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© The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2025-0749; AD 2025-23-06 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
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- Boeing
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- Alert Requirements Bulletin
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- B787-81205-SB530091-00 RB
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- B787-81205-SB530091-00 RB, Issue 001, dated February 7, 2025
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ALERT Alert Requirements Bulletin B787-81205-SB530091-00 RB FUSELAGE - Section 45 - Pressure Deck Splice Fittings 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-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 1 of 148 Export Controlled ECCN: 9E991 See page 1 for details
3.0 B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
Table of Contents Page
A. EFFECTIVITY4
1. Airplanes4
2. Spares Affected5
B. CONCURRENT REQUIREMENTS5
C. COMPLIANCE5
D. APPROVAL7
E. ACCOMPLISHMENT INSTRUCTIONS8
1. General Information8
2. Work Instructions10
TASK 1 – SECTION 45 - STA 1137 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH
FITTING INSPECTION [Group 1]20
TASK 2 – SECTION 45 - STA 1137 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH
FITTING REMOVAL [Group 1]24
TASK 3 – SECTION 45 - STA 1137 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH
FITTING INTERFACING STRUCTURE OPEN HOLE HFEC INSPECTION [Group 1]28
TASK 4 – SECTION 45 - STA 1137 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH
FITTING INSTALLATION [Group 1]32
TASK 5 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING INSPECTION [Group 1-2, 4]41
TASK 6 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING REMOVAL [Group 1-2, 4]45
TASK 7 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH FITTING INTERFACING STRUCTURE OPEN HOLE HFEC INSPECTION [Group 1-2, 4]
.49
TASK 8 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING INSTALLATION [Group 1-2, 4]53
TASK 9 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH
FITTING INSPECTION [Group 3]62
TASK 10 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING REMOVAL [Group 3]65
TASK 11 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH FITTING INTERFACING STRUCTURE OPEN HOLE HFEC INSPECTION [Group 3] . 69 TASK 12 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING INSTALLATION [Group 3]73
TASK 13 – SECTION 45 - STA 1185 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING INSPECTION [Group 1-2]81
TASK 14 – SECTION 45 - STA 1185 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING REMOVAL [Group 1-2]84
TASK 15 – SECTION 45 - STA 1185 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH FITTING INTERFACING STRUCTURE OPEN HOLE HFEC INSPECTION [Group 1-2]
.88
B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 2 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
TASK 16 – SECTION 45 - STA 1185 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING INSTALLATION [Group 1-2]92
TASK 17 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
UPPER SPLICE INSPECTION [Group 1]100
TASK 18 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
UPPER SPLICE REMOVAL [Group 1]104
TASK 19 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) UPPER SPLICE INTERFACING STRUCTURE OPEN HOLE HFEC INSPECTION [Group 1] . 108 TASK 20 – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
UPPER SPLICE INSTALLATION [Group 1]112
TASK 21 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING INSPECTION [Group 5]120
TASK 22 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING REMOVAL [Group 5]124
TASK 23 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD) ATTACH FITTING INTERFACING STRUCTURE OPEN HOLE HFEC INSPECTION [Group 5] . 128 TASK 24 – SECTION 45 - STA 1137 RIGHT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
ATTACH FITTING INSTALLATION [Group 5]132
Appendix A – PROCEDURE FOR X-RAY FLUORESCENCE SPECTROMETER INSPECTION [Group 1-5]
.140
Appendix B – SECTION 45 - STA 1185 LEFT SIDE STUB BEAM HORIZONTAL PRESSURE DECK (HPD)
UPPER SPLICE - HOLES TRANSFER [Group 1]145
B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 3 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 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 787-9, 787-10 Airplane(s), line number(s) 427, 430-433, 435-436, 438-439, 442-447, 449-456, 458-459, 461-464, 466-469, 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, 547-550, 597 in 5 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 787-9 Airplanes installed with pressure deck area fittings that are possibly commercially pure unalloyed titanium at four locations on the left side and right side at Stations (STA) 1137 and 1185.
-1 787-9 Airplanes installed with pressure deck area fittings that are possibly commercially pure unalloyed titanium at two locations on the right side at Stations (STAs) 1137 and 1185.
-2 787-9 Airplanes installed with pressure deck area fittings that are possibly commercially pure unalloyed titanium at one location on the left side at Station (STA) 1185.
-3 787-9 Airplanes installed with pressure deck area fittings that are possibly commercially pure unalloyed titanium at one location on the right side at Station (STA) 1137.
-4 787-10 Airplanes installed with pressure deck area fittings that are possibly commercially pure unalloyed titanium at one location on the right side at Station (STA) 1137.
-5 Airplane Models: 787-10, 787-9 Table 2 B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 4 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
GroupVariable Number 4ZB007 - ZB009 4ZB024 - ZB026 2ZB039 4ZB040 4ZB048 - ZB054 1ZB098 4ZB099 - ZB103 4ZB183 - ZB186 4ZB217 4ZB229 4ZB238 - ZB240 3ZB242 4ZB246 GroupVariable Number 4ZB251 4ZB332 4ZB372 - ZB377 4ZB416 - ZB417 4ZB422 - ZB423 4ZB446 - ZB451 4ZB541 - ZB542 4ZB547 4ZB569 - ZB574 4ZB607 - ZB608 4ZB617 4ZB648 - ZB649 4ZB656 - ZB657 GroupVariable Number 4ZB676 - ZB679 4ZB688 - ZB696 4ZB703 4ZB738 - ZB739 2ZB763 4ZB764 - ZB765 4ZB778 4ZB782 - ZB783 4ZB785 - ZB788 4ZB812 - ZB814 5ZC001 5ZC036 --
2. Spares Affected None.
B. CONCURRENT REQUIREMENTS None.
C. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this Requirements Bulletin. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin B787-81205-SB530091-00 RB mandatory.
Do the required actions based on the applicable condition(s) in Table 7 and 8, in accordance with Accomplishment Instructions.
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.
B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 5 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
Group 1:
Table 7 Stub Beam Horizontal Pressure Deck (HPD) Attach Fitting(s) and Upper Splice Fitting - Inspection and Replacement Boeing Recommended Compliance Time ActionCondition Within 48 months after the Issue 001 date of Requirements Bulletin B787- 81205-SB530091 RB.
Do a High Frequency Eddy Current (HFEC) inspection or handheld X- Ray Fluorescence (XRF) Spectrometer inspection of the affected Stub Beam HPD Attach fitting(s) and Upper Splice fitting to determine titanium alloy material.
All Airplanes -No further action required at that Stub Beam HPD Attach fitting or Upper Splice fitting location.
CONDITION 1: ANY STUB BEAM
HPD ATTACH FITTING OR UPPER
SPLICE FITTING FOUND THAT IS Ti-6Al-4V ALLOY MATERIAL Before further flightCONDITION 2 (ACTION 1): Remove all affected Stub Beam HPD Attach fittings and all affected Upper Splice fittings.
CONDITION 2: ANY STUB BEAM
HPD ATTACH FITTING OR UPPER
SPLICE FITTING FOUND THAT IS NOT Ti-6Al-4V ALLOY MATERIAL
OR TITANIUM ALLOY CANNOT BE DETERMINED Before further flightCONDITION 2 (ACTION 2): At allfastener hole locations common to the interfacing structure of all affected Stub Beam HPD Attach fittings and all affected Upper Splice fittings, do an open hole HFEC inspection for any crack.
Before further flightReplace all affected Stub Beam HPD Attach fittings with new Stub Beam HPD Attach fittings made of Ti-6Al-4V alloy material and replace all affected Upper Splice fittings with new Upper Splice fittings made of Ti-6Al-4V alloy material.
CONDITION 2.1: NO CRACK FOUND Before further flightContact the Boeing Company for repair instructions and for installation instructions for new fittings with Ti- 6Al-4V alloy material (Stub Beam HPD Attach fittings and Upper Splice fittings, as applicable). Do the repair and installation.
CONDITION 2.2: ANY CRACK FOUND B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 6 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
Group 2-5:
Table 8 Stub Beam Horizontal Pressure Deck (HPD) Attach Fitting(s) - Inspection and Replacement Boeing Recommended Compliance Time ActionCondition Within 48 months after the Issue 001 date of Requirements Bulletin B787- 81205-SB530091 RB.
Do a High Frequency Eddy Current (HFEC) inspection or handheld X- Ray Fluorescence (XRF) Spectrometer inspection of the affected Stub Beam HPD Attach fitting(s) to determine titanium alloy material.
All Airplanes -No further action required at that Stub Beam HPD Attach fitting location.
CONDITION 1: ANY STUB BEAM
HPD ATTACH FITTING FOUND THAT IS Ti-6Al-4V ALLOY MATERI- AL Before further flight.CONDITION 2 (ACTION 1): Remove affected Stub Beam HPD Attach fitting.
CONDITION 2: ANY STUB BEAM
HPD ATTACH FITTING FOUND THAT IS NOT Ti-6Al-4V ALLOY
MATERIAL OR TITANIUM ALLOY CANNOT BE DETERMINED Before further flight.CONDITION 2 (ACTION 2): At allfastener hole locations common to the interfacing structure of the affected Stub Beam HPD Attach fitting, do an open hole HFEC inspection for any crack.
Before further flight.Replace affected Stub Beam HPD Attach fitting with a new Stub Beam HPD Attach fitting (Ti-6Al-4V alloy material).
CONDITION 2.1: NO CRACK FOUND Before further flight.Contact the Boeing Company for repair instructions and new Stub Beam HPD Attach fitting installation instructions. Do the repair and install a new Stub Beam HPD Attach fitting with Ti-6Al-4V alloy material.
CONDITION 2.2: ANY CRACK FOUND 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-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 7 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
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-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 8 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
– 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. Use of colors in Tasks is based on guidance from the S1000D International specification for technical publications.
9. 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.
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.
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. If multiple nonconforming parts are identified, do the applicable on-condition corrective action one at a time for each location to minimize effects on surrounding aircraft structure.
B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 9 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
2. WORK INSTRUCTIONS A. Actions Required for Compliance Requirements:(1) Group 1:
Table 1 Stub Beam Horizontal Pressure Deck (HPD) Attach Fitting(s) and Upper Splice Fitting at Station (STA) 1137 and 1185 Left and Right Side - Inspection and Replacement:
Refer to the listed procedures in SB B787-81205- SB530091-00 Issue 001 or later approved issues as an accepted procedure.
Method of ComplianceActionCondition PART 1: OPEN ACCESS
FOR INSPECTION AT STA 1137 AND STA 1185.
-Do a High Frequency Eddy Current (HFEC) inspection or handheld X-Ray Fluorescence (XRF) Spectrometer inspection of the affected Stub Beam HPD Attach fitting(s) and Upper Splice fitting to determine titanium alloy material.
All Airplanes -Task 1 Task 5 Task 13 Task 17 PART 2: CLOSE ACCESS
AFTER INSPECTION AT STA 1137 AND STA 1185.
-No further action required at that Stub Beam HPD Attach fitting or Upper Splice fitting location.
CONDITION 1: ANY STUB
BEAM HPD ATTACH FIT-
TING OR UPPER SPLICE
FITTING FOUND THAT IS Ti-6Al-4V ALLOY MATERI- AL.
B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 10 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
Group 1:
Table 1 Stub Beam Horizontal Pressure Deck (HPD) Attach Fitting(s) and Upper Splice Fitting at Station (STA) 1137 and 1185 Left and Right Side - Inspection and Replacement:
Refer to the listed procedures in SB B787-81205- SB530091-00 Issue 001 or later approved issues as an accepted procedure.
Method of ComplianceActionCondition PART 3: OPEN ACCESS
FOR REPLACEMENT AT REQUIRED STA 1137 AND STA 1185 LOCA- TIONS.
-CONDITION 2 (ACTION
1): Remove all affected Stub Beam HPD Attach fittings and all affected Upper Splice fittings.
CONDITION 2: ANY STUB
BEAM HPD ATTACH FIT-
TING OR UPPER SPLICE
FITTING FOUND THAT IS NOT Ti-6Al-4V ALLOY
MATERIAL OR TITANIUM
ALLOY CANNOT BE DE- TERMINED.
-Task 2 Task 6 Task 14 Task 18 -Task 3CONDITION 2 (ACTION
2): At all fastener hole locations common to the interfacing structure of all affected Stub Beam HPD Attach fittings and all affected Upper Splice fittings, do an open hole HFEC inspection for any crack.
Task 7 Task 15 Task 19 -Task 4Replace all affected Stub Beam HPD Attach fittings with new Stub Beam HPD Attach fittings made of Ti- 6Al-4V alloy material and replace all affected Upper Splice fittings with new Upper Splice fittings made of Ti-6Al-4V alloy material.
CONDITION 2.1: NO CRACK FOUND. Task 8 Task 16 Task 20 PART 4: CLOSE ACCESS
AFTER REPLACEMENT AT REQUIRED STA 1137 AND STA 1185 LOCA- TIONS.
- B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 11 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM
REQUIREMENTS BULLETIN
Group 1:
Table 1 Stub Beam Horizontal Pressure Deck (HPD) Attach Fitting(s) and Upper Splice Fitting at Station (STA) 1137 and 1185 Left and Right Side - Inspection and Replacement:
Refer to the listed procedures in SB B787-81205- SB530091-00 Issue 001 or later approved issues as an accepted procedure.
Method of ComplianceActionCondition --Contact the Boeing Company for repair instructions and for installation instructions for new fittings with Ti-6Al-4V alloy material (Stub Beam HPD Attach fittings and Upper Splice fittings, as applicable). Do the repair and installation.
CONDITION 2.2: ANY CRACK FOUND. PART 4: CLOSE ACCESS
AFTER REPLACEMENT AT REQUIRED STA 1137 AND STA 1185 LOCA- TIONS.
- Group 2:
Table 2 Stub Beam Horizontal Pressure Deck (HPD) Attach Fittings at Station (STA) 1137 and 1185 Right Side - Inspection and Replacement:
Refer to the listed procedures in SB B787-81205- SB530091-00 Issue 001 or later approved issues as an accepted procedure.
Method of ComplianceActionCondition PART 1: OPEN ACCESS
FOR INSPECTION AT STA 1137 AND STA 1185.
-Do a High Frequency Eddy Current (HFEC) inspection or handheld X-Ray Fluorescence (XRF) Spectrometer inspection of the affected Stub Beam HPD attach fitting(s) to determine titanium alloy material.
All Airplanes -Task 5 Task 13 PART 2: CLOSE ACCESS
AFTER INSPECTION AT STA 1137 AND STA 1185.
-No further action required at that Stub Beam HPD Attach fitting location.
CONDITION 1: ANY STUB
BEAM HPD ATTACH FIT- TING FOUND THAT IS Ti- 6Al-4V ALLOY MATERIAL.
B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM Page 12 of 148 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530091-00 RB Issue 001, 07 Feb 2025 12:00:00 AM