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 7 

Kit 036Z0136

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7 -8 -9 -10

This Kit

is used

on the

Inboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-10 . . . . . 1

This Kit

is used

on the

Outboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-11 . . . . . 1

This Kit

is used

on the

Outboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-12 . . . . . 1

This Kit

is used

on the

Inboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-1 1 . . . . .

This Kit

is used

on the

Inboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-2 1 . . . . .

This Kit

is used

on the

Inboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-3 . 1 . . . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 30 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 7 

Kit 036Z0136

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7 -8 -9 -10

This Kit

is used

on the

Inboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-4 . 1 . . . .

This Kit

is used

on the

Outboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-5 1 . . . . .

This Kit

is used

on the

Outboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-6 1 . . . . .

This Kit

is used

on the

Outboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-7 . 1 . . . .

This Kit

is used

on the

Outboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-8 . 1 . . . .

This Kit

is used

on the

Inboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-9 . . . . 1 .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 31 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 7 

Kit 036Z0136

Existing Part Notes

Number

New Part Number QTY Name

-5 -6 -7 -8 -9 -10

This Kit

is used

on the

Inboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-10 . . . . 1 .

This Kit

is used

on the

Outboard

LH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-11 . . . . 1 .

This Kit

is used

on the

Outboard

RH Pylon.

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-12 . . . . 1 .

Table 8 

Kit 711Z1002

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5 -6

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-1 - . . . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-2 . - . . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-3 . . - . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-4 . . . - . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 32 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 8 

Kit 711Z1002

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5 -6

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-5 . . . . - .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-6 . . . . . -

710Z3443-1 1 . 1 . . . SEAL

710Z3443-2 . 1 . 1 . . SEAL

711Z3443-1 . . . . 1 . SEAL

711Z3443-2 . . . . . 1 SEAL

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-3 . . . . 1 .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-4 . . . . . 1

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-7 . . . . 1 .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-8 . . . . . 1

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-3 1 . . . . .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-4 . 1 . . . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 33 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 8 

Kit 711Z1002

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5 -6

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-7 1 . 1 . . .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-8 . 1 . 1 . .

715Z3443-9 . 1 . 1 1 . Seal, MID-SPRT *[1] *[2]

715Z3443-9 1 . 1 . . 1 Seal-MID-SPRT *[1] *[2]

*[1] *[2]

*[3]

BOLT, 100 DEG

TENSION HEAD,

HEX DRIVE, 160

KSI MIN TENSILE,

6AL-4V TITANIUM

(NOM

BACB30NY5HK6 20 20 10 11 20 20

NUT, SELF- *[1] *[2]

LOCKING,

HEXAGON,

COUNTERBORED, ALUMINUM ALLOY

BACN10XJ08 20 20 10 11 20 20

NAS1149V0363M 1 1 1 1 . . WASHER, FLAT *[1] *[2]

*[1] Discard the existing part.

*[2] You cannot use the existing part to replace the new or changed part.

*[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any

fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits.

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 34 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 9 

Kit 711Z1002

Existing Part Notes

Number

New Part Number QTY Name

-7 -8 -9 -10 -11 -12

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-7 - . . . . .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-8 . - . . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-9 . . - . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

711Z1002-10 . . . - . .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-11 . . . . - .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

711Z1002-12 . . . . . -

710Z3443-1 . . 1 . . . SEAL

710Z3443-2 . . . 1 . . SEAL

711Z3443-1 1 . . . 1 . SEAL

711Z3443-2 . 1 . . . 1 SEAL

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-7 1 . . . . .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-8 . 1 . . . .

715Z3443-9 1 . . 1 1 . Seal, MID-SPRT *[1] *[2]

715Z3443-9 . 1 1 . . 1 Seal-MID-SPRT *[1] *[2]

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 35 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 9 

Kit 711Z1002

Existing Part Notes

Number

New Part Number QTY Name

-7 -8 -9 -10 -11 -12

*[1] *[2]

*[3]

BOLT, 100 DEG

TENSION HEAD,

HEX DRIVE, 160

KSI MIN TENSILE,

6AL-4V TITANIUM

(NOM

BACB30NY5HK6 11 20 . . . .

NUT, SELF- *[1] *[2]

LOCKING,

HEXAGON,

COUNTERBORED, ALUMINUM ALLOY

BACN10XJ08 11 20 . . . .

*[1] Discard the existing part.

*[2] You cannot use the existing part to replace the new or changed part.

*[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any

fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits.

Table 10 

Kit 715Z1002

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5 -6

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-1 - . . . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-2 . - . . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-3 . . - . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-4 . . . - . .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-5 . . . . - .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 36 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 10 

Kit 715Z1002

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5 -6

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-6 . . . . . -

710Z3443-1 1 . 1 . . . SEAL

710Z3443-2 . 1 . 1 . . SEAL

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-3 . . . . 1 .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-4 . . . . . 1

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-7 . . . . 1 .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-8 . . . . . 1

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-3 1 . . . . .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-4 . 1 . . . .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-7 1 . 1 . . .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

INBOARD

715Z3233-8 . 1 . 1 . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 37 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 10 

Kit 715Z1002

Existing Part Notes

Number

New Part Number QTY Name

-1 -2 -3 -4 -5 -6

715Z3443-9 . 1 . 1 1 . Seal, MID-SPRT *[1] *[2]

715Z3443-11 . . . . 1 . SEAL

715Z3443-12 . . . . . 1 SEAL

715Z3443-9 1 . 1 . . 1 Seal-MID-SPRT *[1] *[2]

*[1] *[2]

*[3]

BOLT, 100 DEG

TENSION HEAD,

HEX DRIVE, 160

KSI MIN TENSILE,

6AL-4V TITANIUM

(NOM

BACB30NY5HK6 20 20 11 11 20 20

NUT, SELF- *[1] *[2]

LOCKING,

HEXAGON,

COUNTERBORED, ALUMINUM ALLOY

BACN10XJ08 20 20 11 11 20 20

NAS1149V0363M 1 1 1 1 . . WASHER, FLAT *[1] *[2]

*[1] Discard the existing part.

*[2] You cannot use the existing part to replace the new or changed part.

*[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any

fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits.

Table 11 

Kit 715Z1002

Existing Part Notes

Number

New Part Number QTY Name

-7 -8 -9 -10 -11 -12

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-7 - . . . . .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-8 . - . . . .

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-9 . . - . . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 38 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 11 

Kit 715Z1002

Existing Part Notes

Number

New Part Number QTY Name

-7 -8 -9 -10 -11 -12

RETROFIT KIT -

PYLON SEAL

DAM, INBOARD

715Z1002-10 . . . - . .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-11 . . . . - .

RETROFIT KIT -

PYLON SEAL

DAM, OUTBOARD

715Z1002-12 . . . . . -

710Z3443-1 . . 1 . . . SEAL

710Z3443-2 . . . 1 . . SEAL

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-7 1 . . . . .

RETAINER - *[1] *[2]

SEAL, UNDERWING FAIRING,

OUTBOARD

715Z3213-8 . 1 . . . .

715Z3443-9 1 . . 1 1 . Seal, MID-SPRT *[1] *[2]

715Z3443-11 1 . . . 1 . SEAL *[1] *[2]

715Z3443-12 . 1 . . . 1 SEAL *[1] *[2]

715Z3443-9 . 1 1 . . 1 Seal-MID-SPRT *[1] *[2]

*[1] *[2]

*[3]

BOLT, 100 DEG

TENSION HEAD,

HEX DRIVE, 160

KSI MIN TENSILE,

6AL-4V TITANIUM

(NOM

BACB30NY5HK6 20 20 . . . .

NUT, SELF- *[1] *[2]

LOCKING,

HEXAGON,

COUNTERBORED, ALUMINUM ALLOY

BACN10XJ08 20 20 . . . .

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 39 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 11 

Kit 715Z1002

Existing Part Notes

Number

New Part Number QTY Name

-7 -8 -9 -10 -11 -12

*[1] Discard the existing part.

*[2] You cannot use the existing part to replace the new or changed part.

*[3] If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any

fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits.

B. Parts and Materials Supplied by the Operator:

Table 12 

Part Number / QTY Name Notes

Specification

As Re- ADHESIVE *[1]

quired

Type 68

As Re- ADHESIVE *[1]

quired

Type 60

As Re- SEALANT *[1]

quired

BMS 5-63 TYPE

II

As Re- SEALANT *[1]

quired

BMS 5-45 Class

B-1/2

CORROSION INHIBITING COM- *[1]

POUND

As RequiredBMS 3-38

SILICONE FOAM RUBBER *[1] *[2]

SEALANT

As RequiredBMS 1-68 Grade

A, Form III

*[1] See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

*[2] Requirement and Dimensions for Sealant tape can be found in the Task Tables in Data Module SB B787-A-54-00-

0004-00A-933A-D, Step 2., Work Instructions.

C. Parts Modified and Reidentified:

None

D. Parts Removed and Not Replaced:

None

4. Parts Necessary to Change Spares

None.

5. Special Tooling - Price and Availability

None.

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 40 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
6. 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 Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 10.,

References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

Applicable To: B787-A-54-00-0004-00A-934A-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 41 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

ACCOMPLISHMENT INSTRUCTIONS

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SB B787-A-54-00-0004-00A-932A-D Issue 003, References

Paragraph 10.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Manpower

Paragraph 7.

SB B787-A-54-00-0004-00A-932A-D Issue 003, Compliance

Paragraph 5.

Alert Service Bulletin

B787-81205-SB540004-00 – Task 1 – LEFT ROLLS

SB B787-A-54-00-0004-01A-933B-D Issue 003

ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 1: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 2 – RIGHT ROLLS

SB B787-A-54-00-0004-02A-933B-D Issue 003

ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 1: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 3 – LEFT ROLLS

SB B787-A-54-00-0004-03A-933B-D Issue 003

ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 2: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 4 – RIGHT ROLLS

SB B787-A-54-00-0004-04A-933B-D Issue 003

ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 2: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 9 – LEFT ROLLS

SB B787-A-54-00-0004-09A-933B-D Issue 003

ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 5: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 10 – RIGHT

SB B787-A-54-00-0004-10A-933B-D Issue 003

Applicable To: B787-A-54-00-0004-00A-933A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 42 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Reference Title

ROLLS ROYCE ENGINE INBOARD AND

OUTBOARD SEAL DAM INSTALLATION [Group 5:

]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 5 – LEFT GE

SB B787-A-54-00-0004-05A-933B-D Issue 003

ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 3: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 6 – RIGHT GE

SB B787-A-54-00-0004-06A-933B-D Issue 003

ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 3: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 7 – LEFT GE

SB B787-A-54-00-0004-07A-933B-D Issue 003

ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 4: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 8 – RIGHT GE

SB B787-A-54-00-0004-08A-933B-D Issue 003

ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 4: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 11 – LEFT GE

SB B787-A-54-00-0004-11A-933B-D Issue 003

ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 6: ]

Alert Service Bulletin

B787-81205-SB540004-00 – Task 12 – RIGHT GE

SB B787-A-54-00-0004-12A-933B-D Issue 003

ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 6: ]

SOPM 20-50-01 BOLT AND NUT INSTALLATION

Procedure

Group 1-6:

1. 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 Data Module SB B787-A-54-00-0004-00A932A-D, Paragraph 10., References, for definition of the acronyms.

Applicable To: B787-A-54-00-0004-00A-933A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 43 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
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 Data Module SB B787-A-54-00-0004-00A-932A-D, Paragraph 7., 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 SRM Chapter 51

– Torque Values:

– Values for structural fasteners are given in 787 Structural Repair Manual, Chapter 51.

– Values for airframe maintenance tasks are included in Chapter 20 of 787 Aircraft Maintenance Manual (AMM).

– Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring

Practices Manual (SWPM).

– Values for engine maintenance tasks are included in Chapter 70 of 787 Aircraft Maintenance Manual (AMM).

– Non-standard torque values for maintenance tasks are included in the applicable installation step.

5. Use the approved fastener, process and material substitutions in accordance with SRM Chapter

51.

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

standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. In

addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51.

Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation

in this service bulletin.

7. 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 ensure visual access to all surfaces in the inspection area. This level of inspection is made

under normal available lighting conditions such as daylight, hangar lighting, flashlight or droplight 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.

8. 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.

9. The instructions in Step 2., Work Instructions and the Tasks 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

Applicable To: B787-A-54-00-0004-00A-933A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 44 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to

use superseded tools.

10. 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.

11. 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.

12. The compliance times for the actions in Step 2., Work Instructions are in Data Module SB B787-

A-54-00-0004-00A-932A-D, Paragraph 5., Compliance.

2. WORK INSTRUCTIONS

Group 1:

A. WORK PACKAGE A - Rolls Royce Airplanes Group 1 Left Engine

Get access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 1, SB B787-A-54-00-0004-01A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 1:

B. WORK PACKAGE B - Rolls Royce Airplanes Group 1 Right Engine

Get access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 2, SB B787-A-54-00-0004-02A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 2:

C. WORK PACKAGE C - Rolls Royce Airplanes Group 2 Left Engine

Get access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 3, SB B787-A-54-00-0004-03A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 2:

D. WORK PACKAGE D - Rolls Royce Airplanes Group 2 Right Engine

Get access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 4, SB B787-A-54-00-0004-04A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 5:

E. WORK PACKAGE E - Rolls Royce Airplanes Group 5 Left Engine

Get access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 9, SB B787-A-54-00-0004-09A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 5:

F. WORK PACKAGE F - Rolls Royce Airplanes Group 5 Right Engine

Get access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 10, SB B787-A-54-00-0004-10A-933B-D.(1)

Applicable To: B787-A-54-00-0004-00A-933A-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 45 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
(2) Put the airplane back to a serviceable condition.

Group 3:

G. WORK PACKAGE G - GE Airplanes Group 3 Left Engine

Get access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 5, SB B787-A-54-00-0004-05A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 3:

H. WORK PACKAGE H - GE Airplanes Group 3 Right Engine

Get access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 6, SB B787-A-54-00-0004-06A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 4:

I. WORK PACKAGE I - GE Airplanes Group 4 Left Engine

Get access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 7, SB B787-A-54-00-0004-07A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 4:

J. WORK PACKAGE J - GE Airplanes Group 4 Right Engine

Get access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 8, SB B787-A-54-00-0004-08A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 6:

K. WORK PACKAGE K - GE Airplanes Group 6 Left Engine

Get access to the Left Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 11, SB B787-A-54-00-0004-11A-933B-D.(1)

(2) Put the airplane back to a serviceable condition.

Group 6:

L. WORK PACKAGE L - GE Airplanes Group 6 Right Engine

(1) Get access to the Right Side Aft Pylon frame and install the Inboard and Outboard Seal Dam in accordance with Data Module Task 12, SB B787-A-54-00-0004-12A-933B-D.

(2) Put the airplane back to a serviceable condition.

Applicable To: B787-A-54-00-0004-00A-933A-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 46 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 1 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 1: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

SOPM 20-50-19 GENERAL SEALING

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 47 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 1:

ICN-B787-A-000061-A-81205-07440-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 48 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07441-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 49 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07442-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 50 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07443-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 51 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07444-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 52 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07445-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 53 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07446-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 54 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07447-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 55 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07448-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 56 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07449-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 57 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07450-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 58 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 40 -

INBOARD UNDER- 715Z3230-7 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3233-1 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3233-7 1 -

ER

5 Install (New)

BULB SEAL RETAIN- 715Z3233-3 1 -

ER

6 Install (New)

See Fastener Code

Table.

7 Install (New) FASTENERS - 20

8 Remove BLADE SEAL 715Z3443-9 1 *[1]

*[2]

Trim the new Blade

Seal provided in the

kit as shown before

installation.

9 Cut BLADE SEAL 715Z3443-9 1

10 Install (New) BLADE SEAL 715Z3443-9 1 *[3]

11 Install (New) INBOARD SEAL DAM 710Z3443-1 1 *[4]

12 Apply FILLET SEAL - 1 *[5]

13 Remove / Keep FASTENERS - 34 -

OUTBOARD UNDER- 715Z3210-11 1 -

WING PANEL

14 Remove / Keep

15 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3213-1 1 -

ER

16 Remove

BULB SEAL RETAIN- 715Z3213-3 1 -

ER

17 Install (New)

BULB SEAL RETAIN- 715Z3213-7 1 -

ER

18 Install (New)

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 59 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

See Fastener Code

Table.

19 Install (New) FASTENERS - 20

20 Inspect BLADE SEAL 715Z3443-9 1 *[6] *[2]

OUTBOARD SEAL 715Z3443-11 1 *[4]

DAM

21 Install (New)

22 Apply FILLET SEAL - 1 *[5]

23 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-11 1 *[8]

WING PANEL

24 Install (Kept)

See Fastener Code

Table.

25 Install (Kept) FASTENERS - 34

INBOARD UNDER- 715Z3230-7 1 *[9]

WING PANEL

26 Install (Kept)

See Fastener Code

Table.

27 Install (Kept) FASTENERS - 40

*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 60 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

BOLT, 100 DEG BACB31V4-5W 2 -

HEAD

A

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the panel. *[4] *[5]

B BOLT BACB31U3K5W 72 -

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

*[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 61 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-01A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 62 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 2 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 1: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-50-19 GENERAL SEALING

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 63 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 1:

ICN-B787-A-000061-A-81205-07452-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 64 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07453-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 65 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07454-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 66 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07455-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 67 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07456-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 68 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07457-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 69 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07458-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 70 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07459-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 71 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07460-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 72 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07461-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 73 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07462-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 74 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 48 -

OUTBOARD UNDER- 715Z3210-12 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3213-2 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3213-8 1 -

ER

5 Install (New)

BULB SEAL RETAIN- 715Z3213-4 1 -

ER

6 Install (New)

See Fastener Code

Table.

7 Install (New) FASTENERS - 20

8 Inspect BLADE SEAL 715Z3443-9 1 *[1]

OUTBOARD SEAL 715Z3443-12 1 *[2]

DAM

9 Install (New)

10 Apply FILLET SEAL - 1 *[3]

11 Remove / Keep FASTENERS - 26 -

INBOARD UNDER- 715Z3230-8 1 -

WING PANEL

12 Remove / Keep

13 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3233-2 1 -

ER

14 Remove

BULB SEAL RETAIN- 715Z3233-4 1 -

ER

15 Install (New)

BULB SEAL RETAIN- 715Z3233-8 1 -

ER

16 Install (New)

See Fastener Code

Table.

17 Install (New) FASTENERS - 20

18 Remove BLADE SEAL 715Z3443-9 1 *[4]

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 75 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

*[5]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

19 Cut BLADE SEAL 715Z3443-9 1

20 Install (New) BLADE SEAL 715Z3443-9 1 *[6]

21 Install (New) INBOARD SEAL DAM 710Z3443-2 1 *[2]

22 Apply FILLET SEAL - 1 *[3]

INBOARD UNDER- 715Z3230-8 1 -

WING PANEL

23 Install (Kept)

See Fastener Code

Table.

24 Install (Kept) FASTENERS - 26

25 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-12 1 *[8] *[9]

WING PANEL

26 Install (Kept)

See Fastener Code

Table.

27 Install (Kept) FASTENERS - 48

*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[2] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[3] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[4] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[5] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 76 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the panel. *[1] *[2]

BOLT, 100 DEG BACB31U3K5W 72 -

HEAD

A

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

B BOLT BACB31V4-5W 2 -

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

*[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 77 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-02A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 78 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 3 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 2: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

SOPM 20-50-19 GENERAL SEALING

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 79 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 2:

ICN-B787-A-000061-A-81205-07463-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 80 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07464-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 81 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07465-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 82 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07466-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 83 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07467-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 84 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07468-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 85 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07469-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 86 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07470-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 87 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07471-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 88 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07472-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 89 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07473-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 90 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 40 -

INBOARD UNDER- 715Z3230-9 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3233-5 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3233-7 1 -

ER

5 Install (New)

See Fastener Code

Table.

6 Install (New) FASTENERS - 11

7 Remove BLADE SEAL 715Z3443-9 1 *[1]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

8 Cut BLADE SEAL 715Z3443-9 1

9 Install (New) BLADE SEAL 715Z3443-9 1 *[3]

10 Install (New) INBOARD SEAL DAM 710Z3443-1 1 *[4]

11 Apply FILLET SEAL - 1 *[5]

12 Remove / Keep FASTENERS - 34 -

OUTBOARD UNDER- 715Z3210-13 1 -

WING PANEL

13 Remove / Keep

14 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3213-5 1 -

ER

15 Remove

BULB SEAL RETAIN- 715Z3213-7 1 -

ER

16 Install (New)

17 Install (New) FASTENERS - 11 -

18 Inspect BLADE SEAL 715Z3443-9 1 *[6] *[2]

OUTBOARD SEAL 715Z3443-11 1 *[4]

DAM

19 Install (New)

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 91 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

20 Apply FILLET SEAL - 1 *[5]

21 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-13 1 *[8]

WING PANEL

22 Install (Kept)

See Fastener Code

Table.

23 Install (Kept) FASTENERS - 34

INBOARD UNDER- 715Z3230-9 1 *[9]

WING PANEL

24 Install (Kept)

See Fastener Code

Table.

25 Install (Kept) FASTENERS - 40

*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 92 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

BOLT, 100 DEG BACB31V4-5W 2 -

HEAD

A

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the panel. *[4] *[5]

B BOLT BACB31U3K5W 72 -

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

*[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-03A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 93 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 4 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 2: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-50-19 GENERAL SEALING

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 94 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 2:

ICN-B787-A-000061-A-81205-07474-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 95 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07475-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 96 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07476-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 97 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07477-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 98 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07478-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 99 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07479-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 100 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07480-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 101 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07481-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 102 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07482-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 103 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07483-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 104 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07484-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 105 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 48 -

OUTBOARD UNDER- 715Z3210-12 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3213-6 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3213-8 1 -

ER

5 Install (New)

See Fastener Code

Table.

6 Install (New) FASTENERS - 11

7 Inspect BLADE SEAL 715Z3443-9 1 *[1] *[2]

OUTBOARD SEAL 715Z3443-12 1 *[3]

DAM

8 Install (New)

9 Apply FILLET SEAL - 1 *[4]

10 Remove / Keep FASTENERS - 26 -

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

11 Remove / Keep

12 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3233-6 1 -

ER

13 Remove

BULB SEAL RETAIN- 715Z3233-8 1 -

ER

14 Install (New)

See Fastener Code

Table.

15 Install (New) FASTENERS - 11

16 Remove BLADE SEAL 715Z3443-9 1 *[5]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

17 Cut BLADE SEAL 715Z3443-9 1

18 Install (New) BLADE SEAL 715Z3443-9 1 *[6]

19 Install (New) INBOARD SEAL DAM 710Z3443-2 1 *[3]

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 106 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

20 Apply FILLET SEAL - 1 *[4]

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

21 Install (Kept)

See Fastener Code

Table.

22 Install (Kept) FASTENERS - 26

23 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-12 1 *[8] *[9]

WING PANEL

24 Install (Kept)

See Fastener Code

Table.

25 Install (Kept) FASTENERS - 48

*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 107 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the panel. *[1] *[2]

BOLT, 100 DEG BACB31U3K5W 72 -

HEAD

A

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

B BOLT BACB31V4-5W 2 -

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

*[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-04A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 108 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 5 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 3: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

SOPM 20-50-19 GENERAL SEALING

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 109 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 3:

ICN-B787-A-000061-A-81205-07485-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 110 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07486-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 111 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07487-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 112 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07488-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 113 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07489-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 114 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07490-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 115 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07491-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 116 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07492-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 117 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07493-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 118 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07494-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 119 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07495-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 120 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 40 -

INBOARD UNDER- 715Z3230-7 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3233-1 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3233-3 1 -

ER

5 Install (New)

BULB SEAL RETAIN- 715Z3233-7 1 -

ER

6 Install (New)

See Fastener Code

Table.

7 Install (New) FASTENERS - 20

8 Remove BLADE SEAL 715Z3443-9 1 *[1]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

9 Cut BLADE SEAL 715Z3443-9 1

10 Install (New) BLADE SEAL 715Z3443-9 1 *[3]

11 Install (New) INBOARD SEAL DAM 710Z3443-1 1 *[4]

12 Apply FILLET SEAL - 1 *[5]

13 Remove / Keep FASTENERS - 34 -

OUTBOARD UNDER- 715Z3210-11 1 -

WING PANEL

14 Remove / Keep

15 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3213-1 1 -

ER

16 Remove

BULB SEAL RETAIN- 715Z3213-3 1 -

ER

17 Install (New)

BULB SEAL RETAIN- 715Z3213-7 1 -

ER

18 Install (New)

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 121 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

See Fastener Code

Table.

19 Install (New) FASTENERS - 20

20 Inspect BLADE SEAL 715Z3443-9 1 *[6] *[2]

OUTBOARD SEAL 711Z3443-1 1 *[4]

DAM

21 Install (New)

22 Apply FILLET SEAL - 1 *[5]

23 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-11 1 *[8]

WING PANEL

24 Install (Kept)

See Fastener Code

Table.

25 Install (Kept) FASTENERS - 34

INBOARD UNDER- 715Z3230-7 1 *[9]

WING PANEL

26 Install (Kept)

See Fastener Code

Table.

27 Install (Kept) FASTENERS - 40

*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 122 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

BOLT, 100 DEG BACB31V4-5W 2 -

HEAD

A

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the panel. *[4] *[5]

B BOLT BACB31U3K5W 72 -

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

*[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 123 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-05A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 124 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 6 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 3: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-50-19 GENERAL SEALING

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 125 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 3:

ICN-B787-A-000061-A-81205-07496-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 126 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07497-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 127 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07498-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 128 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07499-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 129 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07500-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 130 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07501-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 131 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07502-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 132 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07503-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 133 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07504-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 134 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07505-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 135 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07506-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 136 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 48 -

OUTBOARD UNDER- 715Z3210-12 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3213-2 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3213-4 1 -

ER

5 Install (New)

BULB SEAL RETAIN- 715Z3213-8 1 -

ER

6 Install (New)

7 Install (New) FASTENERS - 20 -

8 Inspect BLADE SEAL 715Z3443-9 1 *[1] *[2]

OUTBOARD SEAL 711Z3443-2 1 *[3]

DAM

9 Install (New)

10 Apply FILLET SEAL - 1 *[4]

11 Remove / Keep FASTENERS - 26 -

INBOARD UNDER- 715Z3230-8 1 -

WING PANEL

12 Remove / Keep

13 Remove FASTENERS - 20 -

BULB SEAL RETAIN- 715Z3233-2 1 -

ER

14 Remove

BULB SEAL RETAIN- 715Z3233-4 1 -

ER

15 Install (New)

BULB SEAL RETAIN- 715Z3233-8 1 -

ER

16 Install (New)

See Fastener Code

Table.

17 Install (New) FASTENERS - 20

18 Remove BLADE SEAL 715Z3443-9 1 *[5]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

19 Cut BLADE SEAL 715Z3443-9 1

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 137 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

20 Install (New) BLADE SEAL 715Z3443-9 1 *[6]

21 Install (New) INBOARD SEAL DAM 710Z3443-2 1 *[3]

22 Apply FILLET SEAL - 1 *[4]

INBOARD UNDER- 715Z3230-8 1 -

WING PANEL

23 Install (Kept)

See Fastener Code

Table.

24 Install (Kept) FASTENERS - 26

25 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-12 1 *[8] *[9]

WING PANEL

26 Install (Kept)

See Fastener Code

Table.

27 Install (Kept) FASTENERS - 48

*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 138 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the panel. *[1] *[2]

BOLT, 100 DEG BACB31U3K5W 72 -

HEAD

A

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

B BOLT BACB31V4-5W 2 -

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

*[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 139 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-06A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 140 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 7 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 4: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

SOPM 20-50-19 GENERAL SEALING

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 141 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 4:

ICN-B787-A-000061-A-81205-07507-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 142 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07508-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 143 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07509-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 144 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07510-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 145 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07511-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 146 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07512-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 147 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07513-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 148 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07514-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 149 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07515-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 150 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07516-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 151 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07517-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 152 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 40 -

INBOARD UNDER- 715Z3230-9 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3233-5 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3233-7 1 -

ER

5 Install (New)

See Fastener Code

Table.

6 Install (New) FASTENERS - 11

7 Remove BLADE SEAL 715Z3443-9 1 *[1]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

8 Cut BLADE SEAL 715Z3443-9 1

9 Install (New) BLADE SEAL 715Z3443-9 1 *[3]

10 Install (New) INBOARD SEAL DAM 710Z3443-1 1 *[4]

11 Apply FILLET SEAL - 1 *[5]

12 Remove / Keep FASTENERS - 34 -

OUTBOARD UNDER- 715Z3210-13 1 -

WING PANEL

13 Remove / Keep

14 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3213-5 1 -

ER

15 Remove

BULB SEAL RETAIN- 715Z3213-7 1 -

ER

16 Install (New)

See Fastener Code

Table.

17 Install (New) FASTENERS - 11

18 Inspect BLADE SEAL 715Z3443-9 1 *[6] *[2]

OUTBOARD SEAL 711Z3443-1 1 *[4]

DAM

19 Install (New)

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 153 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

20 Apply FILLET SEAL - 1 *[5]

21 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-13 1 *[8]

WING PANEL

22 Install (Kept)

See Fastener Code

Table.

23 Install (Kept) FASTENERS - 34

INBOARD UNDER- 715Z3230-9 1 *[9]

WING PANEL

24 Install (Kept)

See Fastener Code

Table.

25 Install (Kept) FASTENERS - 40

*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 154 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

BOLT, 100 DEG BACB31V4-5W 2 -

HEAD

A

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the panel. *[4] *[5]

B BOLT BACB31U3K5W 72 -

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

*[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-07A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 155 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 8 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 4: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-50-19 GENERAL SEALING

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 156 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 4:

ICN-B787-A-000061-A-81205-07518-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 157 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07519-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 158 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07520-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 159 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07521-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 160 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07522-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 161 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07523-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 162 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07524-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 163 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07525-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 164 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07526-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 165 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07527-A-01-1

Figure 10 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 166 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07528-A-01-1

Figure 11 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 167 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 48 -

OUTBOARD UNDER- 715Z3210-14 1 -

WING PANEL

2 Remove / Keep

3 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3213-6 1 -

ER

4 Remove

BULB SEAL RETAIN- 715Z3213-8 1 -

ER

5 Install (New)

See Fastener Code

Table.

6 Install (New) FASTENERS - 11

7 Inspect BLADE SEAL 715Z3443-9 1 *[1] *[2]

OUTBOARD SEAL 711Z3443-2 1 *[3]

DAM

8 Install (New)

9 Apply FILLET SEAL - 1 *[4]

10 Remove / Keep FASTENERS - 26 -

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

11 Remove / Keep

12 Remove FASTENERS - 11 -

BULB SEAL RETAIN- 715Z3233-6 1 -

ER

13 Remove

BULB SEAL RETAIN- 715Z3233-8 1 -

ER

14 Install (New)

See Fastener Code

Table.

15 Install (New) FASTENERS - 11

16 Remove BLADE SEAL 715Z3443-9 1 *[5]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

17 Cut BLADE SEAL 715Z3443-9 1

18 Install (New) BLADE SEAL 715Z3443-9 1 *[6]

19 Install (New) INBOARD SEAL DAM 710Z3443-2 1 *[3]

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 168 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

20 Apply FILLET SEAL - 1 *[4]

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

21 Install (Kept)

See Fastener Code

Table.

22 Install (Kept) FASTENERS - 26

23 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-14 1 *[8] *[9]

WING PANEL

24 Install (Kept)

See Fastener Code

Table.

25 Install (Kept) FASTENERS - 48

*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 12 

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 169 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the panel. *[1] *[2]

BOLT, 100 DEG BACB31U3K5W 72 -

HEAD

A

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

B BOLT BACB31V4-5W 2 -

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

Bolt must be installed flush

to the panel. *[6] *[7]

D BOLT BACB30NY5HK6 39 -

NUT BACN10XJ08 39 - -

Bolt must be installed flush

to the panel. *[6] *[7]

E BOLT BACB30NY5HK6 1 -

WASHER NAS1149V0363M 1 - -

NUT BACN10XJ08 1 - -

*[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[6] Apply BMS 5-45 sealant to all areas of the hole before fastener installation. Refer to SOPM 20-50-19 as an accepted procedure.

*[7] Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-08A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 170 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 9 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 5: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

SOPM 20-50-19 GENERAL SEALING

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 171 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 5:

ICN-B787-A-000061-A-81205-07529-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 172 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07530-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 173 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07531-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 174 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07532-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 175 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07533-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 176 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07534-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 177 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07535-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 178 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07536-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 179 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07537-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 180 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 40 -

INBOARD UNDER- 715Z3230-9 1 -

WING PANEL

2 Remove / Keep

3 Remove BLADE SEAL 715Z3443-9 1 *[1]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

4 Cut BLADE SEAL 715Z3443-9 1

5 Install (New) BLADE SEAL 715Z3443-9 1 *[3]

6 Install (New) INBOARD SEAL DAM 710Z3443-1 1 *[4]

7 Apply FILLET SEAL - 1 *[5]

8 Remove / Keep FASTENERS - 34 -

OUTBOARD UNDER- 715Z3210-13 1 -

WING PANEL

9 Remove / Keep

10 Inspect BLADE SEAL 715Z3443-9 1 *[6] *[2]

OUTBOARD SEAL 715Z3443-11 1 *[4]

DAM

11 Install (New)

12 Apply FILLET SEAL - 1 *[5]

13 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-13 1 *[8]

WING PANEL

14 Install (Kept)

See Fastener Code

Table.

15 Install (Kept) FASTENERS - 34

INBOARD UNDER- 715Z3230-9 1 *[9]

WING PANEL

16 Install (Kept)

See Fastener Code

Table.

17 Install (Kept) FASTENERS - 40

*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 181 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

*[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 10 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

BOLT, 100 DEG BACB31V4-5W 2 -

HEAD

A

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the panel. *[4] *[5]

B BOLT BACB31U3K5W 72 -

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

*[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 182 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-09A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 183 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 10 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL

DAM INSTALLATION [Group 5: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-50-19 GENERAL SEALING

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 184 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 5:

ICN-B787-A-000061-A-81205-07538-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 185 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07539-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 186 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07540-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 187 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07541-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 188 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07542-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 189 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07543-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 190 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07544-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 191 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07545-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 192 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07546-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 193 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 48 -

OUTBOARD UNDER- 715Z3210-12 1 -

WING PANEL

2 Remove / Keep

3 Inspect BLADE SEAL 715Z3443-9 1 *[1] *[2]

OUTBOARD SEAL 715Z3443-12 1 *[3]

DAM

4 Install (New)

5 Apply FILLET SEAL - 1 *[4]

6 Remove / Keep FASTENERS - 26 -

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

7 Remove / Keep

8 Remove BLADE SEAL 715Z3443-9 1 *[5]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

9 Cut BLADE SEAL 715Z3443-9 1

10 Install (New) BLADE SEAL 715Z3443-9 1 *[6]

11 Install (New) INBOARD SEAL DAM 710Z3443-2 1 *[3]

12 Apply FILLET SEAL - 1 *[4]

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

13 Install (Kept)

See Fastener Code

Table.

14 Install (Kept) FASTENERS - 26

15 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-12 1 *[8] *[9]

WING PANEL

16 Install (Kept)

See Fastener Code

Table.

17 Install (Kept) FASTENERS - 48

*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 194 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

*[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 10 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the panel. *[1] *[2]

BOLT, 100 DEG BACB31U3K5W 72 -

HEAD

A

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

B BOLT BACB31V4-5W 2 -

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

*[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 195 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

Applicable To: B787-A-54-00-0004-10A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 196 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 11 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 6: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

SOPM 20-50-19 GENERAL SEALING

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 197 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 6:

ICN-B787-A-000061-A-81205-07547-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 198 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07548-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 199 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07549-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 200 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07550-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 201 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07551-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 202 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07552-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 203 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07553-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 204 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07554-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 205 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07555-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 206 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 40 -

INBOARD UNDER- 715Z3230-9 1 -

WING PANEL

2 Remove / Keep

3 Remove BLADE SEAL 715Z3443-9 1 *[1]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

installation.

4 Cut BLADE SEAL 715Z3443-9 1

5 Install (New) BLADE SEAL 715Z3443-9 1 *[3]

6 Install (New) INBOARD SEAL DAM 710Z3443-1 1 *[4]

7 Apply FILLET SEAL - 1 *[5]

8 Remove / Keep FASTENERS - 34 -

OUTBOARD UNDER- 715Z3210-13 1 -

WING PANEL

9 Remove / Keep

10 Inspect BLADE SEAL 715Z3443-9 1 *[6] *[2]

OUTBOARD SEAL 711Z3443-1 1 *[4]

DAM

11 Install (New)

12 Apply FILLET SEAL - 1 *[5]

13 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-13 1 *[8]

WING PANEL

14 Install (Kept)

See Fastener Code

Table.

15 Install (Kept) FASTENERS - 34

INBOARD UNDER- 715Z3230-9 1 *[9]

WING PANEL

16 Install (Kept)

See Fastener Code

Table.

17 Install (Kept) FASTENERS - 40

*[1] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

*[3] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 207 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

*[4] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[5] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[6] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 10 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

BOLT, 100 DEG BACB31V4-5W 2 -

HEAD

A

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the panel. *[4] *[5]

B BOLT BACB31U3K5W 72 -

Bolt must be installed flush

to the washer. *[1] *[2] *[3]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

*[1] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 208 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[2] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

*[4] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

*[5] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

Applicable To: B787-A-54-00-0004-11A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 209 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Task 12 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM

INSTALLATION [Group 6: ]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

References

Reference Title

SOPM 20-50-12 APPLICATION OF ADHESIVES

SOPM 20-50-19 GENERAL SEALING

SOPM 20-30-03 GENERAL CLEANING PROCEDURES

FASTENER INSTALLATION IN COMPOSITE

STRUCTURES

SOPM 20-50-18

REPAIR OF ELECTRICAL TERMINATIONS AND

ELECTRICAL BONDING AREAS

SOPM 20-11-03

Preliminary Requirements

Required Conditions

Action/Condition Data Module/Technical Publication

Alert Service Bulletin B787-81205-SB540004-00 - B787-A-54-00-0004-00A-933A-D Issue 003

ACCOMPLISHMENT INSTRUCTIONS

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 210 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

This Task applies to Group 6:

ICN-B787-A-000061-A-81205-07556-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 211 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07557-A-01-1

Figure 2 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 212 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07558-A-01-1

Figure 3 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 213 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07559-A-01-1

Figure 4 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 214 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07560-A-01-1

Figure 5 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 215 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07561-A-01-1

Figure 6 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 216 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07562-A-01-1

Figure 7 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 217 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-11000-A-01-1

Figure 8 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 218 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
ICN-B787-A-000061-A-81205-07564-A-01-1

Figure 9 

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 219 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
1. The step numbers shown below agree with the numbers shown in the circle symbols in the Task. The QTY

numbers shown below are the number of parts necessary for this task.

Table 1 

Step Action Name Identification Qty More Data

1 Remove / Keep FASTENERS - 48 -

OUTBOARD UNDER- 715Z3210-14 1 -

WING PANEL

2 Remove / Keep

3 Inspect BLADE SEAL 715Z3443-9 1 *[1] *[2]

OUTBOARD SEAL 711Z3443-2 1 *[3]

DAM

4 Install (New)

5 Apply FILLET SEAL - 1 *[4]

6 Remove / Keep FASTENERS - 26 -

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

7 Remove / Keep

8 Remove BLADE SEAL 715Z3443-9 1 *[5]

*[2]

Trim the new Blade

Seal provided in the

Kit as shown before

Installation.

9 Cut BLADE SEAL 715Z3443-9 1

10 Install (New) BLADE SEAL 715Z3443-9 1 *[6]

11 Install (New) INBOARD SEAL DAM 710Z3443-2 1 *[3]

12 Apply FILLET SEAL - 1 *[4]

INBOARD UNDER- 715Z3230-10 1 -

WING PANEL

13 Install (Kept)

See Fastener Code

Table.

14 Install (Kept) FASTENERS - 26

15 Apply SEALANT - 1 *[7]

OUTBOARD UNDER- 715Z3210-14 1 *[8] *[9]

WING PANEL

16 Install (Kept)

See Fastener Code

Table.

17 Install (Kept) FASTENERS - 48

*[1] Do a General Visual Inspection of the Outboard Blade Seal for damage. If any damage is found, remove the damaged Outboard

Blade Seal and solvent clean the faying surface of the Skate Angle Structure. Install a new Outboard Blade Seal using Type 60 or

Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure. If no damage is found, no action is necessary.

*[2] New Blade Seal supplied in Kit may be longer than the length of the Skate Angle structure. If Blade Seal is longer than required, trim

to the same size as the removed Blade Seal.

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 220 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 1 

Step Action Name Identification Qty More Data

*[3] Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating surface

of the Seal Dam and the Aft Pylon Frame. Refer to SOPM 20-50-19 as an accepted procedure.

*[4] Apply a fillet seal along the entire edge of the mating surface of the Seal Dam and the Aft Pylon Frame except for mating surface

between Seal Dam and the Underwing Panel using BMS 5-63 Type II. Fill any gaps up to 0.200 inches if necessary. Refer to SOPM

20-50-19 as an accepted procedure.

*[5] Remove any residual adhesive on the faying surface of the Skate Angle structure and solvent clean. Refer to SOPM 20-50-12 and

SOPM 20-30-03 as an accepted procedure.

*[6] Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.

*[7] Apply a 0.063 thick, 1.00in wide, and 8.2in long BMS 1-68 Grade A, Form III Silicone Foam Rubber Sealant to the outboard side of

the Aft Pylon frame. Refer to SOPM 20-50-12 as an accepted procedure.

*[8] Apply a parting agent to the underside surface of the outboard fairing panel where the underside surface of the outboard fairing

panel mates with the Splice assembly. Refer to SOPM 20-50-19 as an accepted procedure.

*[9] Apply BMS 5-45 Sealant to the fairing Splice between the row of fastener holes in the splice and the edge of the inboard fairing assembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.

ICN-B787-A-000061-A-81205-07451-A-01-1

Figure 10 

2. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the

Task. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below

are the number of fasteners necessary for this Task.

Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

Bolt must be installed flush

to the panel. *[1] *[2]

BOLT, 100 DEG BACB31U3K5W 72 -

HEAD

A

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

B BOLT BACB31V4-5W 2 -

WASHER BACW10U-C419P 2 - -

Bolt must be installed flush

to the washer. *[3] *[4] *[5]

C BOLT BACB31V4-9W 3 -

WASHER BACW10U-C419P 3 - -

*[1] Refer to SOPM 20-50-18 as an accepted procedure for bolt installation.

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 221 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Table 2 

CODE NAME IDENTIFICATION QTY HOLE DIA MORE DATA

*[2] Apply 25 - 35 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[3] Solvent clean the underside of the fastener head and washer before installation. Refer to SOPM 20-11-03 and SOPM 20-50-18 as

an accepted procedure.

*[4] When installing bolt in the Inboard Underwing Panel, apply 39 - 41 in-lbs of Torque. When installing bolt in the Outboard Underwing

Panel, apply 45 - 55 in-lbs of torque. Refer to SOPM 20-50-18 as an accepted procedure.

*[5] Apply BMS 3-38 Corrosion Inhibiting material to all areas of the hole before fastener installation. Remove squeeze-out and excess

compound with a dry cloth.

Applicable To: B787-A-54-00-0004-12A-933B-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 222 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Alert Service Bulletin B787-81205-SB540004-00

Appendix A – INPUT SURVEY [Group 1-6:]

THIS ALERT SERVICE BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE

AIRPLANES SHOWN IN DATA MODULE SB B787-A-54-00-0004-00A-932A-D, PARAGRAPH 1.,

Alert:

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.

Applicable To: B787-A-54-00-0004-0AA-931D-D

Model 787 Issue 003, 03 Dec 2015

See Applicability of this data module

Page 223 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN
Procedure

Group 1-6:

1.

ICN-B787-A-000061-A-81205-07008-A-01-1

Figure 1 

Applicable To: B787-A-54-00-0004-0AA-931D-D

Model 787 End of data module Issue 003, 03 Dec 2015

See Applicability of this data module

Page 224 of 224

EXPORT CONTROLLED ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.

B787-81205-SB540004-00

Issue 002, 03 Dec 2015

AIRCRAFT SERVICE BULLETIN