# Boeing Service Bulletin B787-81205-SB540004-00

## Copies (2)

Copies the FAA filed in AD dockets on regulations.gov, newest revision first. A newer revision may exist.

- Revision 001 ("U.S. DOT/FAA - SB B787-81205-SB540004-00 Issue 001"), 220 pages: PDF https://openairdocs.org/files/sha256/86/ce/86ce409c70c9e28e95b8c5793444344bd028128eb96a4e5e92418d9f59d64db4; text https://openairdocs.org/service-documents/boeing/b787-81205-sb540004-00/file/86ce409c70c9.md. Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2015-2966; AD 2016-06-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- SB B787-81205-54A0004-00 Issue 002 ("SB B787-81205-54A0004-00 Issue 002"), 224 pages: PDF https://openairdocs.org/files/sha256/68/e9/68e9cc1141074c70fb471715c3693879329ddc1bab824ac62737477302ab95bc; text https://openairdocs.org/service-documents/boeing/b787-81205-sb540004-00/file/68e9cc114107.md. Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2015-2966; AD 2016-06-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.

## Details

- Manufacturer: [Boeing](https://openairdocs.org/service-documents/boeing.md)
- Type: Service bulletin (Service Bulletin)
- Number: B787-81205-SB540004-00
- Latest revision known: B787-81205-SB540004-00, Issue 002, dated December 3, 2015 (OpenAirDocs)
- Page: https://openairdocs.org/service-documents/boeing/b787-81205-sb540004-00

## ADs that cite it (1) (OpenAirDocs)

Newest first, with the revision each names, as OpenAirDocs read it from the AD's text.

- [AD 2016-06-10](https://openairdocs.org/ad/2016-06-10.md), effective May 3, 2016: Revisions 001 and 002

Also cited in [1 proposed AD](https://openairdocs.org/service-documents/boeing/b787-81205-sb540004-00/proposed.md).

## Text (220 pages)

Revision 001, the newest copy. Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2015-2966; AD 2016-06-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N.

### Page 1

Alert Service Bulletin B787-81205-SB540004-00 PYLON - General - Pylon
Structures - Fuel Leak Path Seal Installation
Issue 001, 24 Oct 2014B787-81205-SB540004-00Publication:
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 Unpublished Work.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.
B787-81205-SB540004-00TITLE PAGE
Issue 001, 24 Oct 2014
Page 1 of 220
EXPORT CONTROLLED ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.
3.0
B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN

### Page 2

Alert Service Bulletin B787-81205-SB540004-00
Table of Contents
Page
Summary  ....................................................1 1
PLANNING INFORMATION  ..........................................1 5
1. Effectivity  .............................................1 5
A. Airplanes  ...........................................1 5
B. Spares Affected  ........................................1 8
2. Concurrent Requirements  ....................................1 8
3. Reason  ..............................................1 8
4. Description  ............................................1 8
5. Compliance  ...........................................1 9
6. Approval  .............................................1 9
7. Manpower  ............................................1 9
8. Weight and Balance Changes  .................................2 1
9. Electrical Load Data  .......................................2 1
10. References  ...........................................2 1
A. Existing Data:  .........................................2 1
B. Data Supplied with this Service Bulletin:  ..........................2 1
C. Installation Requirement Modules Used in the Preparation of this Service Bulletin:  ...2 1
11. Publications Affected  ......................................2 2
12. Interchangeability and Intermixability of Parts  .........................2 2
13. Software Accomplishment Summary  ..............................2 2
MATERIAL INFORMATION  ..........................................2 3
1. Material - Price and Availability  .................................2 3
2. Industry Support Information  ..................................2 5
3. Parts Necessary for Each Airplane  ...............................2 5
A. Kits/Parts:  ...........................................2 5
B. Parts and Materials Supplied by the Operator:  .......................3 6
C. Parts Modified and Reidentified:  ...............................3 6
D. Parts Removed and Not Replaced:  .............................3 6
4. Parts Necessary to Change Spares  ..............................3 6
5. Special Tooling - Price and Availability  .............................3 6
6. Special Tooling Necessary to do this Service Bulletin  .....................3 7
ACCOMPLISHMENT INSTRUCTIONS  ...................................3 8
1. GENERAL INFORMATION  ...................................3 9
2. WORK INSTRUCTIONS  ....................................4 1
Task 1 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group
1 :  ] ...................................................4 3
Task 2 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION
[Group 1: ] ...............................................5 9
Task 3 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group
2 :  ] ...................................................7 5
B787-81205-SB540004-00TABLE OF CONTENTS
Issue 001, 24 Oct 2014
Page 2 of 220
EXPORT CONTROLLED ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.
B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN

### Page 3

Task 4 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION
[Group 2: ] ...............................................9 0
Task 5 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ] ...1 0 5
Task 6 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]. . 121
Task 7 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ] ...1 3 7
Task 8 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]. . 152
Task 9 – LEFT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group
5 :  ] ..................................................1 6 7
Task 10 – RIGHT ROLLS ROYCE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION
[Group 5: ] ..............................................1 8 0
Task 11 – LEFT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]. . 193
Task 12 – RIGHT GE ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]. . 206
Appendix A – INPUT SURVEY [Group 1-6:] .................................2 1 9
B787-81205-SB540004-00TABLE OF CONTENTS
Issue 001, 24 Oct 2014
Page 3 of 220
EXPORT CONTROLLED ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.
B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN

### Page 4

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
Used InICN
B787-A-54-00-0004-00A-931C-D Issue 002ICN-B787-A-000061-A-81205-07439-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07440-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07441-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07442-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07443-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07444-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07445-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07446-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07447-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07448-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07449-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002ICN-B787-A-000061-A-81205-07450-A-01-1
B787-A-54-00-0004-01A-933B-D Issue 002
B787-A-54-00-0004-02A-933B-D Issue 002
B787-A-54-00-0004-03A-933B-D Issue 002
B787-A-54-00-0004-04A-933B-D Issue 002
B787-A-54-00-0004-05A-933B-D Issue 002
B787-A-54-00-0004-06A-933B-D Issue 002
B787-A-54-00-0004-07A-933B-D Issue 002
B787-A-54-00-0004-08A-933B-D Issue 002
B787-A-54-00-0004-09A-933B-D Issue 002
B787-A-54-00-0004-10A-933B-D Issue 002
B787-A-54-00-0004-11A-933B-D Issue 002
B787-A-54-00-0004-12A-933B-D Issue 002
ICN-B787-A-000061-A-81205-07451-A-01-1
B787-A-54-00-0004-00A-00AA-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
Page 4 of 220
EXPORT CONTROLLED ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.
B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN

### Page 5

Table 1  List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00
Used InICN
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07452-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07453-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07454-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07455-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07456-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07457-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07458-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07459-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07460-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07461-A-01-1
B787-A-54-00-0004-02A-933B-D Issue 002ICN-B787-A-000061-A-81205-07462-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07463-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07464-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07465-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07466-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07467-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07468-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07469-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07470-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07471-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07472-A-01-1
B787-A-54-00-0004-03A-933B-D Issue 002ICN-B787-A-000061-A-81205-07473-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07474-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07475-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07476-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07477-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07478-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07479-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07480-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07481-A-01-1
B787-A-54-00-0004-00A-00AA-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
Page 5 of 220
EXPORT CONTROLLED ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.
B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN

### Page 6

Table 1  List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00
Used InICN
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07482-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07483-A-01-1
B787-A-54-00-0004-04A-933B-D Issue 002ICN-B787-A-000061-A-81205-07484-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07485-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07486-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07487-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07488-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07489-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07490-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07491-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07492-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07493-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07494-A-01-1
B787-A-54-00-0004-05A-933B-D Issue 002ICN-B787-A-000061-A-81205-07495-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07496-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07497-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07498-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07499-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07500-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07501-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07502-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07503-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07504-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07505-A-01-1
B787-A-54-00-0004-06A-933B-D Issue 002ICN-B787-A-000061-A-81205-07506-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07507-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07508-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07509-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07510-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07511-A-01-1
B787-A-54-00-0004-00A-00AA-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
Page 6 of 220
EXPORT CONTROLLED ECCN: 9E991
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET. See title page for details.
B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN

### Page 7

Table 1  List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00
Used InICN
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07512-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07513-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07514-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07515-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07516-A-01-1
B787-A-54-00-0004-07A-933B-D Issue 002ICN-B787-A-000061-A-81205-07517-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07518-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07519-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07520-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07521-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07522-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07523-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07524-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07525-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07526-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07527-A-01-1
B787-A-54-00-0004-08A-933B-D Issue 002ICN-B787-A-000061-A-81205-07528-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07529-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07530-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07531-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07532-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07533-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07534-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07535-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07536-A-01-1
B787-A-54-00-0004-09A-933B-D Issue 002ICN-B787-A-000061-A-81205-07537-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07538-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07539-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07540-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07541-A-01-1
B787-A-54-00-0004-00A-00AA-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
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AIRCRAFT SERVICE BULLETIN

### Page 8

Table 1  List of Illustrations - Alert Service Bulletin B787-81205-SB540004-00
Used InICN
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07542-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07543-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07544-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07545-A-01-1
B787-A-54-00-0004-10A-933B-D Issue 002ICN-B787-A-000061-A-81205-07546-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07547-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07548-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07549-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07550-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07551-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07552-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07553-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07554-A-01-1
B787-A-54-00-0004-11A-933B-D Issue 002ICN-B787-A-000061-A-81205-07555-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07556-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07557-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07558-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07559-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07560-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07561-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07562-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07563-A-01-1
B787-A-54-00-0004-12A-933B-D Issue 002ICN-B787-A-000061-A-81205-07564-A-01-1
B787-A-54-00-0004-0AA-931D-D Issue 002ICN-B787-A-000061-A-81205-07008-A-01-1
B787-A-54-00-0004-00A-00AA-DApplicable To:
Issue 002, 24 Oct 2014End of data moduleModel 787
See Applicability of this data module
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AIRCRAFT SERVICE BULLETIN

### Page 9

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
Issue DateIssue StatusIssueData Module – Information Name
2014-10-24Changed002B787-A-54-00-0004-00A-00AA-D – List of Illustrations
2014-10-24Changed002B787-A-54-00-0004-00A-00SA-D – List of Effective Data Modules
2014-10-24Changed002B787-A-54-00-0004-00A-931C-D – Summary
2014-10-24Changed002B787-A-54-00-0004-00A-932A-D – PLANNING INFORMATION
2014-10-24Changed002B787-A-54-00-0004-00A-934A-D – MATERIAL INFORMATION
2014-10-24Changed002B787-A-54-00-0004-00A-933A-D – ACCOMPLISHMENT INSTRUCTIONS
2014-10-24Changed002B787-A-54-00-0004-01A-933B-D – Task 1 – LEFT ROLLS ROYCE ENGINE
INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 1: ]
2014-10-24Changed002B787-A-54-00-0004-02A-933B-D – Task 2 – RIGHT ROLLS ROYCE EN-
GINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group
1: ]
2014-10-24Changed002B787-A-54-00-0004-03A-933B-D – Task 3 – LEFT ROLLS ROYCE ENGINE
INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 2: ]
2014-10-24Changed002B787-A-54-00-0004-04A-933B-D – Task 4 – RIGHT ROLLS ROYCE EN-
GINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group
2: ]
2014-10-24Changed002B787-A-54-00-0004-05A-933B-D – Task 5 – LEFT GE ENGINE INBOARD
AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]
2014-10-24Changed002B787-A-54-00-0004-06A-933B-D – Task 6 – RIGHT GE ENGINE INBOARD
AND OUTBOARD SEAL DAM INSTALLATION [Group 3: ]
2014-10-24Changed002B787-A-54-00-0004-07A-933B-D – Task 7 – LEFT GE ENGINE INBOARD
AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]
2014-10-24Changed002B787-A-54-00-0004-08A-933B-D – Task 8 – RIGHT GE ENGINE INBOARD
AND OUTBOARD SEAL DAM INSTALLATION [Group 4: ]
B787-A-54-00-0004-00A-00SA-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
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AIRCRAFT SERVICE BULLETIN

### Page 10

Table 1  List of Effective Data Modules - Alert Service Bulletin B787-81205-SB540004-00
Issue DateIssue StatusIssueData Module – Information Name
2014-10-24Changed002B787-A-54-00-0004-09A-933B-D – Task 9 – LEFT ROLLS ROYCE ENGINE
INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 5: ]
2014-10-24Changed002B787-A-54-00-0004-10A-933B-D – Task 10 – RIGHT ROLLS ROYCE
ENGINE INBOARD AND OUTBOARD SEAL DAM INSTALLATION [Group
5: ]
2014-10-24Changed002B787-A-54-00-0004-11A-933B-D – Task 11 – LEFT GE ENGINE INBOARD
AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]
2014-10-24Changed002B787-A-54-00-0004-12A-933B-D – Task 12 – RIGHT GE ENGINE IN-
BOARD AND OUTBOARD SEAL DAM INSTALLATION [Group 6: ]
2014-10-24Changed002B787-A-54-00-0004-0AA-931D-D – Appendix A – INPUT SURVEY [Group
1-6:]
B787-A-54-00-0004-00A-00SA-DApplicable To:
Issue 002, 24 Oct 2014End of data moduleModel 787
See Applicability of this data module
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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
TitleReference
Spares AffectedSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 1.B.
ComplianceSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 5.
Weight and Balance ChangesSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 8.
Electrical Load DataSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 9.
Publications AffectedSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 11.
Kits/PartsSB B787-A-54-00-0004-00A-934A-D Issue 002,
Paragraph 3.A.
Parts and Materials Supplied by the OperatorSB B787-A-54-00-0004-00A-934A-D Issue 002,
Paragraph 3.B.
Special Tooling Necessary to do this Service BulletinSB B787-A-54-00-0004-00A-934A-D Issue 002,
Paragraph 6.
EffectivitySB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 1.
Industry Support InformationSB B787-A-54-00-0004-00A-934A-D Issue 002,
Paragraph 2.
ManpowerSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 7.
Material - Price and AvailabilitySB B787-A-54-00-0004-00A-934A-D Issue 002,
Paragraph 1.
B787-A-54-00-0004-00A-931C-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
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AIRCRAFT SERVICE BULLETIN

### Page 12

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 in-
vestigation, 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 in-
formation.
Table 1  
Data Module ReferenceAffectedPlanning Data
Data Module SB B787-A-54-00-0004-00A-932A-
D, Paragraph 1.B., Spares Affected
NoSpares Affected
Data Module SB B787-A-54-00-0004-00A-932A-
D, Paragraph 5., Compliance
NoAD Related
Data Module SB B787-A-54-00-0004-00A-932A-
D, Paragraph 8., Weight and Balance Changes
YesWeight and Balance Changed
Data Module SB B787-A-54-00-0004-00A-932A-
D, Paragraph 9., Electrical Load Data
NoElectrical Load Changed
Data Module SB B787-A-54-00-0004-00A-932A-
D, Paragraph 11., Publications Affected
YesPublications Affected
Data Module SB B787-A-54-00-0004-00A-932A-
D, Paragraph 11., Publications Affected
NoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Data Module SB B787-A-54-00-0004-00A-934A-
D, Paragraph 3.A., Kits/Parts
YesKits/Parts Required
B787-A-54-00-0004-00A-931C-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
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### Page 13

Table 1  
Data Module ReferenceAffectedPlanning Data
Data Module SB B787-A-54-00-0004-00A-934A-
D, Paragraph 3.B., Parts and Materials Supplied
by the Operator
YesOperator Supplied Parts/Material
Data Module SB B787-A-54-00-0004-00A-934A-
D, Paragraph 6., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
3. ACTION
(CN-AA39164C)
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
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.
B787-A-54-00-0004-00A-931C-DApplicable To:
Issue 002, 24 Oct 2014Model 787
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AIRCRAFT SERVICE BULLETIN

### Page 14 (OCR)

@ BOEING  B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN
000000000
00  • 0000•00 0:00
B
REMOVE THE INBOARD PYLON
UNDER-WING PANEL AND
INSTALL INBOARD SEAL DAM
REMOVE THE OUTBOARD PYLON
UNDER-WING PANEL AND
INSTALL OUTBOARD SEAL DAM
ND
TYPICAL  TYPICAL
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 002, 24 Oct 2014
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### Page 15

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
TitleReference
REPAIR OF ELECTRICAL TERMINATIONS AND
ELECTRICAL BONDING AREAS
SOPM 20-11-03
GENERAL CLEANING PROCEDURESSOPM 20-30-03
BOLT AND NUT INSTALLATIONSOPM 20-50-01
APPLICATION OF ADHESIVESSOPM 20-50-12
FASTENER INSTALLATION IN COMPOSITE
STRUCTURES
SOPM 20-50-18
GENERAL SEALINGSOPM 20-50-19
Standard Wiring Practices ManualSWPM 20-10-11
Standard Wiring Practices ManualSWPM 20-10-12
Standard Wiring Practices ManualSWPM 20-10-19
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 appli-
cable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to
CN-AA39164 for data about this change.
B787-A-54-00-0004-00A-932A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
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### Page 16

Table 1  
DESCRIPTIONCONFIGURATIONGROUP
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  
GroupVariable Number
3ZA006
1ZA100-ZA103
2ZA104-ZA105
2ZA116-ZA123
5ZA124
2ZA135
5ZA136
3ZA150-ZA151
3ZA175-ZA177
4ZA178-ZA187
6ZA188-ZA189
4ZA215-ZA217
6ZA218-ZA220
4ZA230-ZA243
6ZA244-ZA245
4ZA260-ZA264
6ZA265-ZA268
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### Page 17

Table 2  
GroupVariable Number
2ZA270-ZA274
5ZA275
4ZA285-ZA294
6ZA295
4ZA317-ZA320
6ZA321
4ZA327
6ZA334
4ZA380-ZA387
6ZA388-ZA389
4ZA430-ZA435
6ZA436-ZA437
2ZA445-ZA446
5ZA447-ZA448
2ZA450-ZA453
5ZA454-ZA456
4ZA460-ZA471
6ZA472-ZA474
1ZA504-ZA505
2ZA506-ZA515
5ZA516
1ZA534-ZA535
2ZA536-ZA540
5ZA541-ZA542
4ZA560-ZA563
6ZA564-ZA565
2ZA576-ZA577
5ZA578-ZA580
4ZA586
5ZA588
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### Page 18

Table 2  
GroupVariable Number
6ZA610-ZA612
2ZA650
5ZA651
6ZA655-ZA657
6ZA695
5ZA778-ZA779
1ZA801-ZA804
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.
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.
The work in this service bulletin is done in the maintenance zone(s) given below.
B787-A-54-00-0004-00A-932A-DApplicable To:
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AIRCRAFT SERVICE BULLETIN

### Page 19

Table 3  
Affected Maintenance Zones
ZoneModel
434, 444787-8
5. Compliance
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 air-
planes 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  
Elapsed HoursTask HoursNumber of Per-
sons
Task
5.5011.002Work Package A
5.5011.002Work Package B
11.0022.00TOTAL FOR EACH AIRPLANE
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AIRCRAFT SERVICE BULLETIN

### Page 20

Group 2:
Table 5  
Elapsed HoursTask HoursNumber of Per-
sons
Task
4.509.002Work Package C
4.509.002Work Package D
9.0018.00TOTAL FOR EACH AIRPLANE
Group 5:
Table 6  
Elapsed HoursTask HoursNumber of Per-
sons
Task
3.256.502Work Package E
3.256.502Work Package F
6.5013.00TOTAL FOR EACH AIRPLANE
Group 3:
Table 7  
Elapsed HoursTask HoursNumber of Per-
sons
Task
5.5011.002Work Package G
5.5011.002Work Package H
11.0022.00TOTAL FOR EACH AIRPLANE
Group 4:
Table 8  
Elapsed HoursTask HoursNumber of Per-
sons
Task
4.509.002Work Package I
4.509.002Work Package J
9.0018.00TOTAL FOR EACH AIRPLANE
Group 6:
Table 9  
Elapsed HoursTask HoursNumber of Per-
sons
Task
3.256.502Work Package K
3.256.502Work Package L
6.5013.00TOTAL FOR EACH AIRPLANE
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Issue 002, 24 Oct 2014Model 787
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AIRCRAFT SERVICE BULLETIN

### Page 21

Group 1-6:
8. Weight and Balance Changes
Table 10  
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)
Airplane
+ 1,313.0+ 1.5All Airplanes
9. Electrical Load Data
Not changed.
10. References
A. Existing Data:
1. Change Notice CN-AA39164C
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
B. Data Supplied with this Service Bulletin:
None.
C. Installation Requirement Modules Used in the Preparation of this Service Bulletin:
Table 11  
TitleRequirement Mod-
ule
UNDERWING FAIRING INSTALLATION REWORK715Z3201-17
UNDERWING FAIRING INSTALLATION REWORK715Z3201-18
UNDERWING FAIRING INSTALLATION REWORK715Z3201-21
UNDERWING FAIRING INSTALLATION REWORK715Z3201-22
UNDERWING FAIRINGS - RECONCILIATION IRM715Z3201-23
UNDERWING FAIRINGS - RECONCILIATION IRM715Z3201-24
UNDERWING FAIRING INSTALLATION715Z3201-25
UNDERWING FAIRING INSTALLATION715Z3201-26
UNDERWING FAIRINGS - RECONCILIATION IRM715Z3201-29
UNDERWING FAIRINGS - RECONCILIATION IRM715Z3201-30
UNDERWING FAIRING INSTALLATION715Z3201-55
UNDERWING FAIRING INSTALLATION715Z3201-56
B787-A-54-00-0004-00A-932A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
Page 21 of 220
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AIRCRAFT SERVICE BULLETIN

### Page 22

Table 11  
TitleRequirement Mod-
ule
UNDERWING FAIRING INSTALLATION715Z3201-57
UNDERWING FAIRING INSTALLATION715Z3201-58
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  
Chapter-SectionPublication
54-64787 Maintenance Manual
54-62, ZA4-31, ZA4-41787 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 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.
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AIRCRAFT SERVICE BULLETIN

### Page 23

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
TitleReference
ReferencesSB B787-A-54-00-0004-00A-932A-D Issue 002,
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 en-
couraged 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 Bul-
letin (US Dollars)
ROLT as of the Is-
sue 001 date of this
Service Bulletin
(Calendar Days)
QTYDateNameKit Number
14,611.0013913October 14, 2014PYLON FUEL
LEAKAGE SEAL
INSTALLATION
036Z0136-5
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Issue 002, 24 Oct 2014Model 787
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AIRCRAFT SERVICE BULLETIN

### Page 24

Group 2:
Table 2  
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)
QTYDateNameKit Number
8,695.0013940October 14, 2014PYLON FUEL
LEAKAGE SEAL
INSTALLATION
036Z0136-6
Group 3:
Table 3  
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)
QTYDateNameKit Number
14,449.001396October 14, 2014PYLON FUEL
LEAKAGE SEAL
INSTALLATION
036Z0136-7
Group 4:
Table 4  
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)
QTYDateNameKit Number
8,672.0013978December 18, 2014PYLON FUEL
LEAKAGE SEAL
INSTALLATION
036Z0136-8
Group 5:
Table 5  
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)
QTYDateNameKit Number
5,402.0013918September 19, 2014PYLON FUEL
LEAKAGE SEAL
INSTALLATION
036Z0136-9
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
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AIRCRAFT SERVICE BULLETIN

### Page 25

Group 6:
Table 6  
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)
QTYDateNameKit Number
5,235.0013930September 19, 2014PYLON FUEL
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 Oper-
ator, are necessary for each airplane. 
Table 7  
Kit 036Z0136
NotesExisting Part
Number
NameQTYNew Part Number
-10-9-8-7-6-5
SERVICE BUL-
LETIN TOP KIT -
PYLON FUEL
LEAKAGE SEAL
INSTALLATION
.....-036Z0136-5
SERVICE BUL-
LETIN TOP KIT -
PYLON FUEL
LEAKAGE SEAL
INSTALLATION
....-.036Z0136-6
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
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Page 25 of 220
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AIRCRAFT SERVICE BULLETIN

### Page 26

Table 7  
Kit 036Z0136
NotesExisting Part
Number
NameQTYNew Part Number
-10-9-8-7-6-5
SERVICE BUL-
LETIN TOP KIT -
PYLON FUEL
LEAKAGE SEAL
INSTALLATION
...-..036Z0136-7
SERVICE BUL-
LETIN TOP KIT -
PYLON FUEL
LEAKAGE SEAL
INSTALLATION
..-...036Z0136-8
SERVICE BUL-
LETIN TOP KIT -
PYLON FUEL
LEAKAGE SEAL
INSTALLATION
.-....036Z0136-9
SERVICE BUL-
LETIN TOP KIT -
PYLON FUEL
LEAKAGE SEAL
INSTALLATION
-.....036Z0136-10
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
...1..711Z1002-1
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
...1..711Z1002-2
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
..1...711Z1002-3
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
..1...711Z1002-4
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
...1..711Z1002-5
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
...1..711Z1002-6
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
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AIRCRAFT SERVICE BULLETIN

### Page 27

Table 7  
Kit 036Z0136
NotesExisting Part
Number
NameQTYNew Part Number
-10-9-8-7-6-5
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
..1...711Z1002-7
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
..1...711Z1002-8
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
1.....711Z1002-9
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
1.....711Z1002-10
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
1.....711Z1002-11
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
1.....711Z1002-12
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
.....1715Z1002-1
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
.....1715Z1002-2
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
....1.715Z1002-3
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
....1.715Z1002-4
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.....1715Z1002-5
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.....1715Z1002-6
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
Page 27 of 220
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AIRCRAFT SERVICE BULLETIN

### Page 28

Table 7  
Kit 036Z0136
NotesExisting Part
Number
NameQTYNew Part Number
-10-9-8-7-6-5
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
....1.715Z1002-7
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
....1.715Z1002-8
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
.1....715Z1002-9
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
.1....715Z1002-10
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.1....715Z1002-11
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.1....715Z1002-12
Table 8  
Kit 711Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-6-5-4-3-2-1
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
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
Page 28 of 220
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### Page 29

Table 8  
Kit 711Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-6-5-4-3-2-1
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.-....711Z1002-5
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
-.....711Z1002-6
SEAL...1.1710Z3443-1
SEAL..1.1.710Z3443-2
SEAL.1....711Z3443-1
SEAL1.....711Z3443-2
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
.1....715Z3213-3
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
1.....715Z3213-4
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
.1....715Z3213-7
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
1.....715Z3213-8
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
.....1715Z3233-3
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
....1.715Z3233-4
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
Page 29 of 220
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### Page 30

Table 8  
Kit 711Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-6-5-4-3-2-1
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
...1.1715Z3233-7
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
..1.1.715Z3233-8
*[1] *[2]Seal, MID-SPRT.11.1.715Z3443-9
*[1] *[2]Seal-MID-SPRT1..1.1715Z3443-9
*[1] *[2]
*[3]
BOLT, 100 DEG
TENSION HEAD,
HEX DRIVE, 160
KSI MIN TENSILE,
6AL-4V TITANIUM
(NOM
202011102020BACB30NY5HK6
*[1] *[2]NUT, SELF-
LOCKING,
HEXAGON,
COUNTER-
BORED, ALU-
MINUM ALLOY
202011102020BACN10XJ08
*[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, fastener supplied in the kits may be one grip length longer than indicated. Also, if any
fastener part number are not available or have been superseded, substitute fasteners may be supplied in kits.
Table 9  
Kit 711Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-12-11-10-9-8-7
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.....-711Z1002-7
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
....-.711Z1002-8
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
See Applicability of this data module
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### Page 31

Table 9  
Kit 711Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-12-11-10-9-8-7
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
SEAL...1..710Z3443-1
SEAL..1...710Z3443-2
SEAL.1...1711Z3443-1
SEAL1...1.711Z3443-2
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
.....1715Z3213-7
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
....1.715Z3213-8
*[1] *[2]Seal, MID-SPRT.11..1715Z3443-9
*[1] *[2]Seal-MID-SPRT1..11.715Z3443-9
B787-A-54-00-0004-00A-934A-DApplicable To:
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### Page 32

Table 9  
Kit 711Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-12-11-10-9-8-7
*[1] *[2]
*[3]
BOLT, 100 DEG
TENSION HEAD,
HEX DRIVE, 160
KSI MIN TENSILE,
6AL-4V TITANIUM
(NOM
....2011BACB30NY5HK6
*[1] *[2]NUT, SELF-
LOCKING,
HEXAGON,
COUNTER-
BORED, ALU-
MINUM ALLOY
....2011BACN10XJ08
*[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, fastener supplied in the kits may be one grip length longer than indicated. Also, if any
fastener part number are not available or have been superseded, substitute fasteners may be supplied in kits.
Table 10  
Kit 715Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-6-5-4-3-2-1
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
B787-A-54-00-0004-00A-934A-DApplicable To:
Issue 002, 24 Oct 2014Model 787
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### Page 33

Table 10  
Kit 715Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-6-5-4-3-2-1
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
-.....715Z1002-6
SEAL...1.1710Z3443-1
SEAL..1.1.710Z3443-2
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
.1....715Z3213-3
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
1.....715Z3213-4
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
.1....715Z3213-7
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
1.....715Z3213-8
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
.....1715Z3233-3
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
....1.715Z3233-4
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
...1.1715Z3233-7
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
INBOARD
..1.1.715Z3233-8
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Table 10  
Kit 715Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-6-5-4-3-2-1
*[1] *[2]Seal, MID-SPRT.11.1.715Z3443-9
SEAL.1....715Z3443-11
SEAL1.....715Z3443-12
*[1] *[2]Seal-MID-SPRT1..1.1715Z3443-9
*[1] *[2]
*[3]
BOLT, 100 DEG
TENSION HEAD,
HEX DRIVE, 160
KSI MIN TENSILE,
6AL-4V TITANIUM
(NOM
202011112020BACB30NY5HK6
*[1] *[2]NUT, SELF-
LOCKING,
HEXAGON,
COUNTER-
BORED, ALU-
MINUM ALLOY
202011112020BACN10XJ08
*[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
NotesExisting Part
Number
NameQTYNew Part Number
-12-11-10-9-8-7
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.....-715Z1002-7
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
....-.715Z1002-8
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
...-..715Z1002-9
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Table 11  
Kit 715Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-12-11-10-9-8-7
RETROFIT KIT -
PYLON SEAL
DAM, INBOARD
..-...715Z1002-10
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
.-....715Z1002-11
RETROFIT KIT -
PYLON SEAL
DAM, OUTBOARD
-.....715Z1002-12
SEAL...1..710Z3443-1
SEAL..1...710Z3443-2
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
.....1715Z3213-7
*[1] *[2]RETAINER -
SEAL, UNDER-
WING FAIRING,
OUTBOARD
....1.715Z3213-8
*[1] *[2]Seal, MID-SPRT.11..1715Z3443-9
SEAL.1...1715Z3443-11
SEAL1...1.715Z3443-12
*[1] *[2]Seal-MID-SPRT1..11.715Z3443-9
*[1] *[2]
*[3]
BOLT, 100 DEG
TENSION HEAD,
HEX DRIVE, 160
KSI MIN TENSILE,
6AL-4V TITANIUM
(NOM
....2020BACB30NY5HK6
*[1] *[2]NUT, SELF-
LOCKING,
HEXAGON,
COUNTER-
BORED, ALU-
MINUM ALLOY
....2020BACN10XJ08
*[1]  Discard the existing part.
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Table 11  
Kit 715Z1002
NotesExisting Part
Number
NameQTYNew Part Number
-12-11-10-9-8-7
*[2]  You cannot use the existing part to replace the new or changed part.
*[3]  If grip length shown is not available at Boeing, fastener supplied in the kits may be one grip length longer than indicated. Also, if any
fastener part number are not available or have been superseded, substitute fasteners may be supplied in kits.
B. Parts and Materials Supplied by the Operator:
Table 12  
NotesNameQTYPart Number /
Specification
*[1]ADHESIVEAs Re-
quired
Type 68
*[1]ADHESIVEAs Re-
quired
Type 60
*[1]SEALANTAs Re-
quired
BMS 5-63 TYPE
II
*[1]SEALANTAs Re-
quired
BMS 5-45
*[1]CORROSION INHIBITING COM-
POUND
As Re-
quired
BMS 3-38
*[1]SILICONE FOAM RUBBER
SEALANT
As Re-
quired
BMS 1-68 Grade
A, Form III
*[1]  See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.
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.
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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.
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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
TitleReference
ReferencesSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 10.
ManpowerSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 7.
ComplianceSB B787-A-54-00-0004-00A-932A-D Issue 002,
Paragraph 5.
Alert Service Bulletin
B787-81205-SB540004-00 – Task 1 – LEFT ROLLS
SB B787-A-54-00-0004-01A-933B-D Issue 002
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 002
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 002
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 002
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 002
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 002
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### Page 39

TitleReference
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 002
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 002
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 002
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 002
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 002
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 002
ENGINE INBOARD AND OUTBOARD SEAL DAM
INSTALLATION [Group 6: ]
BOLT AND NUT INSTALLATIONSOPM 20-50-01
Procedure
Group 1-6:
1. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTI-
CLES 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-54-00-0004-00A-
932A-D, Paragraph 10., References, for definition of the acronyms.
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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 Main-
tenance 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 Mainte-
nance Manual (AMM).
– Non-standard torque values for maintenance tasks are included in the applicable instal-
lation 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 substi-
tute, 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 drop-
light 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
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### Page 41

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 accor-
dance 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 ac-
cordance 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 accor-
dance 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 ac-
cordance 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 accor-
dance 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 ac-
cordance with Data Module Task 10, SB B787-A-54-00-0004-10A-933B-D.
(1)
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### Page 42

(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 accor-
dance 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 ac-
cordance 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 accor-
dance 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 ac-
cordance 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 accor-
dance 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 ac-
cordance with Data Module Task 12, SB B787-A-54-00-0004-12A-933B-D.
(2) Put the airplane back to a serviceable condition.
B787-A-54-00-0004-00A-933A-DApplicable To:
Issue 002, 24 Oct 2014End of data moduleModel 787
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### Page 43

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
TitleReference
APPLICATION OF ADHESIVESSOPM 20-50-12
GENERAL CLEANING PROCEDURESSOPM 20-30-03
GENERAL SEALINGSOPM 20-50-19
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
Data Module/Technical PublicationAction/Condition
B787-A-54-00-0004-00A-933A-D Issue 002Alert Service Bulletin B787-81205-SB540004-00 -
ACCOMPLISHMENT INSTRUCTIONS
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AIRCRAFT SERVICE BULLETIN

### Page 44 (OCR)

@ BOEINE  B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN
Procedure
This Task applies to Group 1:
[] 030000
17 LOCATIONS
O%
2328478
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 002, 24 Oct 2014
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### Page 45 (OCR)

BOEING  B787-81205-SB540004-00
Issue 001, 24 Oct 2014
AIRCRAFT SERVICE BULLETIN
G
C
A-A
ICN-B787-A-000061-A-81205-07441-A-01-1
Figure 2
Applicable To:  B787-A-54-00-0004-01 A-933B-D
Model 787  Issue 002, 24 Oct 2014
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ICN-B787-A-000061-A-81205-07442-A-01-1
Figure 3  
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ICN-B787-A-000061-A-81205-07443-A-01-1
Figure 4  
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### Page 48

ICN-B787-A-000061-A-81205-07444-A-01-1
Figure 5  
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### Page 49

ICN-B787-A-000061-A-81205-07445-A-01-1
Figure 6  
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### Page 50

ICN-B787-A-000061-A-81205-07446-A-01-1
Figure 7  
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### Page 51

ICN-B787-A-000061-A-81205-07447-A-01-1
Figure 8  
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### Page 52

ICN-B787-A-000061-A-81205-07448-A-01-1
Figure 9  
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### Page 53

ICN-B787-A-000061-A-81205-07449-A-01-1
Figure 10  
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### Page 54

ICN-B787-A-000061-A-81205-07450-A-01-1
Figure 11  
B787-A-54-00-0004-01A-933B-DApplicable To:
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### Page 55

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  
More DataQtyIdentificationNameActionStep
-40-FASTENERSRemove / Keep1
-1715Z3230-7INBOARD UNDER-
WING PANEL
Remove / Keep2
-20-FASTENERSRemove3
-1715Z3233-1BULB SEAL RETAIN-
ER
Remove4
-1715Z3233-7BULB SEAL RETAIN-
ER
Install (New)5
-1715Z3233-3BULB SEAL RETAIN-
ER
Install (New)6
See Fastener Code
Table.
20-FASTENERSInstall (New)7
*[1]1715Z3443-9BLADE SEALRemove8
*[2]
Trim the new Blade
Seal provided in the
kit as shown before
installation.
1715Z3443-9BLADE SEALCut9
*[3]1715Z3443-9BLADE SEALInstall (New)10
*[4]1710Z3443-1INBOARD SEAL DAMInstall (New)11
*[5]1-FILLET SEALApply12
-34-FASTENERSRemove / Keep13
-1715Z3210-11OUTBOARD UNDER-
WING PANEL
Remove / Keep14
-20-FASTENERSRemove15
-1715Z3213-1BULB SEAL RETAIN-
ER
Remove16
-1715Z3213-3BULB SEAL RETAIN-
ER
Install (New)17
-1715Z3213-7BULB SEAL RETAIN-
ER
Install (New)18
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### Page 56

Table 1  
More DataQtyIdentificationNameActionStep
See Fastener Code
Table.
20-FASTENERSInstall (New)19
*[6] *[2]1715Z3443-9BLADE SEALInspect20
*[4]1715Z3443-11OUTBOARD SEAL
DAM
Install (New)21
*[5]1-FILLET SEALApply22
*[7]1-SEALANTApply23
*[8]1715Z3210-11OUTBOARD UNDER-
WING PANEL
Install (Kept)24
See Fastener Code
Table.
34-FASTENERSInstall (Kept)25
*[9]1715Z3230-7INBOARD UNDER-
WING PANEL
Install (Kept)26
See Fastener Code
Table.
40-FASTENERSInstall (Kept)27
*[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]  Bond the Blade Seal to the structure using Type 60 or Type 68 adhesive. Refer to SOPM 20-50-12 as an accepted procedure.
*[3]  Lightly abrade the Seal Dam to remove surface gloss. Install Seal Dam by applying BMS 5-63 Sealant to the entire mating s urface
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]  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.
*[6]  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.
*[7]  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.
*[8]  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 as-
sembly. Remove any squeeze-out between fairing. Refer to SOPM 20-50-19 as an accepted procedure.
*[9]  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.
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### Page 57

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  
MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE
Bolt must be installed flush
to the washer. *[1] *[2] *[3]
-2BACB31V4-5WBOLT, 100 DEG
HEAD
A
--2BACW10U-C419PWASHER
Bolt must be installed flush
to the panel. *[4] *[5]
-72BACB31U3K5WBOLTB
Bolt must be installed flush
to the washer. *[1] *[2] *[3]
-3BACB31V4-9WBOLTC
--3BACW10U-C419PWASHER
Bolt must be installed flush
to the panel. *[6] *[7]
-1BACB30NY5HK6BOLTD
--1NAS1149V0363MWASHER
--1BACN10XJ08NUT
Bolt must be installed flush
to the panel. *[6] *[7]
-39BACB30NY5HK6BOLTE
--39BACN10XJ08NUT
*[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 an d excess
compound with a dry cloth.
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### Page 58

Table 2  
MORE DATAHOLE DIAQTYIDENTIFICATIONNAMECODE
*[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 proce dure.
*[7]  Apply 13 - 16 in-lbs of Torque. Refer to SOPM 20-50-18 as an accepted procedure.
B787-A-54-00-0004-01A-933B-DApplicable To:
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### Page 59

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
TitleReference
APPLICATION OF ADHESIVESSOPM 20-50-12
GENERAL SEALINGSOPM 20-50-19
GENERAL CLEANING PROCEDURESSOPM 20-30-03
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
Data Module/Technical PublicationAction/Condition
B787-A-54-00-0004-00A-933A-D Issue 002Alert Service Bulletin B787-81205-SB540004-00 -
ACCOMPLISHMENT INSTRUCTIONS
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### Page 60

Procedure
This Task applies to Group 1:
ICN-B787-A-000061-A-81205-07452-A-01-1
Figure 1  
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