## Service Bulletin B787-81205-SB710026-00 POWER PLANT - GEnx-1B,

**Forward Engine Mount - Barrel Nut Change** Issue 001, 10 Jun 2015 B787-81205-SB710026-00 **Publication:**

**BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET** Copyright © 2015 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 Unpublished Work.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 and 787-9 Airplanes equipped with General Electric GEnx-1B engines. Refer to Data Module SB B787-A-71-00-0026-00A-932A-D, Paragraph 1., Effectivity for the list of affected airplanes.

**B787-81205-SB710026-00 TITLE PAGE**  **Issue 001, 10 Jun 2015 Page** **1 of** **38** EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. 6.0 **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **Table of Contents** Page Summary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PLANNING INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1. Effectivity

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A.Airplanes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B.Spares Affected

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2. Concurrent Requirements

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3. Reason

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4. Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5. Compliance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6. Approval

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7. Manpower

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 8. Weight and Balance Changes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 9. Electrical Load Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 10. References

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 A. Existing Data:

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

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

. . . 16 11. Publications Affected

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 12. Interchangeability and Intermixability of Parts

. . . . . . . . . . . . . . . . . . . . . . . . . 17 13. Software Accomplishment Summary

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 MATERIAL INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Material - Price and Availability

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2. Industry Support Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3. Parts Necessary for Each Airplane

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. Kits/Parts:

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

. . . . . . . . . . . . . . . . . . . . . . . 20 C.Parts Modified and Reidentified:

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4. Parts Necessary to Change Spares

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

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

. . . . . . . . . . . . . . . . . . . . . 21 ACCOMPLISHMENT INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. GENERAL INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2. WORK INSTRUCTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Task 1

–FORWARD ENGINE MOUNT BARREL NUT REPLACEMENT [Group 1: ]

. . . . . . . . . . . . 29 Appendix A

–PART DEMAND INTENT [Group 1: ]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

**B787-81205-SB710026-00 TABLE OF CONTENTS**  **Issue 001, 10 Jun 2015 Page** **2 of** **38** EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **List of Illustrations Description**  **Group 1-2:** Table 1 List of Illustrations - Service Bulletin B787-81205-SB710026-00 **Used In ICN**  B787-A-71-00-0026-00A-931C-D Issue 001 ICN-B787-A-000061-A-81205-10382-A-01-1 B787-A-71-00-0026-01A-933B-D Issue 001 ICN-B787-A-000061-A-81205-10383-A-01-1 B787-A-71-00-0026-01A-933B-D Issue 001 ICN-B787-A-000061-A-81205-10384-A-01-1 B787-A-71-00-0026-01A-933B-D Issue 001 ICN-B787-A-000061-A-81205-10385-A-01-1 B787-A-71-00-0026-0AA-931D-D Issue 001 ICN-B787-A-000061-A-81205-07008-A-01-1

**B787-A-71-00-0026-00A-00AA-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 3** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **List of Effective Data Modules**

**Description Group 1-2:**  Table 1 List of Effective Data Modules - Service Bulletin B787-81205-SB710026-00**Issue Date Issue Status**  **Issue Data Module** 
**– Information Name**  2015-06-10 New 001 B787-A-71-00-0026-00A-00AA-D

–List of Illustrations 2015-06-10 New 001 B787-A-71-00-0026-00A-00SA-D

–List of Effective Data Modules 2015-06-10 New 001 B787-A-71-00-0026-00A-931C-D

–Summary 2015-06-10 New 001 B787-A-71-00-0026-00A-932A-D

–PLANNING INFORMATION 2015-06-10 New 001 B787-A-71-00-0026-00A-934A-D

–MATERIAL INFORMATION 2015-06-10 New 001 B787-A-71-00-0026-00A-933A-D

– ACCOMPLISHMENT INSTRUCTIONS 2015-06-10 New 001 B787-A-71-00-0026-01A-933B-D

– Task 1

– FORWARD ENGINE MOUNT BARREL NUT REPLACEMENT [Group 1: ] 2015-06-10 New 001 B787-A-71-00-0026-0AA-931D-D

– Appendix A

–

PART DEMAND INTENT [Group 1: ]

**B787-A-71-00-0026-00A-00SA-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 4** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **Summary References** 

**Title Reference**  Spares Affected SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 1.B. Compliance SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 5. Weight and Balance Changes SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 8. Electrical Load Data SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 9. Publications Affected SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 11. Kits/Parts SB B787-A-71-00-0026-00A-934A-D Issue 001, Paragraph 3.A. Parts and Materials Supplied by the Operator SB B787-A-71-00-0026-00A-934A-D Issue 001, Paragraph 3.B. Special Tooling Necessary to do this Service Bulletin SB B787-A-71-00-0026-00A-934A-D Issue 001, Paragraph 6. Effectivity SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 1. Industry Support Information SB B787-A-71-00-0026-00A-934A-D Issue 001, Paragraph 2. Manpower SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 7. Material - Price and Availability SB B787-A-71-00-0026-00A-934A-D Issue 001, Paragraph 1. Service Bulletin B787-81205-SB710026-00

–Appendix A

– PART DEMAND INTENT [Group 1: ] SB B787-A-71-00-0026-0AA-931D-D Issue 001

**B787-A-71-00-0026-00A-931C-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 5** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Description

**Group 1-2: 1.**  **CONCURRENT REQUIREMENTS** None. **2. BACKGROUND**  Accomplishment of this service bulletin will replace the barrel nuts on the forward engine mount. The forward engine mount barrel nuts have been redesigned to reduce the likelihood of cracking. A crack on both sides of the barrel nut could cause complete failure of the barrel nut. Complete failure of two or more barrel nuts on the same engine reduces the load capacity of the forward engine mount and could result in possible separation of an engine from the airplane during flight. Separation of an engine under power could result in loss of control of the airplane. An operator reported that while replacing the No. 2 engine on a 747-8 airplane, the Non Destructive Test (NDT) inspection of the barrel nuts on the forward engine mount revealed cracks on two of the four barrel nuts. The operator also discovered one cracked barrel nut on the No. 1 engine of the 747-8 airplane. Thiswas the first reported occurrence on the 747-8. The Boeing Company did a Non Destructive Test (NDT) inspection of barrel nuts on a flight test 747-8 airplane. There were two barrel nuts where a crack had initiated. A service bulletin was issued to initiate inspections of the forward engine mount barrel nuts for the 747-8 fleet. Operators have reported three additional cracked barrel nuts on three separate airplanes since the release of that service bulletin. These barrel nuts are located at the forward end of the strut box and are used to fasten the forward engine mount to the strut. A barrel nut with a crack on one side will still be able to carry ultimate load. A crack on both sides of the barrel nut could cause complete failure of the barrel nut. Boeing has not received any reports of a barrel nut with a crack on both sides. 787 airplanes with General Electric (GE) engines have a similar forward engine mount configuration and use the same barrel nut part number as the 747-8. Therefore, Boeing service bulletin B787-81205-SB710021- 00 was released to inspect the forward engine mount barrel nuts on some airplanes. The inspections were performed on all of the airplanes in the effectivity, and no cracks were found. Nonetheless, the barrel nut has been redesigned. The newly designed barrel nut has increased strength due to its improved features. There is a deeper counterbore to help prevent high stress concentrations around the saddle of the barrel nut. As well, the barrel nut has more material added to it than the previous barrel nut to increase strength. In addition, the installation torque is reduced to prevent the newly designed barrel nuts from cracking. Airplanes in Group 2 of this service bulletin effectivity were delivered with the newly designed barrel nut part number on the forward engine mount. However, there is concern that the old barrel nut part number could have been installed during maintenance activity. These airplanes must verify that the old barrel nut part number was not installed after delivery during an engine change or other maintenance activity. Boeing Service Related Problem (SRP) 787-SRP-54-0151 is related to this service bulletin.This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

**B787-A-71-00-0026-00A-931C-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 6** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**Table 1 **Data Module Reference Affected**  **Planning Data** Data Module SB B787-A-71-00-0026-00A-932AD, Paragraph 1.B., Spares Affected Yes Spares Affected
Data Module SB B787-A-71-00-0026-00A-932AD, Paragraph 5., Compliance Yes AD Related
Data Module SB B787-A-71-00-0026-00A-932AD, Paragraph 8., Weight and Balance Changes No Weight and Balance Changed
Data Module SB B787-A-71-00-0026-00A-932AD, Paragraph 9., Electrical Load Data No Electrical Load Changed
Data Module SB B787-A-71-00-0026-00A-932AD, Paragraph 11., Publications Affected Yes Publications Affected
Data Module SB B787-A-71-00-0026-00A-932AD, Paragraph 11., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Data Module SB B787-A-71-00-0026-00A-934AD, Paragraph 3.A., Kits/Parts Yes Kits/Parts Required
Data Module SB B787-A-71-00-0026-00A-934AD, Paragraph 3.B., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material

Data Module SB B787-A-71-00-0026-00A-934AD, Paragraph 6., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**3. ACTION**  (CN-AA49111C) **Group 1:** On each engine, replace the four forward engine mount barrel nuts. **Group 2:** Review maintenance records and inspect, as necessary, to determine if barrel nut part number SL4081C14SP1 is installed at any forward engine mount location. If needed, contact Boeing for necessary action and do the required action. **Group 1-2: 4.**  **EFFECTIVITY** 787-8 and 787-9 Airplanes equipped with General Electric GEnx-1B engines. Refer to Data Module SB B787-A-71-00-0026-00A-932A-D, Paragraph 1., Effectivity for the list of affected airplanes.

**B787-A-71-00-0026-00A-931C-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 7** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN 5.**  **COMPLIANCE**

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. **Group 1:** Boeing recommends that the changes given in this service bulletin be done on both engines within 2 years after the Issue 001 date on this service bulletin. **Group 2:** Boeing recommends that the inspection and any necessary changes that result from the inspection given in this service bulletin be done on both engines within 2 years after the Issue 001 date on this service bulletin. **Group 1-2: 6.**  **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are available for airplanes in warranty as of June 5, 2014. Please refer to Data Module SB B787-A-71-00-0026-00A-934A-D, Paragraph 2., Industry Support Information. The warranty remedies will expire eight years from the Issue 001 date of this service bulletin. **7. MANPOWER**  Refer to Data Module SB B787-A-71-00-0026-00A-932A-D, Paragraph 7., Manpower. **8. MATERIAL INFORMATION**  Boeing Supplied Kits/Parts. Refer to Data Module SB B787-A-71-00-0026-00A-934A-D, Paragraph 1., Material - Price and Availability. Operators are encouraged to complete the survey provided in Data Module Appendix A, SB B787-A-71-00- 0026-0AA-931D-D of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

**B787-A-71-00-0026-00A-931C-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 8** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**ICN-B787-A-000061-A-81205-10382-A-01-1 Figure 1

**B787-A-71-00-0026-00A-931C-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 9** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **PLANNING INFORMATION References** 

**Title Reference**  Work Instructions SB B787-A-71-00-0026-00A-933A-D Issue 001, Step 2. Parts Necessary for Each Airplane SB B787-A-71-00-0026-00A-934A-D Issue 001, Paragraph 3. BOLT AND NUT INSTALLATION SOPM 20-50-01 Standard Wiring Practices Manual SWPM 20-10-11 Standard Wiring Practices Manual SWPM 20-10-12 Standard Wiring Practices Manual SWPM 20-10-19 POWER PLANT 787 AMM G71-00-00 TRAILING EDGE FLAP SYSTEM 787 AMM 27-51-00 LEADING EDGE SLAT SYSTEM 787 AMM 27-81-00 FORWARD FAIRINGS 787 AMM 54-62-01 FAN COWLS 787 AMM G71-11-04 THRUST REVERSER SYSTEM 787 AMM G78-31-00 

## Description **Group 1-2: 1.**  **Effectivity A.**  **Airplanes**This service bulletin is applicable to 787-8 and 787-9 Airplanes equipped with General Electric GEnx1B engines, line numbers 6, 11, 20-138, 141-277, 281-285, and 288-301 in two Groups. The Variable Numbers and Group information for the applicable airplanes is given below. Refer to CN-AA49111 for data about this change.

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 10** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**Table 1 **DESCRIPTION CONFIGURATION**  **GROUP** 787 airplanes equipped with GEnx-1B engines that were delivered with part number SL4081C14SP1 barrel nuts installed on the forward engine mount. - 1

787 airplanes equipped with GEnx-1B engines that were delivered with part number SL4750NA barrel nuts installed on the forward engine mount. These airplanes need to verify that part number SL4081C14SP1 barrel nuts were not installed due to a maintenance activity. - 2

Airplane Models: 787-8, 787-9 Table 2 **Group Variable Number**  1 ZA006 2 ZA152-ZA153 1 ZA175-ZA189 1 ZA195-ZA196 2 ZA197-ZA200 1 ZA215-ZA221 2 ZA222 1 ZA230-ZA247 2 ZA248-ZA249 1 ZA260-ZA269 1 ZA285-ZA295 2 ZA296 1 ZA317-ZA322 2 ZA323-ZA324 1 ZA327 1 ZA334 2 ZA335 2 ZA341-ZA342 1 ZA380-ZA389 1 ZA430-ZA437 2 ZA438-ZA439

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 11** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**Table 2 **Group Variable Number**  1 ZA460-ZA477 2 ZA478-ZA481 1 ZA560-ZA567 1 ZA586 1 ZA610-ZA614 2 ZA615-ZA617 1 ZA655-ZA660 2 ZA661 1 ZA680-ZA681 2 ZA682-ZA683 1 ZA695 1 ZA715-ZA716 1 ZA740 2 ZA741 2 ZA783-ZA784 2 ZA817-ZA822 2 ZA841 2 ZA846-ZA848 2 ZB077-ZB078 1 ZB167-ZB168 2 ZB169-ZB172 2 ZB299
**B. Spares Affected**  Examine your spares supply for the parts or components identified below. If any parts or components are found, refer to Data Module SB B787-A-71-00-0026-00A-933A-D, Step 2., Work Instructions for the recommended action. Table 3

**Part Number** SL4081C14SP1

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 12** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**Examine your Quick Engine Change (QEC) kits for parts or components changed as shown in this service bulletin. If any parts or components are found, refer to Data Module SB B787-A-71-00-0026- 00A-934A-D, Paragraph 3., Parts Necessary for Each Airplane, for the recommended use. Table 4 **Dash Number Part Number**  -5, -6, -30, -36, -38, -39, -40, -44, -45, -46, -47, -48, -49, -52, -53, -55, -61 QECGE787

**2. Concurrent Requirements**  None. **3. Reason**  Accomplishment of this service bulletin will replace the barrel nuts on the forward engine mount. The forward engine mount barrel nuts have been redesigned to reduce the likelihood of cracking. A crack on both sides of the barrel nut could cause complete failure of the barrel nut. Complete failure of two or more barrel nuts on the same engine reduces the load capacity of the forward engine mount and could result in possible separation of an engine from the airplane during flight. Separation of an engine under power could result in loss of control of the airplane. An operator reported that while replacing the No. 2 engine on a 747-8 airplane, the Non Destructive Test (NDT) inspection of the barrel nuts on the forward engine mount revealed cracks on two of the four barrel nuts. The operator also discovered one cracked barrel nut on the No. 1 engine of the 747-8 airplane. This was the first reported occurrence on the 747-8. The Boeing Company did a Non Destructive Test (NDT)inspection of barrel nuts on a flight test 747-8 airplane. There were two barrel nuts where a crack had initiated. A service bulletin was issued to initiate inspections of the forward engine mount barrel nuts for the 747-8 fleet. Operators have reported three additional cracked barrel nuts on three separate airplanes since the release of that service bulletin. These barrel nuts are located at the forward end of the strut box and are used to fasten the forward engine mount to the strut. A barrel nut with a crack on one side will still be able to carry ultimate load. A crack on both sides of the barrel nut could cause complete failure of the barrel nut. Boeing has not received any reports of a barrel nut with a crack on both sides. 787 airplanes with General Electric (GE) engines have a similar forward engine mount configuration and use the same barrel nut part number as the 747-8. Therefore, Boeing service bulletin B787-81205-SB710021- 00 was released to inspect the forward engine mount barrel nuts on some airplanes. The inspections were performed on all of the airplanes in the effectivity, and no cracks were found. Nonetheless, the barrel nut has been redesigned. The newly designed barrel nut has increased strength due to its improved features. There is a deeper counterbore to help prevent high stress concentrations around the saddle of the barrel nut. As well, the barrel nut has more material added to it than the previous barrel nut to increase strength. In addition, the installation torque is reduced to prevent the newly designed barrel nuts from cracking. Airplanes in Group 2 of this service bulletin effectivity were delivered with the newly designed barrel nut part number on the forward engine mount. However, there is concern that the old barrel nut part number could have been installed during maintenance activity. These airplanes must verify that the old barrel nut part number was not installed after delivery during an engine change or other maintenance activity. Boeing Service Related Problem (SRP) 787-SRP-54-0151 is related to this service bulletin.

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 13** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN 4.**  **Description**

**Group 1:** On each engine, replace the four forward engine mount barrel nuts. **Group 2:** Review maintenance records and inspect, as necessary, to determine if barrel nut part number SL4081C14SP1 is installed at any forward engine mount location. If needed, contact Boeing for necessary action and do the required action. **Group 1-2:** The work in this service bulletin is done in the maintenance zone(s) given below. Table 5 **Affected Maintenance Zones Zone**  **Model** 411, 421 787-8, 787-9
**5. Compliance**  The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. **Group 1:** Boeing recommends that the changes given in this service bulletin be done on both engines within 2 years after the Issue 001 date on this service bulletin. **Group 2:** Boeing recommends that the inspection and any necessary changes that result from the inspection given in this service bulletin be done on both engines within 2 years after the Issue 001 date on this service bulletin. **Group 1-2: 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 EuropeanAviation 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 engine. 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:

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 14** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**– 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 6 WORK PACKAGE 1: FORWARD ENGINE MOUNT BARREL NUT CHANGE, LEFT ENGINE **Elapsed Hours**

**Task Hours Number of Per-**  **sons Task** 
1.75 5.25 3 Open Access/Pre- pare 2.00 4.00 2 Task 1 1.75 5.25 3 Close Access 5.50 14.50 TOTAL FOR LEFT ENGINE **Group 1:** Table 7 WORK PACKAGE 2: FORWARD ENGINE MOUNT BARREL NUT CHANGE, RIGHT ENGINE **Elapsed Hours**

**Task Hours Number of Per-**  **sons Task** 
1.75 5.25 3 Open Access/Pre- pare 2.00 4.00 2 Task 1 1.75 5.25 3 Close Access 5.50 14.50 TOTAL FOR RIGHT ENGINE **Group 1:** NOTE: The task hour estimates above include the time necessary to install the forward bootstrap tool and remove the load from the forward engine mount in order to replace the barrel nuts. As an alternative, operators can replace the barrel nuts when an engine is changed. Refer to 787 AMM G71-00-00 as an accepted procedure to remove and install an engine.

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 15** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN Group 2:**  Table 8 WORK PACKAGE 2: FORWARD ENGINE MOUNT BARREL NUT, INSPECTION FOR INSTALLED BARREL NUT PART NUMBER **Elapsed Hours Task Hours**  **Number of Per- sons**  **Task**

1.00*[1] 2.00*[1] 2 Open Access/Pre- pare for Inspection 0.60*[1] 0.60*[1] 1 Inspect
1.00*[1] 2.00*[1] 2 Close Access
2.60*[1] 4.60*[1] TOTAL FOR EACH ENGINE *[1] These hours will only be necessary if the installed barrel nut part number cannot be verified by a review of maintenance records. **Group 1-2: 8.**  **Weight and Balance Changes** None. **9. Electrical Load Data**  Not changed. **10. References**  **A. Existing Data:**  1. Change Notice CN-AA49111C 2. Aircraft Maintenance Manual (AMM) 787 AMM 27-51-00, 787 AMM 27-81-00, 787 AMM 54-62- 01, 787 AMM G71-00-00, 787 AMM G71-11-04, 787 AMM G78-31-00 3. Standard Overhaul Practices Manual (SOPM) SOPM 20-50-01 4. Standard Wiring Practices Manual (SWPM) SWPM 20-10-11, SWPM 20-10-12, SWPM 20-10-19 5. Boeing Service Related Problem (SRP) 787-SRP-54-0151 6. Boeing Service Bulletin B787-81205-SB710021-00
**B. Data Supplied with this Service Bulletin:**  None. **C. Installation Requirement Modules Used in the Preparation of this Service Bulletin:**  Table 9 **Title Requirement Mod-**  **ule** ENGINE TO PYLON INSTALLATION 711Z4010

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 16** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**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 10**Chapter-Section Publication**  71-00 787 Maintenance Manual ZA4-13, ZA4-23, 71-21 787 Illustrated Parts Data 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 affects FCS but no new DTIs are necessary. **12. Interchangeability and Intermixability of Parts**  Refer to Data Module SB B787-A-71-00-0026-00A-934A-D, Paragraph 3., Parts Necessary for Each Airplane, for interchangeability and intermixability information. **13. Software Accomplishment Summary**  Not Affected.

**B787-A-71-00-0026-00A-932A-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 17** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **MATERIAL INFORMATION References** 

**Title Reference**  Service Bulletin B787-81205-SB710026-00

–Appendix A

–PART DEMAND INTENT [Group 1: ] SB B787-A-71-00-0026-0AA-931D-D Issue 001

References SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 10. 

## Description **Group 1-2: 1.**  **Material - Price and Availability Group 1:** Boeing can supply the kit 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. **Group 1:** Reference this service bulletin and submit your purchase order by one of these methods: **Group 1:** 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 **Group 1:** 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.

**B787-A-71-00-0026-00A-934A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 18** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN Group 1:**  Table 1 **Unit Price as of the Issue 001 date of** **this Service Bul letin (US Dollars)** **ROLT as of the Is sue 001 date of this**  **Service Bulletin (Calendar Days)**  **QTY Date**  **Name Kit Number** 

$1,988.00 186 20 December 16, 2014 SERVICE BUL- LETIN TOP KIT -GENX-1B FORWARD ENGINE MOUNT BARRELNUT REPLACEMENT 036Z0257-1 10 January 16, 2015 10 February 20, 2015 10 March 16, 2015 10 April 15, 2015 10 May 15, 2015 10 June 15, 2015 10 July 15, 2015 10 August 17, 2015 **Group 1:** Operators are encouraged to complete the survey provided in Data Module Appendix A, SB B787-A-71-00- 0026-0AA-931D-D of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts. **Group 2:** None. **Group 1-2: 2.**  **Industry Support Information**Boeing warranty remedies are available for 787 airplanes in warranty as of June 5, 2014. 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 Issue 001 date of this service bulletin. **3. Parts Necessary for Each Airplane**  **A. Kits/Parts:**  **Group 1:** To get the kits/parts shown below, refer to Paragraph 1., Material - Price and Availability. **Group 1:** NOTE: One top kit and the items shown in Paragraph 3.B., Parts and Materials Supplied by the Operator, are necessary for each engine.

**B787-A-71-00-0026-00A-934A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 19** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN Group 1:**  Table 2 **Kit 036Z0257 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -1**  SERVICE BULLETIN TOP KIT -GENX-1B FORWARD ENGINE MOUNT BARRELNUT REPLACEMENT - 036Z0257-1

RETROFIT KIT

1 711Z4010-805 **Group 1:** Table 3

**Kit 711Z4010 Notes**  **Existing Part Number**  **Name QTY**  **New Part Number -805**  RETROFIT KIT

- 711Z4010-805 *[1] *[2] *[3] SL4081C14SP1 BARREL NUT, SELF-LOCKING 4 SL4750NA

*[1]Discard the existing part. *[2]This part is used in production. *[3]You cannot use the existing part to replace the new or changed part. **Group 2:** None. **Group 1-2: B.**  **Parts and Materials Supplied by the Operator: Group 1:**  Table 4 **Notes Name**  **QTY Part Number /**  **Specification** *[1] NEVER-SEEZ PURE NICKEL SPECIAL ANTI-SEIZE - -
*[1]USM Corp. Sub of Emhart Industries Inc Bostik Div (V70707), 211 Boston St, Middleton 01949, Essex, MA.

**B787-A-71-00-0026-00A-934A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 20** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN Group 2:**  None. **Group 1-2: 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. **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-71-00-0026-00A-932A-D, Paragraph 10., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

**B787-A-71-00-0026-00A-934A-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 21** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **ACCOMPLISHMENT INSTRUCTIONS**

**References**

**Title Reference**  References SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 10. Manpower SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 7. Compliance SB B787-A-71-00-0026-00A-932A-D Issue 001, Paragraph 5. Service Bulletin B787-81205-SB710026-00

–Task 1

–FORWARD ENGINE MOUNT BARREL NUT REPLACEMENT [Group 1: ] SB B787-A-71-00-0026-01A-933B-D Issue 001

Standard Wiring Practices Manual SWPM 20-10-11 Standard Wiring Practices Manual SWPM 20-10-12 Standard Wiring Practices Manual SWPM 20-10-19 BOLT AND NUT INSTALLATION SOPM 20-50-01 POWER PLANT 787 AMM G71-00-00 LEADING EDGE SLAT SYSTEM 787 AMM 27-81-00 TRAILING EDGE FLAP SYSTEM 787 AMM 27-51-00 THRUST REVERSER SYSTEM 787 AMM G78-31-00 FAN COWLS 787 AMM G71-11-04 FORWARD FAIRINGS 787 AMM 54-62-01 

## Procedure **Group 1-2: 1.**  **GENERAL INFORMATION**

**B787-A-71-00-0026-00A-933A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 22** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN 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-71-00-0026-00A932A-D, Paragraph 10., References, for definition of the acronyms. 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-71-00-0026-00A-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. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted procedures. 7. The necessary conditions for selection of clamp type and size are included in SWPM 20-10-12. If any wire bundle support clamp specified in this service bulletin does not make a correct fit on the wire bundle, refer to SWPM 20-10-12 as an accepted procedure to select a clamp that fits correctly. 8. If the length of any fastener specified in this service bulletin does not meet the installationstandards 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.

**B787-A-71-00-0026-00A-933A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 23** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**9. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. 10.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. 11. 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. 12. 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. 13.This service bulletin includes functional test procedures for the systems changed by this servicebulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. 14. If shading is used, shaded areas in Tasks are to separate the non-critical and non-authoritative information from the critical and authoritative information. 15. Use of colors in Tasks is based on guidance from the S1000D International specification for technical publications. 16.The compliance times for the actions in Step 2., Work Instructions are in Data Module SB B787- A-71-00-0026-00A-932A-D, Paragraph 5., Compliance. 17. Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps identified as RC, including steps indented under an RC step, must be done to comply with the AD. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including indented steps. For steps not identified as RC, alternative procedures can be used, and an AMOC is not necessary, provided the RC steps, including indented steps, can still be done as specified, and the airplane can be put back in a serviceable condition.

**2. WORK INSTRUCTIONS**  **Group 1: A.**  **WORK PACKAGE 1: FORWARD ENGINE MOUNT BARREL NUT CHANGE, LEFT ENGINE**

These work instructions provide the steps necessary to install the forward bootstrap tool andremove the load from the forward engine mount in order to replace the barrel nuts. As an alterNOTE: native, operators can replace the barrel nuts when an engine is changed. Refer to 787 AMM G71-00-00 as an accepted procedure to remove and install an engine. (1) Make sure the leading edge slats and trailing edge flaps are retracted and deactivated. Refer to 787 AMM 27-81-00 and 787 AMM 27-51-00 as accepted procedures.

**B787-A-71-00-0026-00A-933A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 24** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**(2) Make sure the thrust reversers are retracted and deactivated. Refer to 787 AMM G78-31-00 as an accepted procedure. (3) Do these steps to make sure that the ENGINE START switch and the FUEL CONTROL switch are not operated: (a) On the pilot's overhead panel, P5, make sure that the applicable ENGINE START switch is in the NORM position. (b) Put a DO-NOT-OPERATE tag on the applicable ENGINE START switch. (c) On the control stand, P10, make sure that the applicable FUEL CONTROL switch is in the CUTOFF position. (d) Put a DO-NOT-OPERATE tag on the applicable FUEL CONTROL switch. (4) Remove the fan cowl. Refer to 787 AMM G71-11-04 as an accepted procedure. (5) Remove the forward fairing. Refer to 787 AMM 54-62-01 as an accepted procedure. (6) Install the forward bootstrap tool assembly to the pylon. Refer to 787 AMM G71-00-00 as an accepted procedure. (7) Install the two engine-to-bootstrap interface brackets to the engine fan case. Refer to 787 AMM G71-00-00 as an accepted procedure. (8) Attach the forward bootstrap tool hoists to the engine. Refer to 787 AMM G71-00-00 as an accepted procedure. (9) Apply a compressive force to the forward engine mount. Refer to 787 AMM G71-00-00 as an accepted procedure. NOTE: You apply the compressive force to the engine mount to remove the tension load from the forward engine mount bolts. (10) RC - Replace the forward engine mount barrel nuts in accordance with Data Module Task 1, SB B787-A-71-00-0026-01A-933B-D. (11) Remove the compressive force from the forward engine mount. Refer to 787 AMM G71-00-00 as an accepted procedure. (12) Remove the forward bootstrap tool hoists from the engine and remove the two engine-to-bootstrap interface brackets from the engine fan case. Refer to 787 AMM G71-00-00 as an accepted procedure. (13) Remove the forward bootstrap tool assembly. Refer to AMM 787 AMM G71-00-00 as an accepted procedure. (14) Install the forward fairing. Refer to 787 AMM 54-62-01 as an accepted procedure. (15) Install the fan cowl. Refer to 787 AMM G71-11-04 as an accepted procedure. (16) Do these steps to remove the DO-NOT-OPERATE tags from the applicable ENGINE START switch and FUEL CONTROL switch. (a) On the pilot's overhead panel, P5, remove the DO-NOT-OPERATE tag from the applicable ENGINE START switch.

**B787-A-71-00-0026-00A-933A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 25** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**(b) On the control stand, P10, remove the DO-NOT-OPERATE tag from the applicable FUEL CONTROL switch. (17) Activate the thrust reversers. Refer to 787 AMM G78-31-00 as an accepted procedure. (18) Activate the leading edge slats and trailing edge flaps. Refer to 787 AMM 27-81-00 and 787 AMM 27-51-00 as accepted procedures. (19) Put the airplane back to a serviceable condition. **Group 1: B.**  **WORK PACKAGE 2: FORWARD ENGINE MOUNT BARREL NUT CHANGE, RIGHT ENGINE**

These work instructions provide the steps necessary to install the forward bootstrap tool andremove the load from the forward engine mount in order to replace the barrel nuts. As an alterNOTE: native, operators can replace the barrel nuts when an engine is changed. Refer to 787 AMM G71-00-00 as an accepted procedure to remove and install an engine. (1) Make sure the leading edge slats and trailing edge flaps are retracted and deactivated. Refer to 787 AMM 27-81-00 and 787 AMM 27-51-00 as accepted procedures. (2) Make sure the thrust reversers are retracted and deactivated. Refer to 787 AMM G78-31-00 as an accepted procedure. (3) Do these steps to make sure that the ENGINE START switch and the FUEL CONTROL switch are not operated: (a) On the pilot's overhead panel, P5, make sure that the applicable ENGINE START switch is in the NORM position. (b) Put a DO-NOT-OPERATE tag on the applicable ENGINE START switch. (c) On the control stand, P10, make sure that the applicable FUEL CONTROL switch is in the CUTOFF position. (d) Put a DO-NOT-OPERATE tag on the applicable FUEL CONTROL switch. (4) Remove the fan cowl. Refer to 787 AMM G71-11-04 as an accepted procedure. (5) Remove the forward fairing. Refer to 787 AMM 54-62-01 as an accepted procedure. (6) Install the forward bootstrap tool assembly to the pylon. Refer to 787 AMM G71-00-00 as an accepted procedure. (7) Install the two engine-to-bootstrap interface brackets to the engine fan case. Refer to 787 AMM G71-00-00 as an accepted procedure. (8) Attach the forward bootstrap tool hoists to the engine. Refer to 787 AMM G71-00-00 as an accepted procedure. (9) Apply a compressive force to the forward engine mount. Refer to 787 AMM G71-00-00 as an accepted procedure. NOTE: You apply the compressive force to the engine mount to remove the tension load from the forward engine mount bolts. (10) RC - Replace the forward engine mount barrel nuts in accordance with Data Module Task 1, SB B787-A-71-00-0026-01A-933B-D.

**B787-A-71-00-0026-00A-933A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 26** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**(11) Remove the compressive force from the forward engine mount. Refer to 787 AMM G71-00-00 as an accepted procedure. (12) Remove the forward bootstrap tool hoists from the engine and remove the two engine-to-bootstrap interface brackets from the engine fan case. Refer to 787 AMM G71-00-00 as an accepted procedure. (13) Remove the forward bootstrap tool assembly. Refer to AMM 787 AMM G71-00-00 as an accepted procedure. (14) Install the forward fairing. Refer to 787 AMM 54-62-01 as an accepted procedure. (15) Install the fan cowl. Refer to 787 AMM G71-11-04 as an accepted procedure. (16) Do these steps to remove the DO-NOT-OPERATE tags from the applicable ENGINE START switch and FUEL CONTROL switch. (a) On the pilot's overhead panel, P5, remove the DO-NOT-OPERATE tag from the applicable ENGINE START switch. (b) On the control stand, P10, remove the DO-NOT-OPERATE tag from the applicable FUEL CONTROL switch. (17) Activate the thrust reversers. Refer to 787 AMM G78-31-00 as an accepted procedure. (18) Activate the leading edge slats and trailing edge flaps. Refer to 787 AMM 27-81-00 and 787 AMM 27-51-00 as accepted procedures. (19) Put the airplane back to a serviceable condition. **Group 2: C.**  **WORK PACKAGE 3: FORWARD ENGINE MOUNT BARREL NUT, INSPECTION FOR INSTALLED BARREL NUT PART NUMBER**  (1) RC - For each airplane engine, review maintenance records to determine if the airplane engine has been removed/installed or replaced. (a) If the airplane engine has not been removed/installed or replaced, no further action is required for this engine for Work Package 3. (b) If the airplane engine has been removed/installed or replaced, review maintenance records to determine if barrel nut part number SL4081C14SP1 was installed at any forward engine mount location. After reviewing maintenance records to determine if barrel nut part number SL4081C14SP1 was installed, do one of the following: 1) If maintenance records conclusively show that barrel nut part number SL4081C14SP1 was not installed, no further action is required for this engine for Work Package 3. 2) If maintenance records indicate that barrel nut part number SL4081C14SP1 was installed, or if the installation status of barrel nut part number SL4081C14SP1 is not conclusive, do the following steps on the applicable engine: a) Get access to the forward engine mount for inspection. Remove the forward fairing. Refer to 787 AMM 54-62-01 as an accepted procedure. NOTE: Access may be gained by opening the fan cowl if the appropriate lift or ladder equipment is available. To open the fan cowl, refer to 787 AMM G71-11-04 as

**B787-A-71-00-0026-00A-933A-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 27** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**an accepted procedure. Otherwise, access to the forward engine mount has been confirmed from above by removing the forward fairing. b) Do a detailed inspection of the four forward engine mount barrel nut locations to determine if the installed barrel nut is part number SL4750NA or part number SL4081C14SP1. Barrel nut part number SL4750NA has two vertical grooves cut into each face of the barrel nut. Barrel nut part number SL4081C14SP1 has a smooth face, which may includepart or serial number information. After doing the detailed inspection, do one of the following: <1> If barrel nut part number SL4750NA is installed at all four locations, install the forward fairing and close the fan cowl, if opened, as described below. <2> If barrel nut part number SL4081C14SP1 is installed at any location, or if the barrel nut part number cannot be determined, contact Boeing for the necessary action and do the required action. c) Install the forward fairing. Refer to 787 AMM 54-62-01 as an accepted procedure. d) Close the fan cowl, if opened. Refer to 787 AMM G71-11-04 as an accepted procedure. e) Put the airplane back to a serviceable condition.

**B787-A-71-00-0026-00A-933A-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 28** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00

**Task 1**
**– FORWARD ENGINE MOUNT BARREL NUT REPLACEMENT [Group**  **1: ] References** 

**Title Reference**  LUBRICATION SOPM 20-50-07 POWER PLANT 787 AMM G71-00-00 

## Preliminary Requirements **Required Conditions Data Module/Technical Publication**  **Action/Condition** B787-A-71-00-0026-00A-933A-D Issue 001 Service Bulletin B787-81205-SB710026-00 - ACCOMPLISHMENT INSTRUCTIONS

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 29** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Procedure

**This Task applies to Group 1:**

ICN-B787-A-000061-A-81205-10383-A-01-1 Figure 1

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 30** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**ICN-B787-A-000061-A-81205-10384-A-01-1 Figure 2

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 31** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**ICN-B787-A-000061-A-81205-10385-A-01-1 Figure 3

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 32** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 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 each engine. Table 1 **More Data Qty**  **Identification Name**  **Action Step**  Refer to 787 AMM G71-00-00 as an accepted procedure. 4 BACB30US14K39M BOLT Remove / Keep 1

Refer to 787 AMM G71-00-00 as an accepted procedure. 4 BACW10BP14ACU WASHER Remove / Keep

Refer to 787 AMM G71-00-00 as an accepted procedure. 4 SL4081C14SP1 NUT, BARREL Remove

Refer to 787 AMM G71-00-00 as an accepted procedure. 4 SLR4124C14 RETAINER Remove / Keep

Remove any existing grease from the bolt. 4
- BOLT Clean 2

Remove any existing grease from the bolt hole. 4
- BOLT HOLE Clean

Remove any existing grease from the barrel nut bores in the forward engine mount. 4
- BARREL NUT BORE Clean

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 33** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**Table 1 **More Data Qty**  **Identification Name**  **Action Step**  Do a Detailed Inspection of the kept bolts for damage. Replace any bolts that have visibledamage found during inspection. 4 BACB30US14K39M BOLT Inspect 3

Do a Detailed Inspection of the keptwashers for damage. Replace any washers that have visible damagefound during inspection. 4 BACW10BP14ACU WASHER Inspect

Do a Detailed Inspection of the keptretainers for damage. Replace any retainers that have visible damagefound during inspection. 4 SLR4124C14 RETAINER Inspect

Apply anti-seize compound to the threads and shank of the bolt and the cylindrical surfaces of the barrel nut. Refer to SOPM 20-50-07 as an accepted procedure. 4
- NEVER-SEEZ PURENICKEL SPECIAL ANTI-SEIZE Apply 4

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 34** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**Table 1 **More Data Qty**  **Identification Name**  **Action Step**  **CAUTION :**  DO NOT APPLY MORE THAN THE MAXIMUM SPECIFIED TORQUE WHEN YOU TIGHTEN

THE FASTENERS. DAMAGE TO THE PARTS MAY OCCUR IF TOO MUCH TORQUE IS APPLIED.
Hold the retainers on the barrel nutsand put the retainers and barrel nutsinto the forward engine mount with the rounded side of the nuts facing up. Make sure that the barrel nuts align correctly with the bolt holes. 4 SL4750NA BARREL NUT Install (New) 5

Make sure that theretainers are correctly installed in the index hole. 4 SLR4124C14 RETAINER Install (Kept)

4 BACB30US14K39M BOLT Install (Kept) 6 Install countersunk side of the washer adjacent to the bolt head. 4 BACW10BP14ACU WASHER Install (Kept)

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 35** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**Table 1 **More Data Qty**  **Identification Name**  **Action Step**  Monitor the torque necessary to turn the bolts. Make sure that the barrel nut run-on torque ismore than 70 inchpounds and lessthan 600 inchpounds with the boltlubricated with Never-Seez Pure Nickel Special anti-seize. If the run-on torque isnot in the limits, replace the barrel nut.If a barrel nut is replaced, check therun-on torque of replacement barrel nut. 4 SL4750NA BARREL NUT, SELF- LOCKING Torque 7

Tighten the bolts to an initial torque of1600-1800 inchpounds. Make sure to tighten the bolts evenly. Keep the differences in torque between the bolts to a minimum. 4 BACB30US14K39M BOLT Torque 8

Tighten the bolts to a final torque of3300-3500 inchpounds. Make sure to tighten the bolts evenly. Keep the differences in torque between the bolts to a minimum. 4 BACB30US14K39M BOLT Torque 9

After installing and applying the full torque to each ofthe four bolts, re-apply the final torqueof 3300-3500 inchpounds to each bolt. 4 BACB30US14K39M BOLT Torque 10

**B787-A-71-00-0026-01A-933B-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 36** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Service Bulletin B787-81205-SB710026-00 **Appendix A**
**–**

**PART DEMAND INTENT [Group 1: ]**

**B787-A-71-00-0026-0AA-931D-D Applicable To:**  **Issue 001, 10 Jun 2015** Model 787 See Applicability of this data module **Page 37** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**

## Procedure

**Group 1:** 1.

ICN-B787-A-000061-A-81205-07008-A-01-1 Figure 1

**B787-A-71-00-0026-0AA-931D-D Applicable To:**  **Issue 001, 10 Jun 2015 End of data module**  Model 787 See Applicability of this data module **Page 38** **of 38**  EXPORT CONTROLLED ECCN: 9E991 BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details. **B787-81205-SB710026-00 Issue 001, 10 Jun 2015**  **AIRCRAFT SERVICE BULLETIN**