Boeing Alert Requirements Bulletin B787-81205-SB530089-00 RB

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Manufacturer: Boeing
Type: Alert Requirements Bulletin
Number: B787-81205-SB530089-00 RB
Latest revision known: B787-81205-SB530089-00 RB, Issue 001, dated February 7, 2025
Copies: 2 files of 1 revision

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AD 2026-01-06Fuselage · Boeing 787-9 and 787-10Effective Feb 20, 2026 · Revision 001

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Revision 001, part 1 of 2, the newest copy. Some pages are OCR from a scan. OCR can misread letters and numbers. © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2025-1110; AD 2026-01-06 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.

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ALERT Alert Requirements Bulletin B787-81205-SB530089-00 RB FUSELAGE - Section 46 - Cargo Barrier Fitting Links Inspection and Replacement Copyright © 2025 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-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 1 of 73 Export Controlled ECCN: 9E991 See page 1 for details

3.0 B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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Table of Contents Page

A. EFFECTIVITY3

1. Airplanes3

2. Spares Affected4

B. CONCURRENT REQUIREMENTS4

C. COMPLIANCE4

D. APPROVAL5

E. ACCOMPLISHMENT INSTRUCTIONS6

1. General Information6

2. Work Instructions7

TASK 1 – SECTION 46 LEFT AND RIGHT CARGO BARRIER FITTING LINKS INSPECTION [Group 1-3] . 12

TASK 2 – SECTION 46 LEFT CARGO BARRIER FITTING LINK REMOVAL [Group 1]16

TASK 3 – SECTION 46 LEFT CARGO BARRIER FITTING LINK INSTALLATION [Group 1]20

TASK 4 – SECTION 46 RIGHT CARGO BARRIER FITTING LINK REMOVAL [Group 1]25

TASK 5 – SECTION 46 RIGHT CARGO BARRIER FITTING LINK INSTALLATION [Group 1]29

TASK 6 – SECTION 46 LEFT CARGO BARRIER FITTING LINK REMOVAL [Group 2]34

TASK 7 – SECTION 46 LEFT CARGO BARRIER FITTING LINK INSTALLATION [Group 2]38

TASK 8 – SECTION 46 RIGHT CARGO BARRIER FITTING LINK REMOVAL [Group 2]43

TASK 9 – SECTION 46 RIGHT CARGO BARRIER FITTING LINK INSTALLATION [Group 2]47

TASK 10 – SECTION 46 LEFT CARGO BARRIER FITTING LINK REMOVAL [Group 3]52

TASK 11 – SECTION 46 LEFT CARGO BARRIER FITTING LINK INSTALLATION [Group 3]56

TASK 12 – SECTION 46 RIGHT CARGO BARRIER FITTING LINK REMOVAL [Group 3]61

TASK 13 – SECTION 46 RIGHT CARGO BARRIER FITTING LINK INSTALLATION [Group 3]65

Appendix A – PROCEDURE FOR X-RAY FLUORESCENCE SPECTROMETER INSPECTION [Group 1-3]

.69

B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 2 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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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 787-9, 787-10 Airplane(s), line number(s) 451-456, 458-459, 461-469, 471-473, 475, 477-481, 483-488, 490-494, 496-498, 500-504, 507, 509-510, 512, 514-518, 520- 521, 523-531, 533-534, 536-539, 541-545, 547-551, 553-556, 558, 560-567, 569-572, 574-578, 580-582, 584-591, 593-594, 596-598, 600-608, 610-617, 619-624, 626, 628-651, 653-659, 661- 687, 689-700 in 3 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.

The variable Numbers and Group information for the applicable airplanes is given below.

Table 1

DESCRIPTIONCONFIGURATIONGROUP 787-9 Airplanes installed with cargo barrier fitting links that are possibly commercially pure unalloyed titanium.

-1 787-10 Airplanes installed with cargo barrier fitting links that are possibly commercially pure unalloyed titanium.

-2 787-9 Airplane with cargo barrier fitting links that are possibly commercially pure unalloyed titanium installed with oversized fasteners.

-3 Airplane Models: 787-10, 787-9 Table 2 GroupVariable Number 1ZB007 - ZB011 1ZB025 - ZB026 1ZB040 - ZB043 1ZB050 - ZB060 1ZB099 - ZB101 GroupVariable Number 3ZB102 1ZB103 - ZB111 1ZB133 - ZB134 1ZB185 - ZB191 1ZB217 GroupVariable Number 1ZB219 - ZB220 1ZB229 1ZB239 - ZB242 1ZB246 - ZB248 1ZB251 - ZB258 B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 3 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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GroupVariable Number 1ZB261 - ZB262 1ZB265 - ZB266 1ZB269 - ZB272 1ZB303 - ZB304 1ZB332 - ZB334 1ZB373 - ZB379 1ZB417 - ZB418 1ZB422 - ZB427 1ZB446 - ZB460 1ZB541 - ZB543 1ZB547 1ZB571 - ZB583 GroupVariable Number 1ZB607 - ZB610 1ZB618 1ZB649 1ZB656 - ZB660 1ZB676 - ZB681 1ZB688 - ZB701 1ZB703 - ZB707 1ZB733 - ZB735 1ZB738 - ZB739 1ZB742 - ZB743 1ZB753 1ZB755 - ZB756 GroupVariable Number 1ZB764 - ZB768 1ZB779 - ZB780 1ZB783 - ZB794 1ZB812 - ZB818 1ZB828 - ZB833 1ZB858 1ZB874 1ZB910 - ZB911 2ZC001 - ZC007 2ZC036 -- --

2. Spares Affected None.

B. CONCURRENT REQUIREMENTS None.

C. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin B787-81205-SB530089 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin B787-81205-SB530089 RB mandatory.

Accomplish the required action, based on the applicable condition in Table 5 in accordance with the Accomplishment Instructions B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 4 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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Table 5 Cargo Barrier Fitting Links at Station (STA) 1292, Left and Right Buttock Line (LBL and RBL) 19 – Inspection and Replacement:

Boeing Recommended Compliance Time ActionCondition Within 48 months after the Issue 001 date of Requirements Bulletin B787- 81205-SB530089 RB.

Do a High Frequency Eddy Current (HFEC) or handheld XRF Spectrometer Inspection of Cargo Barrier Fitting Link to determine titanium alloy material.

All Airplanes -No further action required at that Cargo Barrier Fitting Link location.

CONDITION 1: ANY CARGO BAR-

RIER FITTING LINK FOUND THAT IS Ti-6Al-4V ALLOY MATERIAL.

Before further flight.Replace affected fitting link with a new Cargo Barrier Fitting Link (Ti- 6Al-4V alloy material).

CONDITION 2: ANY CARGO BAR-

RIER FITTING LINK FOUND THAT IS NOT Ti-6Al-4V ALLOY MATERI-

AL OR TITANIUM ALLOY CANNOT BE DETERMINED.

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.

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REQUIREMENTS BULLETIN

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E. ACCOMPLISHMENT INSTRUCTIONS

1. GENERAL INFORMATION

KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATE-

RIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE.CAUTION 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. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 6 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in SRM Chapter 51 – Torque Values:

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

51.

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

– Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).

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

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

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 requirements 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 requirements bulletin.

8. 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.

9. 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.

10. The CONDITIONS, ACTIONS and OPTIONS shown apply to each Cargo Barrier Fitting Link independently.

2. WORK INSTRUCTIONS A. Actions Required for Compliance

(1) Requirements:

B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 7 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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Group 1:

Table 1 Cargo Barrier Fitting Links at Station (STA) 1292, Left and Right Buttock Link (LBL and RBL) 19 - Inspection and Replacement:

Refer to the listed procedures in SB B787-81205- SB530089-00 Issue 001 or later approved issues as an accepted procedure.

Method of ComplianceActionCondition PART 1: OPEN ACCESS-Do a High Frequency Eddy Current (HFEC) or handheld XRF Spectrometer Inspection of Cargo Barrier Fitting Link to determine titanium alloy material.

All Airplanes -Task 1 PART 2: CLOSE ACCESS-No further action required at that Cargo Barrier Fitting Link location.

CONDITION 1: ANY CAR-

GO BARRIER FITTING LINK FOUND THAT IS Ti- 6Al-4V ALLOY MATERIAL.

-Task 2Replace affected fitting link with a new Cargo Barrier Fitting Link (Ti-6Al-4V alloy material).

CONDITION 2: ANY CAR-

GO BARRIER FITTING

LINK FOUND THAT IS NOT Ti-6Al-4V ALLOY

MATERIAL OR TITANIUM

ALLOY CANNOT BE DE-

TERMINED -Task 3 -Task 4 -Task 5 PART 2: CLOSE ACCESS- Group 2:

Table 2 Cargo Barrier Fitting Links at Station (STA) 1292, Left and Right Buttock Link (LBL and RBL) 19 - Inspection and Replacement:

Refer to the listed procedures in SB B787-81205- SB530089-00 Issue 001 or later approved issues as an accepted procedure.

All Airplanes -Task 1 B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 8 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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Group 2:

Table 2 Cargo Barrier Fitting Links at Station (STA) 1292, Left and Right Buttock Link (LBL and RBL) 19 - Inspection and Replacement:

Refer to the listed procedures in SB B787-81205- SB530089-00 Issue 001 or later approved issues as an accepted procedure.

Method of ComplianceActionCondition PART 2: CLOSE ACCESS-No further action required at that Cargo Barrier Fitting Link location.

CONDITION 1: ANY CAR-

GO BARRIER FITTING LINK FOUND THAT IS Ti- 6Al-4V ALLOY MATERIAL.

-Task 6Replace affected fitting link with a new Cargo Barrier Fitting Link (Ti-6Al-4V alloy material) CONDITION 2: ANY CAR-

GO BARRIER FITTING

LINK FOUND THAT IS NOT Ti-6Al-4V ALLOY

MATERIAL OR TITANIUM

ALLOY CANNOT BE DE-

TERMINED -Task 7 -Task 8 -Task 9 PART 2: CLOSE ACCESS- Group 3:

Table 3 Cargo Barrier Fitting Links at Station (STA) 1292, Left and Right Buttock Link (LBL and RBL) 19 - Inspection and Replacement:

Refer to the listed procedures in SB B787-81205- SB530089-00 Issue 001 or later approved issues as an accepted procedure.

All Airplanes -Task 1 PART 2: CLOSE ACCESS-No further action required at that Cargo Barrier Fitting Link location.

CONDITION 1: ANY CAR-

GO BARRIER FITTING LINK FOUND THAT IS Ti- 6Al-4V ALLOY MATERIAL.

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REQUIREMENTS BULLETIN

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Group 3:

Table 3 Cargo Barrier Fitting Links at Station (STA) 1292, Left and Right Buttock Link (LBL and RBL) 19 - Inspection and Replacement:

Refer to the listed procedures in SB B787-81205- SB530089-00 Issue 001 or later approved issues as an accepted procedure.

Method of ComplianceActionCondition -Task 10Replace affected fitting link with a new Cargo Barrier Fitting Link (Ti-6Al-4V alloy material) CONDITION 2: ANY CAR-

GO BARRIER FITTING

LINK FOUND THAT IS NOT Ti-6Al-4V ALLOY

MATERIAL OR TITANIUM

ALLOY CANNOT BE DE-

TERMINED -Task 11 -Task 12 -Task 13 PART 2: CLOSE ACCESS- B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 10 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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Task 1 – SECTION 46 LEFT AND RIGHT CARGO BARRIER FITTING LINKS INSPECTION [Group 1-3:]

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:

B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 11 of 73 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN

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A BOEING B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM

REQUIREMENTS BULLETIN Procedure This Task applies only to: Group 1-3.

STA 1292

AFT CARGO

COMPARTMENT (EXAMPLE)

AFT CARGO COMPARTMENT CEILING (CARGO BARRIER WALL PANELS NOT SHOWN FOR CLARITY) ICN-B787-A-000061-A-81205-20191-A-01-1 Task 1 Figure 1 B787-81205-SB530089-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 12 of 73 Export Controlled ECCN: 9E991 See page 1 for details

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