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ALERT Alert Requirements Bulletin B787-81205-SB530085-00 RB FUSELAGE - Section 41 and 46 - Floor Panels and Seat Track - Sealant and Tape Application Copyright © 2024 The Boeing Company 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 This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774). No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 740 of the EAR.
ECCN: 9E991 B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 1 of 73 Export Controlled ECCN: 9E991 See page 1 for details
3.0 B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
Table of Contents Page
A. EFFECTIVITY3
1. Airplanes3
2. Spares Affected4
B. CONCURRENT REQUIREMENTS5
C. COMPLIANCE5
D. APPROVAL11
E. ACCOMPLISHMENT INSTRUCTIONS12
1. General Information12
2. Work Instructions13
TASK 1 – STA 1209 PASSENGER CABIN FLOOR SEAT TRACK DETAILED INSPECTION [Group 1] . 19 TASK 2 – STA 1209 PASSENGER CABIN FLOOR SEAT TRACK SEALANT APPLICATION [Group 1] . 22 TASK 3 – STA 1209 PASSENGER CABIN FLOOR SEAT TRACK MOISTURE BARRIER TAPE APPLICATION
[Group 1]25
TASK 4 – STA 1209 PASSENGER CABIN FLOOR SEAT TRACK DETAILED INSPECTION [Group 2] . 28 TASK 5 – STA 1209 PASSENGER CABIN FLOOR SEAT TRACK SEALANT APPLICATION [Group 2] . 31 TASK 6 – STA 1209 PASSENGER CABIN FLOOR SEAT TRACK MOISTURE BARRIER TAPE [Group 2] . 34 TASK 7 – STA 338 PASSENGER CABIN FLOOR SEAT TRACK DETAILED INSPECTION [Group 3] . . 37 TASK 8 – STA 338 PASSENGER CABIN FLOOR SEAT TRACK SEALANT APPLICATION [Group 3] . . 41 TASK 9 – STA 338 PASSENGER CABIN FLOOR SEAT TRACK TAPE DAM APPLICATION [Group 3] . 45 TASK 10 –STA 1209 PASSENGER CABIN FLOOR SEAT TRACK DETAILED INSPECTION [Group 3] . 49 TASK 11 –STA 1209 PASSENGER CABIN FLOOR SEAT TRACK SEALANT APPLICATION [Group 3] . 52 TASK 12 –STA 1209 PASSENGER CABIN FLOOR SEAT TRACK MOISTURE BARRIER TAPE APPLICATION
[Group 3]55
TASK 13 –STA 1209 PASSENGER CABIN FLOOR SEAT TRACK DETAILED INSPECTION [Group 4] . 58 TASK 14 –STA 1209 PASSENGER CABIN FLOOR SEAT TRACK SEALANT APPLICATION [Group 4] . 61 TASK 15 –STA 1209 PASSENGER CABIN FLOOR SEAT TRACK MOISTURE BARRIER TAPE APPLICATION
[Group 4]64
Appendix A – GENERAL PASSENGER CABIN FLOOR SEAT TRACK SEALING REQUIREMENTS [Group
1-4]67
B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 2 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND Alert:
THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING PROCESSES USED TO CREATE THE SERVICE
BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS...) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
A. EFFECTIVITY
1. Airplanes This bulletin is applicable to 787-8, 787-9, 787-10 Airplane(s), line number(s) 548, 582, 584, 587, 589, 591, 594, 596, 598, 601, 603, 605, 607, 610, 612, 614, 617, 619, 622, 624, 626, 629, 631, 633, 635, 638, 640, 642, 645, 647, 649, 651, 654, 656, 658, 661, 663, 665, 667, 670, 672, 674, 677-679, 681, 683, 686, 689-690, 693-695, 697, 699, 702, 704, 706-707, 709-713, 715, 718-722, 725-727, 729-731, 734, 736-738, 741, 743, 745, 747, 750, 752, 754, 757-759, 761-764, 766-768, 770-771, 773, 775-777, 779-784, 786-793, 795-811, 814-816, 818, 820, 822-826, 828, 830-832, 834, 836-838, 840-844, 846-848, 850-852, 854-862, 864-866, 868-874, 876-886, 888-892, 894- 897, 899-904, 906, 908-912, 914-918, 920, 922, 924-928, 930-940, 942-954, 956-964, 966-968, 970, 972-982, 984, 986-987, 989-990, 993-994, 996, 999, 1001-1002, 1004-1008, 1012-1013, 1017-1018, 1021-1022, 1024-1025, 1030, 1032, 1038, 1044, 1048, 1054, 1056, 1058, 1094 in 4 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
Table 1
DESCRIPTIONCONFIGURATIONGROUP 787-8 Airplanes that require sealant and moisture barrier tape in section 46 aft EE bays -1 787-9 Airplanes that require sealant and moisture barrier tape in section 46 aft EE bays -2 787-9 Airplanes that require sealant and tape dam in section 41 fwd and section 46 aft EE bays -3 787-10 Airplanes that require sealant and moisture barrier tape in section 46 aft EE bays -4 Airplane Models: 787-10, 787-8, 787-9 Table 2 GroupVariable Number 1ZA954 - ZA959 GroupVariable Number 1ZA963 - ZA965 GroupVariable Number 1ZA968 - ZA972 B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 3 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
GroupVariable Number 2ZB010 - ZB011 2ZB041 - ZB043 2ZB056 - ZB060 2ZB113 - ZB121 2ZB133 - ZB134 2ZB187 - ZB191 2ZB335 - ZB338 2ZB419 2ZB427 - ZB435 2ZB455 - ZB463 3ZB465 - ZB467 2ZB579 2ZB610 2ZB618 2ZB659 2ZB664 2ZB697 - ZB700 2ZB706 - ZB707 2ZB734 2ZB742 - ZB743 3ZB744 - ZB745 2ZB749 - ZB750 2ZB755 - ZB757 2ZB768 2ZB771 - ZB775 2ZB791 - ZB792 2ZB796 - ZB798 2ZB800 - ZB805 GroupVariable Number 3ZB810 - ZB811 2ZB815 - ZB817 2ZB831 2ZB834 2ZB841 2ZB858 - ZB863 2ZB890 2ZB893 - ZB903 2ZB908 - ZB918 2ZB924 2ZB926 - ZB927 2ZB934 - ZB943 2ZB967 - ZB971 2ZB977 - ZB978 2ZB980 - ZB985 2ZB993 3ZB994 2ZB995 - ZB996 4ZC003 - ZC015 4ZC036 - ZC048 4ZC061 - ZC069 4ZC101 - ZC102 4ZC116 - ZC117 4ZC126 - ZC129 4ZC151 - ZC152 4ZC155 - ZC158 4ZC211 - ZC216 4ZC221 - ZC225 GroupVariable Number 1ZD013 - ZD015 2ZE001 2ZE003 - ZE006 2ZE008 2ZE013 2ZE016 - ZE017 2ZE031 - ZE032 2ZE040 - ZE043 3ZE044 - ZE045 2ZE085 - ZE086 2ZE095 - ZE096 2ZE105 - ZE106 2ZE115 2ZE150 2ZE165 - ZE166 2ZE170 - ZE171 2ZE195 - ZE198 2ZE220 - ZE234 2ZE270 2ZE310 - ZE311 2ZE340 - ZE341 2ZE350 - ZE362 2ZE375 2ZE380 2ZE415 - ZE416 2ZE425 - ZE426 2ZE436 --
2. Spares Affected None.
B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 4 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
B. CONCURRENT REQUIREMENTS None.
C. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin B787-81205-SB530085-00 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin B787-81205-SB530085-00 RB mandatory.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.
Accomplish the required action, based on the applicable condition in Table 7, 8, 9, 10 and 11 in accordance with the Accomplishment Instructions.
Group 1:
Table 7 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application Boeing Recommended Compliance TimeActionCondition Within 5 years after the Issue 001 date of the Requirements Bulletin B787-81205-SB530085-00 RB.
Do a Detailed Inspection on the left and right buttock lines (BL) 11, BL 19, BL
39.5, and BL 66 seat tracks from STA 1209 until the end of the seat track for any missing, damaged, or deteriorated sealant and missing, damaged, or deteriorated moisture barrier tape.
All Airplanes.
-No further action required.
CONDITION 1:
NO MISSING, NO
DAMAGED AND NO
DETERIORATED
SEALANT AND NO
MISSING, NO DAM-
AGED AND NO DE-
TERIORATED
MOISTURE BARRI- ER TAPE FOUND.
B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 5 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
Group 1:
Table 7 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application Boeing Recommended Compliance TimeActionCondition Before further flight.Apply sealant to each affected area.
CONDITION 2:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
SEALANT FOUND.*[1]*[2] Before further flight.Apply moisture barrier tape to the seat tracks.
CONDITION 3:
ANY MISSING,
DAMAGED, OR DE-
TERIORATED
MOISTURE BARRI-
ER TAPE FOUND.*[1]*[3] *[1] Disposition each seat track individually for the given conditions.
*[2] Damaged or deteriorated sealant is defined as sealant with any crack, gap or disbondment of the seal.
*[3] Damaged or deteriorated moisture barrier tape is defined as tape with any tear or hole that overlaps any seat track hole.
Group 2:
Table 8 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application Boeing Recommended Compliance TimeActionCondition Within 5 years after the Issue 001 date of the Requirements Bulletin B787-81205-SB530085-00 RB.
Do a Detailed Inspection on the left and right buttock lines (BL) 11, BL 19, BL
39.5, and BL 66 seat tracks from STA 1209 until the end of the seat track for any missing, damaged, or deteriorated sealant and missing, damaged, or deteriorated moisture barrier tape.
All Airplanes.
B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 6 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
Group 2:
Table 8 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application Boeing Recommended Compliance TimeActionCondition -No further action required.
CONDITION 4:
NO MISSING, NO
DAMAGED AND NO
DETERIORATED
SEALANT AND NO
MISSING, NO DAM-
AGED AND NO DE-
TERIORATED
MOISTURE BARRI- ER TAPE FOUND.
Before further flight.Apply sealant to each affected area.
CONDITION 5:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
SEALANT FOUND.*[1]*[2] Before further flight.Apply moisture barrier tape at each affected area.
CONDITION 6:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
MOISTURE BARRI-
ER TAPE FOUND.*[1]*[3] *[1] Disposition each seat track individually for the given conditions.
*[2] Damaged or deteriorated sealant is defined as sealant with any crack, gap or disbondment of the seal.
*[3] Damaged or deteriorated moisture barrier tape is defined as tape with any tear or hole that overlaps any seat track hole.
B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 7 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
Group 3:
Table 9 Section 41 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Tape Dam Application Boeing Recommended Compliance TimeActionCondition Within 5 years after the Issue 001 date of the Requirements Bulletin B787-81205-SB530085-00 RB.
Do a Detailed Inspection on seat tracks from STA 338 to forward end of seat tracks at left and right buttock lines (BL) 66 and BL 86.5 in the forward Electronic Equipment Bay Sealing Zone for any missing, damaged, or deteriorated sealant in the vertical gaps at the seat track ends and any missing, damaged or deteriorated tape dams.
All Airplanes.
-No further action required.
CONDITION 7:
NO MISSING, NO
DAMAGED AND NO
DETERIORATED
SEALANT AND NO
MISSING, NO DAM-
AGED AND NO DE-
TERIORATED
MOISTURE BARRI- ER TAPE FOUND.
Before further flight.Apply sealant to each affected area.
CONDITION 8:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
SEALANT FOUND.*[1]*[2] Before further flight.Apply tape dam to each affected area.
CONDITION 9:
ANY MISSING,
DAMAGED OR DE-
TERIORATED TAPE DAMS FOUND.*[1]*[3] *[1] Disposition each seat track individually for the given conditions.
*[2] Damaged or deteriorated sealant is defined as sealant with any crack, gap or disbondment of the seal.
*[3] Damaged or deteriorated moisture barrier tape is defined as tape with any tear or hole that overlaps any seat track hole.
B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 8 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
Group 3:
Table 10 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application Boeing Recommended Compliance TimeActionCondition Within 5 years after the Issue 001 date of the Requirements Bulletin B787-81205-SB530085-00 RB.
Do a Detailed Inspection on the left and right buttock lines (BL) 11, BL 19, BL
39.5, and BL 66 seat tracks from STA 1209 until the end of the seat track for any missing, damaged, or deteriorated sealant and missing, damaged, or deteriorated moisture barrier tape.
All Airplanes.
-No further action required.
CONDITION 10:
NO MISSING, NO
DAMAGED AND NO
DETERIORATED
SEALANT AND NO
MISSING, NO DAM-
AGED AND NO DE-
TERIORATED
MOISTURE BARRI-
ER TAPE FOUND.ISTURE
BARRIER TAPE
FOUND ON THE
SEAT TRACK AND IS UNDAMAGED.
Before further flight.Apply sealant to each affected area.
CONDITION 11:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
SEALANT FOUND.*[1]*[2] Before further flight.Apply moisture barrier tape to each affected area.
CONDITION 12:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
MOISTURE BARRI-
ER TAPE FOUND.*[1]*[3] B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 9 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
Group 3:
Table 10 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application *[1] Disposition each seat track individually for the given conditions.
*[2] Damaged or deteriorated sealant is defined as sealant with any crack, gap or disbondment of the seal.
*[3] Damaged or deteriorated moisture barrier tape is defined as tape with any tear or hole that overlaps any seat track hole.
Group 4:
Table 11 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application Boeing Recommended Compliance TimeActionCondition Within 5 years after the Issue 001 date of the Requirements Bulletin B787-81205-SB530085-00 RB.
Do a Detailed Inspection on the left and right buttock lines (BL) 11, BL 19, BL
39.5, and BL 66 seat tracks from STA 1209 until the end of the seat track for any missing, damaged, or deteriorated sealant and missing, damaged, or deteriorated moisture barrier tape.
All Airplanes.
-No further action required.
CONDITION 13:
NO MISSING, NO
DAMAGED AND NO
DETERIORATED
SEALANT AND NO
MISSING, NO DAM-
AGED AND NO DE-
TERIORATED
MOISTURE BARRI- ER TAPE FOUND.
Before further flight.Apply sealant to each affected area.
CONDITION 14:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
SEALANT FOUND.*[1]*[2] B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 10 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
Group 4:
Table 11 Section 46 Passenger Cabin Floor Seat Track Detailed Inspection, Sealant and Moisture Barrier Tape Application Boeing Recommended Compliance TimeActionCondition Before further flight.Apply moisture barrier tape to each affected area.
CONDITION 15:
ANY MISSING,
DAMAGED OR DE-
TERIORATED
MOISTURE BARRI-
ER TAPE FOUND.*[1]*[3] *[1] Disposition each seat track individually for the given conditions.
*[2] Damaged or deteriorated sealant is defined as sealant with any crack, gap or disbondment of the seal.
*[3] Damaged or deteriorated moisture barrier tape is defined as tape with any tear or hole that overlaps any seat track hole.
D. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document comply with the applicable regulations and are FAA approved, as well as European Union Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in this Requirements Bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM Page 11 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530085-00 RB Issue 001, 06 Mar 2024 12:00:00 AM
REQUIREMENTS BULLETIN
E. ACCOMPLISHMENT INSTRUCTIONS
1. GENERAL INFORMATION NOTE: 1. This is an Enhanced Required for Compliance document. There will be a separate Service Bulletin (SB) and a separate Requirements Bulletin (RB). If an RB is mandated by an Airworthiness Directive (AD), then all applicable requirements specified in the RB must be done. In the RB, the "Refer to the listed procedures..." column of the table(s) in the Work Instructions is for reference only. The procedures in that column are not required by the AD and are for guidance only. For the related SB, some locations are marked RC Start and RC End to identify the requirements that are restated from the RB. For the related SB, the areas between RC Start and RC End, including sub-steps and any figures identified between RC Start and RC End, must be done to comply with the AD. Therefore, an Alternative Method of Compliance (AMOC) is required for any deviations to steps between RC Start and RC End, including substeps and identified figures. For the related SB, the steps not between RC Start and RC End may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC; this is provided that the steps between RC Start and RC End, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. Figures not required for compliance are omitted from the RB.
2. This is an Enhanced Required for Compliance document. The Boeing processes used to create the Service Bulletin (SB) and the Requirements Bulletin (RB) ensure that the information between "RC Start" and "RC End" in the SB are identical to the information in the same sections (Compliance, Work Instructions...) of the RB which the SB refers to as the related document.
3. 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.
4. The compliance times for the actions in Work Instructions are in Compliance.
5. Use of colors in Tasks is based on guidance from the S1000D International specification for technical publications.
6. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.
7. If the length of any fastener specified in this bulletin does not meet the installation standards in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this bulletin.
8. Unless shown differently, these dimensions and tolerances are used:
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