Boeing Alert Requirements Bulletin B787-81205-SB530093-00 RB

ALERT Alert Requirements Bulletin B787-81205-SB530093-00 RB FUSELAGE - Section 41 - Forward Pressure Bulkhead Attach Angles, Splice Chords, Y-Chords, and Dome Web Inspection 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-SB530093-00 RB Issue 001, 05 Oct 2024 12:00:00 AM Page 1 of 29 Export Controlled ECCN: 9E991 See page 1 for details

3.0 B787-81205-SB530093-00 RB Issue 001, 05 Oct 2024 12:00:00 AM

REQUIREMENTS BULLETIN

Table of Contents Page

A. EFFECTIVITY3

1. Airplanes3

2. Spares Affected5

B. CONCURRENT REQUIREMENTS5

C. COMPLIANCE5

D. APPROVAL7

E. ACCOMPLISHMENT INSTRUCTIONS8

1. General Information8

2. Work Instructions9

TASK 1 – FORWARD PRESSURE BULKHEAD (EXTERNAL) - Y-CHORD AND DOME WEB - DETAILED

INSPECTION [Group 1-2]12

TASK 2 – FORWARD PRESSURE BULKHEAD (INTERNAL) - SPLICE CHORD - DETAILED INSPECTION

[Group 1-2]16

TASK 3 – FORWARD PRESSURE BULKHEAD (INTERNAL) - ATTACH ANGLE - DETAILED INSPECTION

[Group 1-2]23

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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) 6-687, 689-886, 888- 892, 894-897, 899-904, 906-912, 914-954, 956-968, 970, 972-982, 984, 986-987, 989, 993-996, 999, 1001-1007, 1012-1013, 1017-1018, 1021-1022, 1024-1025, 1029-1030, 1032, 1038, 1044, 1047-1048, 1054, 1056-1059, 1094-1095 in 2 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 and 787-9 airplanes with Forward Access Door 113AL and Forward Electrical Equipment Bay Door 118R installed.

-1 787-8, 787-9 and 787-10 Airplanes with no Forward Access Door 113AL and only Forward Electrical Equipment Bay Door 118R installed.

-2 Airplane Models: 787-10, 787-8, 787-9 Table 2 GroupVariable Number 1ZA006 1ZA100 - ZA105 1ZA116 - ZA124 1ZA135 - ZA143 2ZA144 1ZA152 - ZA153 2ZA154 - ZA156 1ZA175 - ZA189 1ZA195 - ZA201 GroupVariable Number 2ZA202 - ZA204 1ZA215 - ZA225 1ZA230 - ZA250 2ZA251 - ZA256 1ZA260 - ZA275 2ZA276 - ZA277 1ZA285 - ZA296 1ZA317 - ZA324 1ZA327 GroupVariable Number 1ZA334 - ZA335 1ZA341 - ZA342 1ZA380 - ZA389 1ZA430 - ZA439 1ZA445 - ZA448 2ZA449 1ZA450 - ZA457 2ZA458 - ZA459 1ZA460 - ZA484 B787-81205-SB530093-00 RB Issue 001, 05 Oct 2024 12:00:00 AM Page 3 of 29 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530093-00 RB Issue 001, 05 Oct 2024 12:00:00 AM

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GroupVariable Number 2ZA485 - ZA489 1ZA506 - ZA516 1ZA536 - ZA545 1ZA560 - ZA567 1ZA576 - ZA580 1ZA586 1ZA588 - ZA593 1ZA610 - ZA617 1ZA650 - ZA652 1ZA655 - ZA663 1ZA665 - ZA671 2ZA672 - ZA677 1ZA680 - ZA685 1ZA695 2ZA696 - ZA698 1ZA715 - ZA716 1ZA718 - ZA719 1ZA740 - ZA741 1ZA768 2ZA769 1ZA778 - ZA779 1ZA783 - ZA784 1ZA817 - ZA828 2ZA829 - ZA831 1ZA839 1ZA841 - ZA842 1ZA846 - ZA848 1ZA853 - ZA855 2ZA856 - ZA862 2ZA873 - ZA876 2ZA881 - ZA888 GroupVariable Number 2ZA916 - ZA920 2ZA949 - ZA950 2ZA954 - ZA959 2ZA963 - ZA965 2ZA968 - ZA972 2ZA990 1ZB001 - ZB006 2ZB007 - ZB012 1ZB021 - ZB022 2ZB023 - ZB026 1ZB027 - ZB034 2ZB035 - ZB043 2ZB047 - ZB060 1ZB077 - ZB081 2ZB097 - ZB121 1ZB127 - ZB132 2ZB133 - ZB136 1ZB167 - ZB179 2ZB180 - ZB191 1ZB197 - ZB198 2ZB217 2ZB219 - ZB220 1ZB224 - ZB227 2ZB228 - ZB229 1ZB234 - ZB235 2ZB236 - ZB242 2ZB246 - ZB248 2ZB251 - ZB258 2ZB261 - ZB262 2ZB265 - ZB279 1ZB299 GroupVariable Number 2ZB302 - ZB305 2ZB332 - ZB338 1ZB362 - ZB365 2ZB366 - ZB379 1ZB407 - ZB413 2ZB414 - ZB435 2ZB446 - ZB467 1ZB536 - ZB539 2ZB540 - ZB543 2ZB545 - ZB547 1ZB558 - ZB561 2ZB562 - ZB586 2ZB603 - ZB610 1ZB611 - ZB612 2ZB613 - ZB618 2ZB646 - ZB649 2ZB656 - ZB665 2ZB676 - ZB681 2ZB688 - ZB707 2ZB733 - ZB735 2ZB738 - ZB740 2ZB742 - ZB745 2ZB749 - ZB750 2ZB753 - ZB757 2ZB763 - ZB768 2ZB771 - ZB775 2ZB778 - ZB805 2ZB810 - ZB821 2ZB828 - ZB841 2ZB858 - ZB863 2ZB874 - ZB876 B787-81205-SB530093-00 RB Issue 001, 05 Oct 2024 12:00:00 AM Page 4 of 29 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530093-00 RB Issue 001, 05 Oct 2024 12:00:00 AM

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GroupVariable Number 2ZB890 2ZB893 - ZB902 2ZB908 - ZB918 2ZB922 2ZB924 2ZB926 - ZB927 2ZB934 - ZB943 2ZB967 - ZB971 2ZB977 - ZB978 2ZB980 - ZB985 2ZB990 - ZB991 2ZB993 - ZB997 2ZC001 - ZC015 2ZC036 - ZC048 2ZC061 - ZC069 2ZC101 - ZC102 2ZC116 - ZC117 2ZC126 - ZC129 GroupVariable Number 2ZC151 - ZC152 2ZC155 - ZC158 2ZC211 - ZC215 2ZC221 - ZC225 1ZD001 - ZD009 1ZD012 2ZD013 - ZD016 2ZE001 - ZE006 2ZE008 2ZE013 2ZE016 - ZE017 2ZE031 - ZE032 2ZE040 - ZE045 2ZE085 - ZE086 2ZE090 - ZE091 2ZE095 - ZE096 2ZE100 2ZE105 - ZE106 GroupVariable Number 2ZE110 2ZE115 2ZE150 2ZE165 - ZE166 2ZE170 - ZE171 2ZE195 - ZE198 2ZE220 - ZE234 2ZE270 2ZE310 - ZE311 2ZE340 - ZE341 2ZE350 - ZE362 2ZE375 2ZE380 2ZE415 - ZE416 2ZE425 - ZE426 2ZE436 - ZE437 2ZE455 - ZE456 2ZE486

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-SB530093-00 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin B787-81205-SB530093-00 RB mandatory.

Accomplish the required actions, based on the applicable conditions in Table 5 and 6 in accordance with Accomplishment Instructions.

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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 or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.

Table 5 Forward Pressure Bulkhead - Dome Web and Y-Chord - External Detailed Inspection Boeing Recommended Compliance TimeActionCondition Whichever occurs first;Do an external Detailed Inspection (DET) of the Forward Pressure Bulkhead (FPB) Dome Web and Y- Chord for any damage. *[1] All Airplanes

1. Before 24,000 Total Flight Cycles (TFC)

2. Within 12 years after the issuance of the original standard certificate of airworthiness or the original export certificate of airworthiness or within 1 year after the Issue 001 date of Requirements Bulletin B787-81205- SB530093-00 RB, whichever occurs later.

-No further action required.CONDITION 1:

NO FPB DOME

WEB AND NO Y-

CHORD DAMAGE FOUND.

Before further flight.Contact The Boeing Company for repair instructions and do the repair.

CONDITION 2:

ANY FPB DOME

WEB DAMAGE

FOUND OR ANY

Y-CHORD DAM- AGE FOUND.

*[1] Damage is defined in 787-8 SRM 51-11-02 Rev 46 or 787-9 SRM 51-11-02 Rev 28 or 787-10 SRM 51-11-02 Rev 14 or later revisions published on MyBoeingFleet.

Table 6 Forward Pressure Bulkhead - Attach Angle and Splice Chords - Internal Detailed Inspection Boeing Recommended Compliance TimeActionCondition Whichever occurs first;Do an internal DET of the FPB Attach Angle and Splice Chords for any damage. *[1] All Airplanes

1. Before 24,000 Total Flight Cycles (TFC)

2. Within 12 years after the issuance of the original standard certificate of airworthiness or the original export certificate of airworthiness or within 1 year after the Issue 001 date of Requirements Bulletin B787-81205- SB530093-00 RB, whichever occurs later.

-No further action required.CONDITION 3:

NO FPB ATTACH

ANGLE AND NO

SPLICE CHORD DAMAGE FOUND.

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REQUIREMENTS BULLETIN

Table 6 Forward Pressure Bulkhead - Attach Angle and Splice Chords - Internal Detailed Inspection Boeing Recommended Compliance TimeActionCondition Before further flight.Contact The Boeing Company for repair instructions and do the repair.

CONDITION 4:

ANY FPB AT-

TACH ANGLE

DAMAGE FOUND

OR ANY SPLICE

CHORD DAMAGE FOUND.

*[1] Damage is defined in 787-8 SRM 51-11-02 Rev 46 or 787-9 SRM 51-11-02 Rev 28 or 787-10 SRM 51-11-02 Rev 14 or later revisions published on MyBoeingFleet.

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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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. 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:

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– 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. A Detailed Inspection (DET) is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. This could include tactile assessment in which a component or assembly can be checked for tightness/security.

Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors and magnifying lenses may be necessary. Surface cleaning and elaborate procedures may be required.

7. Boeing Service Letter 787-SL-51-001, Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided.

8. Obey all of the warnings and cautions given in the specified manual sections.

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. Jacking and shoring limitations must be observed.

11. Use of colors in Tasks is based on guidance from the S1000D International specification for technical publications.

2. WORK INSTRUCTIONS A. Actions Required for Compliance

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Table 1 Forward Pressure Bulkhead - Dome Web and Y-Chord - External Detailed Inspection Refer to the listed procedures in SB B787-81205- SB530093-00 Issue 001 or later approved issues as an accepted procedure Method of ComplianceActionCondition PART 1: OPEN EXTER-

NAL ACCESS -Do an external Detailed Inspection (DET) of the Forward Pressure Bulkhead (FPB) Dome Web and Y-Chord for any damage. *[1] All Airplanes -Task 1 PART 2: CLOSE EXTER-

NAL ACCESS -No further action required.CONDITION 1: NO FPB

DOME WEB AND NO Y-

CHORD DAMAGE FOUND.

PART 1: OPEN EXTER-

NAL ACCESS -Contact The Boeing Company for repair instructions and do the repair.

CONDITION 2: ANY FPB

DOME WEB DAMAGE

FOUND OR ANY Y-

CHORD DAMAGE FOUND.

PART 2: CLOSE EXTER-

NAL ACCESS - *[1] Damage is defined in 787-8 SRM 51-11-02 Rev 46 or 787-9 SRM 51-11-02 Rev 28 or 787-10 SRM 51-11-02 Rev 14 or later revisions published on MyBoeingFleet.

Table 2 Forward Pressure Bulkhead - Attach Angle and Splice Chords - Internal Detailed Inspection Refer to the listed procedures in SB B787-81205- SB530093-00 Issue 001 or later approved issues as an accepted procedure Method of ComplianceActionCondition PART 3: OPEN INTER-

NAL ACCESS -Do an internal DET of the FPB Attach Angle and Splice Chords for any damage. *[1] All Airplanes -Task 2 -Task 3 PART 4: CLOSE INTER-

NAL ACCESS -No further action required.CONDITION 3: NO FPB

ATTACH ANGLE AND NO

SPLICE CHORD DAM- AGE FOUND.

PART 3: OPEN INTER-

NAL ACCESS -Contact The Boeing Company for repair instructions and do the repair.

CONDITION 4: ANY FPB

ATTACH ANGLE DAM-

AGE FOUND OR ANY

SPLICE CHORD DAM- AGE FOUND.

PART 4: CLOSE INTER-

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Table 2 Forward Pressure Bulkhead - Attach Angle and Splice Chords - Internal Detailed Inspection *[1] Damage is defined in 787-8 SRM 51-11-02 Rev 46 or 787-9 SRM 51-11-02 Rev 28 or 787-10 SRM 51-11-02 Rev 14 or later revisions published on MyBoeingFleet.

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Task 1 – FORWARD PRESSURE BULKHEAD (EXTERNAL) - Y-CHORD AND DOME WEB - DETAILED INSPECTION [Group 1-2:]

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.

Procedure This Task applies only to: Group 1-2.

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