Boeing Alert Requirements Bulletin B787-81205-SB530106-00 RB

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ALERT Alert Requirements Bulletin B787-81205-SB530106-00 RB FUSELAGE - Section 41 - Large Forward Cargo Door (LFCD) Surround Structure Upper Split Frame Inspection and Replacement Copyright © 2026 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-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM Page 1 of 154 Export Controlled ECCN: 9E991 See page 1 for details

3.0 B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM

REQUIREMENTS BULLETIN

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Table of Contents Page A. EFFECTIVITY .

1. Airplanes3

2. Spares Affected3

B. CONCURRENT REQUIREMENTS3

C. COMPLIANCE4

D. APPROVAL4

E. ACCOMPLISHMENT INSTRUCTIONS5

1. General Information5

2. Work Instructions6

TASK 1 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME - INSPECTION [Group 1]9

TASK 2 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME AT STA441 - REPLACEMENT [Group

1]12

TASK 3 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME AT STA465 - REPLACEMENT [Group

1]42

TASK 4 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME AT STA489 - REPLACEMENT [Group

1]69

TASK 5 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME AT STA513 - REPLACEMENT [Group

1]97

TASK 6 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME AT STA537 - REPLACEMENT [Group

1]124

Appendix A – LARGE FORWARD CARGO DOOR SPLIT FRAME - AFFECTED BATCH NUMBERS [Group

1]151

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REQUIREMENTS BULLETIN

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THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO Alert:

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.

EFFECTIVITY

1. Airplanes This bulletin is applicable to 787-8 Airplane(s), line number(s) 1115, 1137, 1140, 1143, 1146, 1149, 1154, 1159, 1162 in 1 Group(s).

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

Table 1

DESCRIPTIONCONFIGURATIONGROUP 787-8 airplanes.- 1 Airplane Models: 787-8 Table 2 GroupVariable Number 1ZA864 1ZA980 - ZA981 GroupVariable Number 1ZD026 - ZD029 1ZD048 - ZD049 GroupVariable Number -- --

2. Spares Affected None.

CONCURRENT REQUIREMENTS None.

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C. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin B787-81205-SB530106-00 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin B787-81205-SB530106-00 RB mandatory.

Accomplish the required actions, based on the applicable conditions in Table 4, in accordance with the Accomplishment Instructions.

Table 4 Large Forward Cargo Door (LFCD) Split Frame Inspection And Replacement Repeat Interval (Not to Exceed) Boeing Recommended Compliance Time ActionCondition -Within 28 months after the Issue 001 date of Requirements Bulletin B787-81205-SB530106- 00 RB.

Do an inspection of the LFCD Split Frames for the affected Batch numbers.

*[1] All Airplanes --No further action requiredCONDITION 1: NO SPLIT

FRAME FOUND WITH AN

AFFECTED BATCH NUM- BER -Before further flightReplace affected LFCD Split Frame with a new LFCD Split Frame with Ti- 6Al-4V alloy material.

CONDITION 2: ANY SPLIT

FRAME FOUND WITH AN

AFFECTED BATCH NUM-

BER OR BATCH NUM-

BERS CANNOT BE DE-

TERMINED *[1] Refer to Appendix A for affected Batch numbers.

D. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). This Requirements Bulletin contains no information that changes the approved configuration of the airplane. The actions specified in this Requirements Bulletin are FAA approved, as well as European Union Aviation Safety Agency (EASA) approved for all EASA approved airplanes listed in the Requirements Bulletin effectivity.

This Requirements 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 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

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 Tasks 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 Tasks. 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 Tasks, can still be done as specified, and the airplane can be put back in an airworthy condition. Tasks not required for compliance are omitted from the RB.

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 Structural Repair Manual (SRM) Chapter 51 – Torque Values:

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– Values for structural fasteners are given in 787 SRM 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.

Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.

7. 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 substitute, with a length which meets the installation standards in SRM Chapter 51 may be used. Refer to SOPM 20-50-01 for ADJUSTMENT OF GRIP LENGTH and USE OF WASHERS as an accepted procedure.

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. Only remove and replace one frame at a time. Do not remove any fasteners from any other frame.

10. 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.

11. Do not use any kept bolts, screws, nuts, or washers with damage that impairs fit, form, or function. Refer to SOPM 20-50-01 GENERAL.

12. 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 Requirements:(1) B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM Page 6 of 154 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM

REQUIREMENTS BULLETIN

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Table 1 Large Forward Cargo Door (LFCD) Split Frame Inspection And Replacement Refer to the listed procedures in SB B787-81205- SB530106-00 Issue 001 or later approved issues as an accepted procedure.

Method Of ComplianceActionCondition PART 1: OPEN ACCESS --All Airplanes -Task 1Do an inspection of the LFCD Split Frames for the affected Batch numbers.*[1] PART 2: CLOSE ACCESS -No further action requiredCONDITION 1: NO SPLIT

FRAME FOUND WITH AN

AFFECTED BATCH NUM- BER -Task 2Replace affected LFCD Split Frame with a new LFCD Split Frame with Ti- 6Al-4V alloy material.

CONDITION 2: ANY SPLIT

FRAME FOUND WITH AN

AFFECTED BATCH NUM-

BER OR BATCH NUM-

BERS CANNOT BE DE-

TERMINED Task 3 Task 4 Task 5 Task 6 PART 2: CLOSE ACCESS - *[1] Refer to Appendix A for affected Batch numbers.

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REQUIREMENTS BULLETIN

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Task 1 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME - INSPECTION [Group 1:]

THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO Alert:

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT.

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REQUIREMENTS BULLETIN

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Q BOEING B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM

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

00000000000 2000000000000000000000000000 STA 489

LARGE FORWARD CARGO DOOR (LFCD)

UPPER SPLIT FRAMES 3106734 ICN-B787-A-000061-A-81205-21262-A-01-1 Task 1 Figure 1 B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM Page 9 of 154 Export Controlled ECCN: 9E991 See page 1 for details

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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 *[1]1418Z5451-12LFCD UPPER SPLIT FRAME - STA441 Inspect1 *[1]1418Z5451-11LFCD UPPER SPLIT FRAME - STA465 Inspect *[1]1418Z5451-14LFCD UPPER SPLIT FRAME - STA489 Inspect *[1]1418Z5451-13LFCD UPPER SPLIT FRAME - STA513 Inspect *[1]1418Z5451-15LFCD UPPER SPLIT FRAME - STA537 Inspect *[1] Do an inspection of the LFCD Split Frames for the affected Batch number. Refer to Appendix A for affected Batch numbers.

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REQUIREMENTS BULLETIN

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Task 2 – LARGE FORWARD CARGO DOOR (LFCD) SPLIT FRAME AT STA441 - REPLACEMENT [Group 1:]

THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO Alert:

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT.

B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM Page 11 of 154 Export Controlled ECCN: 9E991 See page 1 for details B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM

REQUIREMENTS BULLETIN

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A BOEING B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM

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

00000000000 2000000000000000000000000 STA 441 STA 465 STA 489 LARGE FORWARD CARGO DOOR (LFCD) 3106738

UPPER SPLIT FRAMES ICN-B787-A-000061-A-81205-21263-A-01-1 Task 2 Figure 1 B787-81205-SB530106-00 RB Issue 001, 04 Feb 2026 12:00:00 AM Page 12 of 154 Export Controlled ECCN: 9E991 See page 1 for details

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