2019 Jan 787 - AWL

0
U.S. Department
of Transportation
Aviation Safety Seattle ACO Branch
Federal Aviation Aircraft Certification Service 2200 S. 2161h Street
Administration Compliance & Airworthiness Division Des Moines, WA 98198
FEB 13 2019
In Reply
Refer to 783-19-155
Ms. Elizabeth Pasztor

ODA Lead Administrator
Regulatory Administration
The Boeing Company
P.O. Box 3707, MC 081-53
Seattle, WA 98124-2207
Dear Ms. Pasztor:
Subject: Approval of Alternative Method of Compliance (AMOC) to Airworthiness

Directive (AD) 2013-08-12
Reference: (1) Boeing letter RA-19-00066, dated January 10, 2019

(2) Boeing 787 Airworthiness Limitations (AWLs) Document
D011Z009-03-01, dated April 2013
(3) Boeing 787 AWLs Document D011Z009-03-01, dated January 2019,
(Watermark 01/07/2019_2:44PM)
The Federal Aviation Administration (FAA) received the referenced (1) letter requesting
approval of an AMOC to AD 2013-08-12. AD 2013-08-12 requires replacing the main and
Auxiliary Power Unit (APU) batteries, and other actions. Paragraph (h) of AD 2013-08-12
requires revising the maintenance program to incorporate Item No. lb in Section D of the
reference (2) document.
Your letter requests an AMOC to paragraph (h) of AD 2013-08-12 to allow the use of the
reference (3) document. The document has been revised to make unrelated changes to those
required by AD 2013-08-12.
Your letter also requests approval of any future revision to the reference (3) document as an
AMOC to paragraph (h) of AD 2013-08-12, as long as those future revisions do not impact
Item No. lb in Section D.
Your proposal provides an acceptable level of safety because the content required by AD
2013-08-12 in the reference (2) document remains unchanged in the reference (3) document,
and will remain unchanged in any future revision of the 787 A WLs document that utilizes
the AMOC approval in this letter.
783-19-155 2
The manager of the Seattle ACO Branch approves use of the reference (3) document as an
AMOC to use of the reference (2) document as required by paragraph (h) of AD
2013-08-12.
In addition, the manager of the Seattle ACO Branch approves using any future revision to
the reference (3) document that includes the version ofltem No. 1bin Section D as
published in the reference (2) document as an AMOC to the requirements of paragraph (h)
of AD 2013-08-12.
In accordance with FAA Order 8110.103, the following conditions apply:
1. All provisions of AD 2013-08-12 that are not specifically referenced above remain
fully applicable and must be complied with accordingly.
2. This approval is applicable only to Boeing Model 787-8 series airplanes in the
applicability of AD 2013-08-12.
3. This FAA AMOC is transferable with the aircraft to another owner/operator.
4. Before using this AMOC, notify your appropriate principal inspector, or lacking a
principal inspector, the manager of the local Flight Standards District
Office/Certificate Holding District Office.
5. The preceding paragraph also applies to any applicable foreign-registered aircraft

upon transfer of the aircraft to the U.S. registry if compliance with the AMOC has
not been accomplished.
6. This AMOC only applies to the FAA AD listed above. The FAA does not have the
authority to approve this as an AMOC to any AD issued by another civil aviation
authority (CAA). Approval of an AMOC to another CAA's AD must come from
that CAA.
If you have any questions regarding this correspondence, please contact this office or
Mr. Julio Alvarez, Aerospace Engineer, by telephone at (206) 231-3657, or by email at
julio.c.alvarez@faa.gov.
Sincerely,
Aviation Safety
Manager, Seattle ACO Branch, AIR-780
Compliance & Airworthiness Division
Aircraft Certification Service
787 AIRWORTHINESS LIMITATIONS
787
AIRWORTHINESS LIMITATIONS (AWLs)
D011Z009-03-01
JANUARY 2019
This document has EAR data with an Export Control Classification Number (ECCN) of 9E991.
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for
development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
Boeing claims copyright in each page of this document on to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective
work. This document includes proprietary information owned by the Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with
Boeing. For more information, contact the Boeing Company, P.O. Box 3707, Seattle WA 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, BBJ, DC-8,
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COMPILED AND PUBLISHED BY:

MAINTENANCE PROGRAMS ENGINEERING
BOEING COMMERCIAL AIRPLANE GROUP
SEATTLE, WASHINGTON
D011Z009-03-01
JAN 2019 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-1
EXPORT CONTROLLED - EAR ECCN: 9E991
THIS PAGE INTENTIONALLY LEFT BLANK
D011Z009-03-01
BLANK BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-2
TABLE OF CONTENTS
REVISIONS .................................................................................................................................................................................................................................. 1.0-5
LIST OF EFFECTIVE PAGES .................................................................................................................................................................................................... 1.0-19
REFERENCES ........................................................................................................................................................................................................................... 1.0-20
TERMS AND ACRONYMS ......................................................................................................................................................................................................... 1.0-21
A. SCOPE ................................................................................................................................................................................................................................... 1.0-22
B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITS.............................................................................................................................. 1.0-23
C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS ....................................................................................... 1.0-25
D. AIRWORTHINESS LIMITATIONS – LIFE LIMITS .................................................................................................................................................................. 1.0-90
E. OTHER AIRWORTHINESS LIMITATIONS – SYSTEMS AND STRUCTURES.....................................................................................................................1.0-113
F. AWLS - STRUCTURAL LIMIT OF VALIDITY (LOV).............................................................................................................................................................. 1.0-132
APPENDIX A. POST-THRESHOLD INTERVALS FOR STRUCTURES AND ZONAL TASKS ................................................................................................. 1.0-133
D011Z009-03-01
JUL 2018 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3
D011Z009-03-01
REVISIONS
REVISION AND REVISION DESCRIPTION

AUGUST 2011
Original Release
SEPTEMBER 2011
Revised Threshold (787-8 Airplanes) section by changing the 20 year interval to 22 years in two locations.
Moved two Notes in the Threshold (787-8 Airplanes) section to a location better suited for their content.
Revised the Lock Link Assembly item in Table 3 by adding a “1” in the Notes column to refer to Table Note 1.
Revised the list of Systems Life-Limited Parts by adding life limitations for the Passenger Entry Door Emergency Power Assist System Pressure Reservoir Assembly.
The listing of Supplemental Structural Fatigue Inspections was added as a result of the completed damage tolerance assessment. The appropriate front matter text was also revised
in support of the addition.
Revised the first paragraph in Appendix A by adding direction for operators working with tasks that may be allowed to be escalated in the future.
OCTOBER 2011
For this revision, minor changes to wording were made in several areas.
Revised the Airplane Operational Limitation Table in the Freedom From Widespread Fatigue Damage section by updating the Accumulated Cycles – Full-Scale Fatigue Test to
18,843 Fatigue Test Cycles and the Fleet Operational Limitation to 9,421 Flight Cycles.
Revised Figure 1, clarifying Note (4) by changing “Operators must plan the inspection” to “Operators must accomplish the inspection”.
Revised Table 1 in Section C, removing Notes (5) and (6) from the table heading and including them in each PSE, as applicable, within the table.
Updated the illustrations for Figures 7 and 8, and added an improved illustration for Figure 13.
Revised the introductory paragraph in Appendix A to provide clarification.
NOVEMBER 2011
Revised Section B introductory paragraph to correct subsection references.
Revised the Airplane Operational Limitation Table in the Freedom From Widespread Fatigue Damage section by updating the Accumulated Cycles – Full-Scale Fatigue Test to
21,895 Fatigue Test Cycles and the Fleet Operational Limitation to 10,947 Flight Cycles.
Revised the Supplemental Structural Inspection Threshold for PSEs 57-53-01A, 57-53-01B, 57-53-08A, and 57-53-15A from 3,250 Flight Cycles to 5,500 Flight Cycles.
Revised the Group 1 Flight Hours for the right hand vertical portion of the curve In Figure 1 from 101,250 FH to 101,300 FH, and reworded Table Note 2 to improve clarity.
Revised Table 1 by deleting Flag Note 6 and the associated references, and renumbered Footnotes 7 and 8 accordingly.
Deleted PSE 53-31-34 “Passenger Entry Door 2 - Edge Frame”, “Edge Frame Web at BS 682 S-19 (stop fitting 3A Interface)” as this detail was redundant to the two other entries for
this same PSE detail.
Clarified the Table 1 DTR Check Form Title and DTR Location information for PSE 53-58-03.
(Continued on next page)
D011Z009-03-01

NOVEMBER 2011, Continued
Revised the DTR Check Form Title for three PSE 55-33-10 items by adding “(L/N 7 and on)”.
Added three new PSE 57-10-05 details to Table 1, effective for L/N 34 and on.
Added the following statement to Footnote 5 for Table 1: “If the applicable published inspection procedure cannot be accomplished, an alternative FAA accepted procedure must
be used.”
Revised Footnote 7 by changing the repeat interval of 1,625 cycles to 2,750 flight cycles.
Updated the Systems Life Limited Parts Section as follows:
Added Part Number and Line Number clarifications for the Static-Dissipative Hydraulic Isolators.
Added Nose Wheel Steering Valve module, P/N 2-8300-5 limitation.
Added a limitation for the Trent 1000 Package /B/ Locking Actuator, P/N 725Z3161-215 and the GEnx Locking Actuator limitation P/N was changed from 721Z3161-175 to
721Z3161-215.
Removed Life Limitation for item 10b. Fan Cowl Aft Hold Open Rod (HOR) 725Z2161-103 and item 11b. Fan Cowl Aft HOR 721Z2161-103 following full life testing.
Added Structures Airworthiness Limitation No. 2 to Section E.
Made minor wording changes to Section E Structures Airworthiness Limitation No. 1 for clarification.
DECEMBER 2011
Revised the table of Life-Limited Items in the Systems Life-Limited Parts section by adding Item 1b, Variable Frequency Starter/Generator (VFSG) and Item 1c, Auxiliary Starter/
Generator (ASG).
Revised Item 3b in the table of Life-Limited Items in the Systems Life-Limited Parts section by changing “life this limitation” to “this life limitation” to make the statement
grammatically correct.
DECEMBER 2011 R1
Revised the Life-Limited Parts table by re-inserting Systems Life Limitations for Trent 1000 item 10b, Fan Cowl Aft Hold Open Rod (HOR) 725Z2161-103 and GEnx Hold Open Rods
Item 11b, Fan Cowl Aft HOR 721Z2161-103 in support of Airplane Certification activities.
JUNE 2012
Revised Section C by moving the Note regarding escalation of MPD Tasks from the Threshold subsection to the Introduction subsection. Added a reference to Appendix A to the
second paragraph of the Introduction subsection, and revised the last sentence of the third paragraph for consistency.
Revised the first sentence of the first and third paragraphs in the Threshold subsection of Section C for consistency.
For Table 1 in Section C, the following changes were made:
Added new PSE 53-11-07 DTR Location "Aft Edge Frame BS 327.5 - Web at Nutplate Retainer", effective for L/N 55 and on.
Revised existing PSE 53-41-05B DTR Location "Lug Base Corner Fillet Radius" to be applicable to L/N 4-70.
Added two new PSE 53-41-05B DTR Locations: “Lug Base Corner Fillet Radius” and "Forward and Aft Flanges common to Wheel Well Longeron Extension", effective for L/N 71
and on.
D011Z009-03-01

JUNE 2012, Continued
Revised existing PSE 57-10-02 L/N applicability from "Side of Body Splice - Lower Surface LHS (L/N 22-67), RHS (L/N 21-65)" to "Side of Body Splice - Lower Surface LHS (L/N 22
and on), RHS (L/N 21 and on)".
Revised PSEs 57-53-08A "Outboard Flap Box" and 57-53-15A "Aileron Box" Applicability Thresholds from "5,550" to "5,500".
For Table 4 in Section D, clarified Shock Strut Outer Cylinder P/N 511Z3001-5/-6, implemented starting at 787-8 L/N 55, as preferred spare. Added Shock Strut Inner Cylinder
P/N 512Z3001-2 implemented starting at 787-8 L/N 65.
Revised the Life-Limited Items Table in the Systems Life-Limited Parts section of Section D by adding Items 2b through 2i, Power Electronics Cooling System (PECS) Ram Heat
Exchanger and Forward Cargo Air Conditioning (FCAC) Ram Heat Exchanger (for airplanes equipped with the FCAC option).
Revised Section D, Systems Life Limited Parts, by adding item 6e, Primary Exhaust Nozzle, and 6f, Primary Exhaust Forward Centerbody. Revised Items 10b, 10c, 11b, and 11c to
eliminate the acronym "HOR" for clarity. Revised Item 12a Applicability Specifications to reflect availability of replacement part.
Revised Section D, Structures Life Limited Parts by revising "Horizontal Stabilizer Pivot Pins" for greater clarity, and changing the Note to reflect earlier production incorporation of
non-life-limited pins.
Revised Structures Airworthiness Limitation No. 2 in Section E for greater clarity and to revise MPD reference to 57-522-00 with associated Task Card 57-522-01.
JULY 2012
Revised Section D, Systems Life-Limited Parts, by deleting Item 1b, Variable Frequency Starter/Generator (VFSG), and 1c, Auxiliary Starter/Generator (ASG). Added Item 2j, Power
Electronics Cooling System (PECS) Pump.
Revised Section D, Systems Life-Limited Parts, to modify the quantity of parts per airplane for Items 4a.(ii) and 4b.(ii), Static-Dissipative Hydraulic Isolator.
Revised Section E, Structures Airworthiness Limitation No. 2, Airplane Applicability, to those airplanes delivered prior to implementation of the bearing pad durability improvement
design change.
SEPTEMBER 2012
Revised the data for the MLG Truck Assembly in Table 4 of Section D by deleting Part Number 515Z3009-2, since this part is not life-limited.
Revised the Note in the Structures Life-Limited Parts section of Section D to reflect the release of Service Bulletin 787-55-0001.
The next four revisions were made to the table of Systems Life-Limited Parts in Section D:
Revised the Applicability Specifications for Item 5d, Main Landing Gear Door Uplock since the airplane applicability originally noted for this part is no longer accurate.
Deleted Item 10b, Fan Cowl Aft Hold Open Rod, since this part is not life-limited.
Deleted Item 11b, Fan Cowl Aft Hold Open Rod, since this part is not life-limited.
Revised Item 12a, Emergency Power Assist System (EPAS) Pressure Reservoir Assembly to reflect the release of Boeing Service Letter 787-SL-52-001.
Added “and 60” to the list of 787-8 Production Line Numbers provided in Structures Airworthiness Limitation No. 2.
D011Z009-03-01

FEBRUARY 2013
Revised the table shown in the Freedom From Widespread Fatigue Damage section in Section B by updating the Accumulated Cycles - Full-Scale Fatigue Test to 61,059 Fatigue
Test Cycles and the Fleet Operational Limitation to 30,529 Flight Cycles.
Revised Section C by deleting PSEs 57-53-01A, 57-53-01B, 57-53-08A, and 57-53-15A from the PSE Table and Table 1, as these PSEs no longer require directed inspections.
Deleted Note 7 from Table 1 as it referred to these deleted items.
Revised Section D by updating the Nose and Main Landing Gear safe life limits and associated descriptions. Revised Figures 2 through 5. Deleted Figure 6, then renumbered the
remaining figures. Revised figure references in text and Table 4 to match new figure numbering. Revised Table 4 to update figure references, revise the Part Description for the
MLG Side and Drag Brace Assemblies, and new P/Ns 521Z3013-2, 523Z3009-2, 521Z3015-2, 513Z3105-2, and 514Z3103-2.
Revised the Life-Limited Items Table in the Systems Life-Limited Parts section of Section D by deleting Items 2b through 2j, Power Electronics Cooling System (PECS) Ram Heat
Exchanger and Forward Cargo Air Conditioning (FCAC) Ram Heat Exchanger (for airplanes equipped with the FCAC option) based on successful completion of component
pressure-impulse fatigue life testing.
Revised the Applicability Specifications for Items 6a - 6d in Section D to reflect availability of non-life-limited replacement parts and associated service bulletin. Deleted Items 6e,
Primary Exhaust Nozzle, and 6f, Primary Exhaust Forward Centerbody, as testing completed to substantiate the redesigned P/Ns 725Z4100-11 and 725Z4200-11 demonstrated that
a life limitation was not required. Deleted the reference to Boeing Service Letter 787-SL-52-001 from Item 12a, Emergency Power Assist System (EPAS) Pressure Reservoir
Assembly.
Revised System Airworthiness Limitation No. 5 in Section E, Other Airworthiness Limitations – Systems and Structures, by adding Airplane Line Number and Engine Serial Number
effectivity for airplanes and engines without a Fuel Accumulator (FSVA) installed.
The following changes were made to Appendix A:
Revised the Post-Threshold Repeat Interval for Item 53-507-00 from 12000 FC/6 YR to 6000 FC/3 YR to reflect a recent change to the baseline MRBR requirement.
Revised the description of MPD Item Numbers 52-514-01, 57-518-00, 57-528-00, 57-532-00, 57-534-00, 57-562-00, 57-566-00, and 57-568-00 for clarification and consistency with
the MPD.
Revised the Inspection Level of MPD Item Numbers 52-512-01 and 52-514-01 from “INT” to “EXT” for consistency with the MPD.
Added MPD Item Numbers 57-854-01, 57-870-01, 57-948-02, and 57-964-02 to be consistent with the current MPD listing.
APRIL 2013
Revised the Life-Limited Parts Table in Section D by adding Systems Life Limitation No.1b. for the Main and APU Battery Enclosure Vent Burst Disc in support of the new 787 Main
and APU Battery installations.
Revised System Airworthiness Limitation No. 5 in Section E, Other Airworthiness Limitations – Systems and Structures, by correcting the engine serial numbers for engines without a
Fuel Accumulator (FSVA) installed.
D011Z009-03-01

AUGUST 2013
There was data omitted from the FEB 2013 Revision Description which only made the Description itself incomplete. The data within the FEB 2013 document tables were complete
and accurate with proper revision bars. The third paragraph of the FEB 2013 Revision Description should have read as follows:
Revised Section D by updating the Nose and Main Landing Gear safe life limits and associated descriptions. Revised Figures 2 through 5. Deleted Figure 6, then renumbered the
remaining figures. Revised figure references in text and Table 4 to match new figure numbering. Revised Table 3 to add new P/Ns 521Z3013-2, 523Z3009-2, and 521Z3015-2.
Revised Table 4 to update figure references, revise the Part Description for the MLG Side and Drag Brace Assemblies, and add new P/Ns 513Z3105-2, and 514Z3103-2.
Revised Section C, Table 1 data associated with inspection details for PSEs 53-11-01, 53-11-03, 53-11-07, 53-11-17, 53-11-18, 53-11-19, 53-11-20, 53-17-01, 53-18-01, 53-18-04,
53-18-05, 53-18-06, 53-18-07, and 53-58-03B, and added inspection details for PSE 53-11-21, 53-41-12, 53-71-08.
Revised Section D, Table 3 to add new P/Ns 521Z3001-3, 521Z3009-2, 524Z3102-1, 524Z3103-1, and 521Z3019-3. Revised Table 4 to add new P/Ns 511Z3004-2, 511Z3023-2,
513Z3005-4, 514Z3010-2, 513Z3104-2, 126Z2525-3, and 126Z2605-5, -7, -9.
Revised Section D, Systems Life-Limited Parts Table to add references to applicable service bulletins for Items 5b and 5c.
OCTOBER 2013
The following changes were made to Section D, Airworthiness Limitations - Life Limits:
Deleted the statement from the Structural Safe-Life Parts section regarding in-progress safe-life testing of the nose landing gear and main landing gear and support structure. Added
“787-8” to the damage tolerance information for the main landing gear drag brace to provide clarification.
Revised Figure 2 and Table 3 by adding new P/N 524Z3104-1.
Added Item 4 to the Instructions for using Safe Life Charts to explain the usage of “(Testing in Progress)”.
Revised Figure 8 to remove part numbers. Revised Table 4 by adding new P/Ns 151Z3301-7/-8 and to indicate preferred spares for P/Ns 126Z2604, 126Z2605, and 151Z3300.
Revised the Systems Life-Limited Parts Table to clarify the Applicability Specifications for Item 12a.
NOVEMBER 2013
Revised Section E – Other Airworthiness Limitations – Systems and Structures by adding System Airworthiness Limitation No. 6 – GE ENGINE OPERATING LIMITATIONS FOR ICE
CRYSTAL ICING.
FEBRUARY 2014
Added a list of TERMS AND ACRONYMS.
Revised Section A, Scope, to define FAA Oversight Office and replaced all references to "Seattle FAA ACO" with "FAA Oversight Office" throughout the entire document.
Revised Section B, AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITS by deleting “-8” at four locations, as this information is not specific to the 787-8 minor
model, and other editorial changes for clarity.
Revised Section C, AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS to remove sentence describing 22 year calendar threshold
(sentence is redundant to Note 6 of Table 1).
Revised Table 1 for PSEs 53-41-03 and 53-41-04 to indicate applicability to L/N 4-157 for 14 PSE details, and added 4 new PSE details with applicability for L/N 158 and on to reflect
a production design change implemented at 787-8 L/N 158.
D011Z009-03-01

MARCH 2014
Revised the REFERENCES section by adding MSG-3 Revision 2011.1 and revising the date for document D011Z009-02.
Added “BBJ – Boeing Business Jet”. “CFR – Code of Federal Regulations”, and “CFRP – Carbon Fiber Reinforced Plastic” to the Terms and Acronyms section.
Added "Title 14 CFR §" to references to FAA regulations to accurately reflect FAA regulation citations throughout the document.
Deleted the “-8” indicators from the first paragraph in Section A because the statement applies to all 787 models. Added information to clarify the use of “in accordance with” and
“refer to” verbiage when referencing other Instructions for Continued Airworthiness documents, and a Note explaining that some limitations defined in this document have unique
requirements for BBJ 787 airplanes.
In Section B, added “787-9” to the Applicability column of the table in the “Freedom From Widespread Fatigue Damage” subsection. Updated the Accumulated Cycles – Full-Scale
Fatigue Test to 88,000 Fatigue Test Cycles and the Fleet Operational Limitation to 44,000 Flight Cycles.
The following revisions were made in Section C:
Added a Note to the “Threshold (787-8/-9 Airplanes)” subsection regarding PSE thresholds for BBJ 787 airplanes.
Added “(and any applicable Service Bulletins or repair instructions)”, a statement regarding application of BMS 5-45 and an AMM reference to Item 3 in the “Removal of Excess
Sealant When Inspecting” subsection. Deleted the last statement regarding sealant removal.
Added “787 = All B787 Airplanes” to the list of airplanes in the Supplemental Structural Fatigue Inspection Requirements” subsection.
Added data for the 787-9 to Table 1 and revised existing items to improve clarity. Revised Table 1 Note 6 to address BBJ 787 airplanes.
The following revisions were made in Section D:
Revised the headings in Table 2 for clarity and added 787-9 data. Deleted the Note and statement regarding the carbon fiber reinforced plastic portion of the 787-8 main landing gear
drag brace, as this information was no longer relevant to this section.
Added “787-9” and revised the Figure information in the table for Landing Gear and Support Structure.
Revised certain Figures for improvement and revised the Figure Titles to better reflect the actual data shown. Revised Figure 5 to segregate 787-8 (Table 5A) and 787-9 (Figure 5B)
safe-life limits, and to add Titanium Side & Drag Brace Assemblies for the 787-8 (P/Ns 513Z3003-51/-52, 513Z3103-51, 513Z3301-1, 513Z3302-1, 514Z3301-501, and
514Z3302-501) implemented starting at production line number 210.
Deleted the “-8” indicator from the “787 Nose Landing Gear (NLG) Part List” subsection.
Deleted “Gross” from the Airplane Applicability column heading of Tables 3 and 4, added information for the 787-9 model, and added Table Notes to provide correlation between Part
Numbers and Line Numbers associated with the table items. Revised Table 4 to reference Figures 5A and 5B, and to add the aforementioned Titanium Side & Drag Brace
Assemblies P/Ns applicable to the 787-8. Added 787-8 P/Ns 151Z1320-3/-4 and 151Z3300-7/-8 to Table 4.
Revised the first paragraph of the “787 Main Landing Gear (MLG) Part List” subsection to provide more information and clarity regarding the 787-8 and 787-9 MLG truck beam
assembly. Added a Note regarding the carbon fiber reinforced plastic portion of the 787-8 main landing gear drag brace.
Revised the subheadings in the table of Systems Life-Limited Parts for clarity and added applicability information to items in Section 4 – Hydraulics.
In Section D. Airworthiness Limitations - Life Limits, Systems Life Limited Parts;
Added 787-8 and 787-9 applicability specifications to the following items for clarification: Items 4a.(ii), 4b.(ii), 4c(ii), 4d(ii), 4e.(ii), 4f.(ii), 4g.(ii), 4h.(ii), 4j.(ii), 4k.(ii), 4l.(ii), Static-
Dissipative Hydraulic Isolators:
Items 4a.(ii), 4b.(ii) Revised the quantity per airplane for (LN) 126 and on 787-9 only.
D011Z009-03-01

MARCH 2014, Continued
In Section E, added applicable 787-8 production line numbers and limitation information to System AWL No. 1. Added information regarding limitations for 787-8 production line
numbers and GEnx-1B serial numbers to System AWL No. 3. Clarified the AWL wording to ensure what airplane and engine modifications are necessary to remove the AWL
restrictions for Trent 1000 and GEnx-1B engines in System AWLs No. 1 and 3. Added System AWL No. 7, Engine Oil Consumption Rates – 787-9 Airplanes with Trent 1000 Engines,
System AWL No. 8, Wing Upper Panel Vent Stringer Inner Flange and Structures AWL No. 3, Wing Upper Panel Vent Stringer Cutout Inspection.
The following revisions were made in Appendix A:
Revised the first paragraph for clarification by adding a supplemental fatigue inspection threshold “of 44,000 flight cycles or 22 years, whichever occurs first” and deleting the
statement regarding escalation.
Added information for BBJ 787 airplanes and guidelines for when a Corrosion Prevention and Control Program should be implemented.
Added “(787-8 only)” to the table items, as required, and updated the Post-Threshold Repeat Interval information.
Added flight cycle intervals for tasks for which previously only a calendar interval was defined.
Deleted Task 53-815-00 and added Tasks 57-839-01, 57-842-01, 57-844-01, 57-846-01, 57-848-01, 57-862-01, 57-864-01, 57-933-02, 57-936-02, 57-938-02, 57-940-02, 57-942-02,
57-956-02, and 57-958-02.
Revised the inspection level for Tasks 57-520-00 and 57-554-00 from EXT - DET to INT - DET to be consistent with recent changes made to Section 2 of document D011Z009-03.
Added Note 1 to the table.
JUNE 2014
Revised Section E - Other Airworthiness Limitations - Systems and Structures by adding System Airworthiness Limitation No. 9 and No. 10.
JUNE 2014 R1
Revised Table 1 – Airworthiness Limitations – Supplemental Structural Fatigue Inspections in Section C by adding two new items for 53-41-04 – Aft Wheel Well Bulkhead Frame –
BS 1209 and by revising Line Number information to specify 787-8 and 787-9 applicability.
Deleted the asterisk from P/N 511Z3003-2 for the Pin, Torsion Link Apex Item in Table 4 – Main Landing Gear – List of Safe-Life Parts and Assemblies because this part is not the
preferred spare in the group.
Revised the entry for the Nut, Spindle, Drag Brace, P/N 513Z3029-501 in Table 4 – Main Landing Gear – List of Safe-Life Parts and Assemblies by checking the column for the
787-9 model instead of the 787-8MI column to fix a typographical error.
JULY 2014
Added Structures Airworthiness Limitation No. 4 - 787-9 General Electric Forward Engine Mount Barrel Nut Replacement.
Added 787-9 applicability to the title of System Airworthiness Limitation No. 6 because this AWL is applicable to both 787-8 and 787-9 airplanes.
D011Z009-03-01

AUGUST 2014
Deleted the Boeing submittal signature column from the Revision Log to improve the layout and provide consistency across all Section 9/AWL/CMR/SCI documents. A submittal
signature will no longer be included in the revision log; only the FAA BASOO approval date will be shown.
Section D; Airworthiness Limitations - Life Limits, Systems Life Limited Parts
Following completion of successful endurance and fatigue testing the following changes were incorporated:
8. Propulsion - Thrust Reverser Actuation System (TRAS) - Rolls-Royce Trent 1000
Deleted the Life Limit requirements for component Item Numbers 8b-8d, (T-PC Assy 725Z3161-211, Deploy Hose, Short 725Z3161-195, Deploy Tube 725Z3161-155),8f (Stow Tube
(LW T/R) 725Z3161-203) and 8h (Stow Tube (LW T/R) 725Z3161-205), 8j-8m (Flexible Shaft, Side 720Z3161-179, Flexible Shaft, Side 720Z3161-181, Flexible Shaft, Crossover
725Z3161-207, Track Lock 725Z3161-177).
Item Numbers 8e and 8g; added text stating the component will remain life limited but will not be installed on any aircraft.
Item Numbers 8n, 8p and 8r; Added text stating a Service Bulletin will be available to install a new part that will not be life limited.
9. Propulsion - Thrust Reverser Actuation System - General Electric GEnx-1B
Deleted the Life Limit requirements for component Item Numbers 9b-9h (T-PC Assy 721Z3161-211, Deploy Hose, Short 721Z3161-195, Deploy Tube 721Z3161-155, Stow Tube
721Z3161-123, Stow Tube 721Z3161-125, Flexible Shaft, Side 720Z3161-179, Flexible Shaft, Side 720Z3161-181) and 9j-9k (Flexible Shaft, Crossover 721Z3161-207, Track Lock
721Z3161-177).
Item Numbers 9l, 9m and 9p; Added text stating a Service Bulletin will be available to install a new part that will not be life limited.
OCTOBER 2014
In Section C. Airworthiness Limitations – Supplemental Structural Fatigue Inspections:
Table 1: Added production Line Number (L/N) applicability's to PSE 53-61-07 Passenger Entry Door 3 - Cutout Surround Structure items.
In Section D. Airworthiness Limitations – Life Limits – Structural Safe Life Parts:
The following changes were made to Table 3, Nose Landing Gear – List of Safe-Life Parts and Assemblies:
Revised table to reflect the 787-9 parts that are now acceptable for use on the -8. This impacted the Inner Cylinder 522Z3001-501, Outer Cylinder 521Z3001-501 by adding 787-8
applicability to those items.
Deleted Note 1 from the Forward Lock Link and added Note 1 to the Aft Lock Link.
Added 787-9 applicability to the Metering Pin and 787-8 applicability to the Orifice Support Tube. Deleted the second row of information for Item 522Z3022-1 as this information is
now covered in the revised entry for 522Z3022-1, -2.
The following changes were made to Table 4, Main Landing Gear – List of Safe-Life Parts and Assemblies:
Added Torsion Link Part Numbers 511Z3002-5/-6.
Deleted the asterisk from the Shackle, Drag Brace Part Numbers 513Z3003-51/52 as these items are no longer the preferred spare in the group.
Revised Figure 5B; 787-9 Main Landing Gear Side and Drag Brace Assemblies Safe-Life Limits to correct a typographical error. Previous value of 57269, 3909 was corrected to
52769, 3909.
D011Z009-03-01

OCTOBER 2014, Continued
In Section E - Other Systems and Structures Airworthiness Limitations:
Revised System Airworthiness Limitation No. 1, Inspection of the Fuel Oil Heat Exchanger Following Fuel Tank Entry - 787-8 Airplanes with Trent 1000 Engines, by adding text to
reflect the latest FAA and EASA compliance dates and revising the engine applicability fields.
Revised System Airworthiness Limitation No. 2, Engine Oil Consumption Rates – 787-8 Airplanes with Trent 1000 Engines, by updating the oil consumption rate and the maximum
airplane fuel endurance flight hours to reflect the latest certification basis.
Revised System Airworthiness Limitation No. 3, Inspection of the Fuel Pump Strainer following Center Wing Fuel Tank Entry - 787-8 Airplanes with GEnx-1B Engines, by adding text
to reflect the latest FAA and EASA compliance dates and revising the engine applicability fields.
Added System Airworthiness Limitation No. 11, 787-8/9 Flight Deck Annunciation of GEnx-1B Engine Variable Bleed Valve Ice Protection System, to limit operations of 787-8/-9
GEnx-1B airplanes unless the flight deck annunciation modification for the Engine Variable Bleed Valve Ice Protection System has been accomplished.
JANUARY 2015
Revised System Airworthiness Limitation No. 4 by adding the 787-9 model and deleting the 25 flight hour limitation for maximum airplane fuel endurance.
APRIL 2015
Revised Structures Airworthiness Limitation No. 4 by adding limited interchangeability information for the 787 Forward Engine Mount Barrel Nut, applicable to all 787 airplanes.
JUNE 2015
In Section D, Systems Life-Limited Parts:
Item Number 2a, Supplemental Cooling Unit (SCU): Revised the Applicability Specification by adding text to clarify that the life limited component in the SCU is the condenser unit.
Additional text was added to provide options and guidance for controlling the life limit for compliance.
Revised the Life Limit of Item Numbers 4a through 4l for the Hydraulic Isolator from 27,000 Flight Hours to 54,000 Flight Hours.
JULY 2015
Section C, Table 1: Airworthiness Limitations – Supplemental Structural Fatigue Inspections:
Updated Principal Structural Element (PSE) 53-59-01, where applicable, to support a Boeing production block point change. The 787-9 under wing web and BL 0 web of the
Section 45 Keel Material changed for L/N 338 and on.
JUNE 2016
Deleted the Boeing submittal signature column and the FAA Approval signature column from the Revision Log to improve the layout and provide consistency across all
Section 9/AWL/CMR/SCI documents. Submittal signatures will no longer be included in the Revision Log.
Per FAA request, deleted exceptions from Subsection C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS front matter regarding
FAA Oversight Office's approval requirement of alternate inspections.
Revised Table 1 – AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS in Subsection C by deleting the existing PSE 54-51-01-B Pylon
to Wing Fittings for the Rolls Royce Engine Pylon with a threshold of 44,000 flight cycles and replacing it with three distinct DTR Check Forms, each for PSE 54-51-01-B, depending
on airplane Line Number, which are now flight length sensitive.
Revised the table of Systems Life-Limited Parts in Section D. AIRWORTHINESS LIMITATIONS – LIFE LIMITS by deleting the General Electric Primary Exhaust life limits.
Specifically, Items 7a, 7b, 7c, 7d and 7e comprising Section 7 were deleted from the subject table. As such, since Section 7 was deleted, Sections 8 through 12 were renumbered to
7 through 11, respectively.
D011Z009-03-01

SEPTEMBER 2016
Added new System Airworthiness Limitation No. 12, "UNCONTROLLABLE HIGH THRUST DUE TO THRUST CONTROL MODULE FAILURES - 787-8 AND 787-9 AIRPLANES
WITH GEnx-1B ENGINES" requiring a modification of the Thrust Control Module by 31 Dec. 2020 to prevent a possible Uncontrollable High Thrust condition.
Added new System Airworthiness Limitation No. 13, "REPORTING UNCONTROLLABLE HIGH THRUST FAILURE CONDITIONS" stipulating criteria for reporting such conditions.
NOVEMBER 2016
Revised Figure 2 for the Nose Landing Gear Safe-life Limits in respect to the Steering collar. This chart now represents final data.
Revised Figure 5A for the 787-8 Main Landing Gear Side and Drag Brace Safe-life Limits. Testing for these components is still in progress as noted on the chart.
Revised Figure 5B for the 787-9 Main Landing Gear Side and Drag Brace Safe-life Limits. Testing for these components is still in progress as noted on the chart.
Revised Table 4 for MAIN LANDING GEAR - LIST OF SAFE-LIFE PARTS AND ASSEMBLIES to update part dash numbers and notes for the Truck Beam, Pivot Pin, Outer Cylinder
Shock Strut, Inner Cylinder Shock Strut.
Revised Table 4 for MAIN LANDING GEAR BEAM ASSEMBLY part numbers 151Z1300-501/-502/-503/-504 by adding the improved beam dash numbers -701*/-702* for 787-9.
The -701*/-702* dash numbers are now the preferred spares.
Revised Table Note 1 to update effectivity for parts 515Z3001-2 and 515Z3001-3.
Revised Table Note 2 to update effectivity for parts 511Z3001-5/-6 and 511Z3001-7/-8.
Revised Table Note 5 to update effectivity for parts 512Z3001-2 and 512Z3001-3.
Added Table Note 32 to specify effectivity for parts 515Z3003-1 and 515Z3003-2.
JANUARY 2017
Revised Section A, Scope, to specify that only one revision of this Airworthiness Limitations document may be used at a time, and that various revisions should not be combined.
Revised Section C. THRESHOLD subsection to update the reference table summarizing PSE details in Table 1 that have a threshold less than 33,000 Flight Cycles.
Revised Section C. THRESHOLD subsection to include explanation for removal of the PSE 57-13-02A Overwing Beam Web Pocket DTR Location from Table 1.
Revised Table 1 to delete the following DTR Locations from PSE 57-13-02A: Overwing Beams, Seat Track (Upper Chord) - Web Attachment at BL11, 39.5, 66, and 90; Overwing
Beams, Web at Seat Track (Upper Chord) Attachment at BL 11, 39.5, 66 and 90; Overwing Beams, Lower Chord - Upper Skin Attachment at BL 11, 39.5, 66, and 90; Overwing
Beams, Lower Chord - Upper Skin Attachment @ BL 66, Overwing Beam hidden details @ BL 11, 39.5, 66, and 90; Overwing Beams, Web Pocket at BL 11 @ BS 1021-1104,
1071-1104; BL 39 @ BS 1011-1031, 1071-1104; BL 66 @ BS 948-979, 1011-1041, 1081-1104.
Revised Table 1 to correct a PSE number and title for PSE 57-13-02A by deleting reference to 57-13-02B, Overwing Beams - Miscellaneous Fittings.
Revised Table 1 to correct the threshold for PSE 57-13-02B, Overwing Beams - Miscellaneous Fittings, Rear Spar Splice Fittings - Horizontal Flange, BS 1072 to 1087 (LHS and
RHS) from 33,000(5) to FLS(5).
Deleted System Airworthiness Limitation No. 8 - WING UPPER PANEL VENT STRINGER INNER FLANGE following successful lightning testing and analysis which confirmed that
adhesive fillet cracking will not create a hazardous condition.
D011Z009-03-01

MAY 2017
Revised the 787-9 Maximum Taxi Weight in Table 2 from 559,000 LB (253,558 KG) to 561,500 LB (254,692 KG), to provide more customer range.
Revised note in Figure 2 to reference Interchangeability Document 520Z0001 for list of affected nose landing gear components, in lieu of Table 3, due to the transfer of landing gear
applicability information from the AWL.
Revised note in Figure 3, Figure 4, Figure 5A, and Figure 5B to reference Interchangeability Document 510Z0001 for list of affected main landing gear components, in lieu of Table 4,
due to the transfer of landing gear applicability information from the AWL.
Revised Figure 3 with new, interim safe-life limits for the Main Landing Gear Truck Assembly, based on recent test results. Testing is still in progress as noted on the chart.
Revised Figure 4 with new, interim safe-life limits for the Main Landing Gear Shock Strut Assembly, based on recent test results. Testing is still in progress as noted on the chart.
Revised Figure 5A to increase the Flight Cycles scale, and modify part identification verbiage from "Side and Drag Brace Assemblies (Titanium)" to "Titanium Brace Assembly
Members" for consistency to Figure 5B. There is no technical change to this Figure.
Revised Figure 5B with new, interim safe-life limits for the 787-9 Main Landing Gear Side and Drag Brace Assemblies, based on recent test results. Testing is still in progress as
noted on the chart.
Revised Figure 6 with new safe-life limits for the Main Landing Gear Support Fittings, based on recent test results. This chart now represents final data.
Revised note in Figure 6 to reference Interchangeability Document 126Z0007 for list of affected main landing gear wing box support fitting components, in lieu of Table 4, due to the
transfer of landing gear support structure applicability information from the AWL.
Revised Figure 7 with new safe-life limits for the Main Landing Gear Beam Assembly, based on recent test results. This chart now represents final data.
Revised note in Figure 7 to reference Interchangeability Document 151Z0000 for list of affected main landing gear trailing edge support fitting components, in lieu of Table 4, due to
the transfer of landing gear support structure applicability information from the AWL.
Revised Section D, 787 Nose Landing Gear (NLG) Part List, to delete all content and replace with reference to Interchangeability Document 520Z0001 for list of affected nose landing
gear components, due to the transfer of landing gear applicability information from the AWL.
Revised Section D, 787 Main Landing Gear (MLG) Part List, to delete all content and replace with reference to Interchangeability Documents 510Z0001, 151Z0000, and 126Z0007
for list of affected main landing gear and support structure components, due to the transfer of landing gear applicability information from the AWL.
Revised Item Number 2a in Section D, Systems Life-Limited Parts, to delete reference three (3.) for Supplemental Cooling Unit (SCU) Part Number 7011015H03, which is not subject
to a life limit. No other SCU part numbers except 7011015H02 will be life limited, therefore eliminating the need to list any additional numbers.
AUGUST 2017
Revised Section B to delete reference to the "Freedom From Widespread Fatigue Damage" subsection, as well as the "Freedom From Widespread Fatigue Damage" subsection,
itself. This subsection defines a Temporary Operational Limit, which is no longer needed with the completion of full-scale fatigue testing.
Revised Section B to delete the "Limit of Validity" subsection. The final limit of validity is reflected in Section F, based on recently completed full-scale fatigue testing.
Deleted Structures Airworthiness Limitation No. 3 (Wing Upper Panel Vent Stringer Cutout Inspection), as it was determined that vent stringer cutouts will maintain ultimate load
capability with barely visible impact damage, thus rendering the inspection unnecessary.
Added Section F (AWLs - Structural Limit of Validity (LOV)), to reflect the recently established limit of validity.
OCTOBER 2017
Added System Airworthiness Limitation No. 14 for RR TRENT 1000-TEN Engine Smoke Number Emissions.
D011Z009-03-01

NOVEMBER 2017
Revised the REFERENCES section to add MSG-3 Revision 2015.1 for the 787-10.
Revised the Section C. INTRODUCTION subsection to add reference to MSG-3 Revision 2015.1 for the 787-10. This subsection also deletes reference to Appendix A, the content
of which is removed in this revision.
Revised the Section C. THRESHOLD title to include the 787-10.
Revised the Section C. THRESHOLD subsection to clarify the 22 year threshold for all Supplemental Structural Fatigue Inspections. This subsection also deletes two references to
Appendix A, the content of which is removed in this revision.
Revised Figure 1 to include flight length sensitive threshold curves for the 787-10.
Revised the Section C. REPEAT INSPECTION INTERVAL subsection to delete the paragraph on DTR Check Form options, as it is currently irrelevant and will be included in the
DTR Check Forms document. This subsection also specifies which DTR Check Forms to utilize for 787-10, 8.0 hour long missions.
Revised the Section C. SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTION REQUIREMENTS subsection to delete reference to Appendix A, the content of which is removed
in this revision. This subsection also adds the 787-10 to the airplane applicability abbreviations list.
Revised Table 1 to include Supplemental Structural Fatigue Inspections for the 787-10. This table is also revised to move reference to NOTE (5) from each individual threshold to the
"Applicability Thresholds" title; and to rename PSE "54-51-01B" to "54-51-01," as the inspection is applicable to the complete pylon to wing installation and not a specific detail part.
Revised Table 2 to include the 787-10 Maximum Taxi Weight. This table also deletes the "Airplane Effectivity" and "Table 3 and Table 4 Column Heading" columns due to
redundancy.
Revised the Landing Gear and Support Structure, Safe-Life Limit Figure references table to include the 787-10 and corresponding Figure numbers.
Added item number 5 to the Instructions for using Safe Life Charts, to ensure that minor model usage is tracked (as well as flight hours and flight cycles) on parts that are common to
the -8/-9 and -10 and used interchangeably, when determining the safe-life limit.
Revised Figure 2 to re-number this to Figure 2A, and specify applicability to the 787-8 and 787-9 only. The reference to Interchangeability Document 520Z0001 was also revised to
include the 787-10.
Added Figure 2B to include Nose Landing Gear Safe-Life Limits for the 787-10.
Revised the reference to Interchangeability Document 510Z0001 in Figure 3, Figure 4, Figure 5A, and Figure 5B to include the 787-10.
Added Figure 5C to include Main Landing Gear Side and Drag Brace Assemblies Safe-Life Limits for the 787-10.
Revised Figure 6 to include Main Landing Gear Support Fitting Safe-Life Limits for the 787-10. The reference to Interchangeability Document 126Z0007 was also revised to include
the 787-10.
Revised Figure 7 to include Main Landing Gear Beam Assembly Safe-Life Limits for the 787-10. The reference to Interchangeability Document 151Z0000 was also revised to include
the 787-10.
Revised the Section D. 787 NOSE LANDING GEAR (NLG) PART LIST subsection to include the 787-10 in the reference to Interchangeability Document 520Z0001.
Revised the Section D. 787 MAIN LANDING GEAR (MLG) PART LIST subsection to include the 787-10 in the reference to Interchangeability Documents 510Z0001, 151Z0000, and
126Z0007.
D011Z009-03-01

NOVEMBER 2017, Continued
Revised the table in the Section D. SYSTEMS LIFE-LIMITED PARTS subsection to update 787-8, 787-9, and 787-10 data for the Hydraulic Isolators.
Revised SYSTEM AIRWORTHINESS LIMITATION NO. 6 to include the 787-10.
Revised SYSTEM AIRWORTHINESS LIMITATION NO. 14 to include the 787-10.
Added SYSTEM AIRWORTHINESS LIMITATION NO. 15 to include the engine oil consumption rate for 787-10 airplanes with Trent 1000 engines.
Added SYSTEM AIRWORTHINESS LIMITATION NO. 16 to include the engine oil consumption rate for 787-10 airplanes with GEnx-1B engines.
Added STRUCTURES AIRWORTHINESS LIMITATION NO. 5 to require replacement of the instrumented fin root tension bolts, due to aspects associated with the use of a
composite fin deck.
Revised Section F. AWLs - STRUCTURAL LIMIT OF VALIDITY to include reference to the requirements of Title 14 CFR § 25.571(b) Amendment 25-132 for the 787-10. This section
also adds the 787-10 to the LIMIT OF VALIDITY table.
Revised APPENDIX A to remove all content, including the post-threshold repeat interval table for structures and zonal tasks. Structural and zonal tasks are not permitted to be
escalated, and therefore there is no need to de-escalate any tasks to the original intervals defined at type certification.
MAY 2018
Revised Section A to add an Airworthiness Limitations subsection, which ensures that any revisions or alternate inspections are approved by the FAA Oversight Office.
Revised Section C. INTRODUCTION subsection to add reference to Title 14 CFR § 25.1529, and a pointer to the location of the Supplemental Fatigue Inspection Thresholds and
future DTR Check Forms. This subsection also deletes information on Airworthiness Limitations, which was moved to Section A.
Revised NOTE 4 in Figure 1, item 2 of Section C. REMOVAL OF EXCESS SEALANT WHEN INSPECTING, and Section C. SUPPLEMENTAL STRUCTURAL FATIGUE
INSPECTION REQUIREMENTS, to specify Boeing document D011Z009-04 (under development) as the future location for DTR Check Forms.
Revised Section C. REPEAT INSPECTION INTERVAL subsection to clarify use of the Damage Tolerance Rating System to determine the necessary fatigue repeat intervals and
inspections.
Revised Section C. REPORTING RESULTS OF STRUCTURAL INSPECTIONS to clarify the requirements for reporting structural significant defects.
Revised Table 1 to delete and add numerous PSEs due to post-ATC re-evaluation of the Supplemental Inspection Program.
Revised DTR Check Form Titles, DTR Location, and Applicability Threshold for PSE 55-37-05 (group 1 and 2), to acknowledge a design change at LN733 for the 787-8.
Revised Landing Gear and Support Structure table to reference new Figure 5D.
Added Figure 5D to include Main Landing Gear Safe-Life limits for Steel Drag Brace Assembly Components on the 787-9 and 787-10.
Revised the Section D. Systems Life-Limited Parts Table to update the life limit for item number 2a Supplemental Cooling Unit (SCU), from the rounded limitation of 4 years / 48
months to the actual calculated limitation of 4.35 years / 52 months, to support part shortage.
Revised STRUCTURES AIRWORTHINESS LIMITATION NO. 5 to add applicability for the 787-8 at LN 733 and on.
Added STRUCTURES AIRWORTHINESS LIMITATION NO. 6 to require High Frequency Eddy Current inspection of the Side of Body Rib Web on 787-8, L/N 6, only.
Deleted APPENDIX B. DISCREPANT STRUCTURE REPORT FORM, which will be moved to Appendix F of the Maintenance Planning Data Document, D011Z009-03.
D011Z009-03-01

JULY 2018
Revised Table 1 to add 787-8 applicability thresholds for PSE 53-41-04-5 and PSE 53-58-03, resulting from a stringer splice fitting material change.
Revised the Section D. Systems Life-Limited Parts Table to update the life limit for item number 2a, Supplemental Cooling Unit (SCU), to 5.8 years / 70 months to align with more
accurate and less conservative pressure cycle profiles that were also used to qualify the 7011015H03 SCU.
Revised the SYSTEM AIRWORTHINESS LIMITATION NO. 4 oil consumption rate from 0.45 quart (0.43 liter) per hour to 0.42 US quart (0.40 liter) per hour for the 787-8, based on
the results of new analysis using a new means of compliance. System Airworthiness Limitation No. 4 also deleted reference to the 787-9, the limitation of which is now included in
SYSTEMS AIRWORTHINESS LIMITATION NO. 16.
Revised SYSTEM AIRWORTHINESS LIMITATION NO. 16 to include the 787-9, formerly referenced in SYSTEM AIRWORTHINESS LIMITATION NO. 4, based on the results of new
analysis using a new means of compliance.
Added SYSTEM AIRWORTHINESS LIMITATION NO. 17 to prohibit operation in Ice Crystal Icing Conditions unless EEC B200 Software is installed, for 787-10 airplanes with
GEnx-1B/P2 engines.
OCTOBER 2018
Revised Table 1 to clarify line number applicabilities and add a new Supplemental Structural Fatigue Inspection for PSE 57-13-02C, resulting from a new tie rod implemented on the
787-8 at line number 781.
JANUARY 2019
Revised Table 1 to add 787-8, L/N 821 and on applicability to ATA 55 PSEs to capture commonality with 787-9/-10 Horizontal Stabilizer. Revised numerous ATA 55 PSEs to limit
applicability to up to 787-8 L/N 820 to retain information for the original configuration.
Revised numerous ATA 55 PSEs to add 787-8/-9 to the DTR Check Form Title Column for clarification.
D011Z009-03-01
LIST OF EFFECTIVE PAGES
Section Page Date Section Page Date Section Page Date Section Page Date Section Page Date
1.0 1 JAN 2019 1.0 40 NOV 2017 1.0 79 NOV 2017 1.0 118 JUL 2018
1.0 2 BLANK 1.0 41 NOV 2017 1.0 80 NOV 2017 1.0 119 JAN 2017
1.0 3 JUL 2018 1.0 42 NOV 2017 1.0 81 NOV 2017 1.0 120 SEP 2016
1.0 4 BLANK 1.0 43 NOV 2017 1.0 82 NOV 2017 1.0 121 SEP 2016
1.0 5 JAN 2019 1.0 44 NOV 2017 1.0 83 NOV 2017 1.0 122 NOV 2017
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1.0 7 JAN 2019 1.0 46 NOV 2017 1.0 85 NOV 2017 1.0 124 JUL 2018
1.0 8 JAN 2019 1.0 47 NOV 2017 1.0 86 NOV 2017 1.0 125 MAR 2014
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1.0 10 JAN 2019 1.0 49 NOV 2017 1.0 88 NOV 2017 1.0 127 AUG 2017
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1.0 21 MAR 2014 1.0 60 JAN 2019 1.0 99 NOV 2017
1.0 22 MAY 2018 1.0 61 JAN 2019 1.0 100 NOV 2017
1.0 23 AUG 2017 1.0 62 JAN 2019 1.0 101 NOV 2017
1.0 24 FEB 2014 1.0 63 JAN 2019 1.0 102 NOV 2017
1.0 25 MAY 2018 1.0 64 JAN 2019 1.0 103 MAR 2014
1.0 26 MAY 2018 1.0 65 NOV 2017 1.0 104 MAR 2014
1.0 27 MAR 2014 1.0 66 NOV 2017 1.0 105 MAY 2017
1.0 28 JAN 2017 1.0 67 MAY 2018 1.0 106 JUL 2018
1.0 29 MAY 2018 1.0 68 NOV 2017 1.0 107 NOV 2017
1.0 30 MAY 2018 1.0 69 NOV 2017 1.0 108 NOV 2017
1.0 31 MAY 2018 1.0 70 NOV 2017 1.0 109 JUN 2015
1.0 32 MAY 2018 1.0 71 NOV 2017 1.0 110 JUN 2016
1.0 33 MAY 2018 1.0 72 NOV 2017 1.0 111 JUN 2016
1.0 34 MAY 2018 1.0 73 NOV 2017 1.0 112 OCT 2014
1.0 35 MAY 2018 1.0 74 NOV 2017 1.0 113 OCT 2014
1.0 36 JUL 2018 1.0 75 NOV 2017 1.0 114 OCT 2014
1.0 37 NOV 2017 1.0 76 NOV 2017 1.0 115 OCT 2014
1.0 38 MAY 2018 1.0 77 OCT 2018 1.0 116 OCT 2015
1.0 39 NOV 2017 1.0 78 OCT 2018 1.0 117 JAN 2015
D011Z009-03-01
REFERENCES
APPLICABLE FEDERAL AVIATION REGULATIONS:

Sections 25.1309 (ARSENAL), 25.571, 25.1529 of Title14 CFR Part 25 of the Federal Aviation Regulations
RELATED DOCUMENTS:
Advisory Material Joint (AMJ) 25.1309, System Design and Analysis
FAA Advisory Circular 25-19, Certification Maintenance Requirements
FAA Advisory Circular 121-22A, Maintenance Review Board (MRB) Procedures
FAA Advisory Circular 120-17A, Maintenance Program Management through Reliability Methods
FAA Advisory Circular 20-114, Manufacturers Service Documents
Air Transport Association of America (ATA) Maintenance Steering Group (MSG-3), Operator/Manufacturer Scheduled Maintenance Development
document, MSG-3 Revision 2005.1, January 2005 (for 787-8)
document, MSG-3 Revision 2011.1, September 2011 (for 787-9)
document, MSG-3 Revision 2015.1, September 2015 (for 787-10)
Air Transport Association of America (ATA) Specification for Manufacturers Technical Data, A.T.A. Specification No. 100, October 31, 1991, "Airline
Requirements for Aircraft Zoning"
Boeing Document D011Z009-03, 787 Maintenance Planning Data
Boeing Document D011Z009-03-02, 787 Airworthiness Limitations (AWLs) - Line No. Specific
Boeing Document D011Z009-03-04, 787 Special Compliance Items (SCIs)/Airworthiness Limitations (AWLs)
Boeing Document D634Z301, Non Destructive Testing (NDT) Manual
Boeing Document D011Z009-02, 787 Maintenance Review Board Report Document, 17 December 2013
Boeing Document B787-81205-A0101-00, Aircraft Maintenance Manual (AMM)
D011Z009-03-01
NOV 2017 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-20
TERMS AND ACRONYMS
BBJ Boeing Business Jet
BCL Bottom Centerline
BL Buttock Line
CFR Code of Federal Regulations
CFRP Carbon Fiber Reinforced Plastic
DTR Damage Tolerance Rating
FLS Flight Length Sensitive
FTG Fitting
I/B Inboard
L Left
LHS Left-hand Side
LWR Lower
O/B Outboard
PSE Principal Structural Element
R Right
RHS Right-hand Side
RS Rear Spar
S-n Stringer Number “n”, where “n” is the integer number defining the stringer
TCL Top Centerline
WL Waterline
D011Z009-03-01
MAR 2014 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-21
A. SCOPE
The scheduled maintenance requirements described in this document result from Model 787 airplane certification activities with the U.S. Federal Aviation
Administration (FAA). Accordingly, this FAA approved Airworthiness Limitations document is cross-referenced in the Model 787 Type Certificate Data
Sheet. These maintenance actions are mandatory.
This Airworthiness Limitations document is FAA approved and specifies maintenance required under Sec. 43.16 and 91.403 of the Federal Aviation
Regulations, unless an alternative program has been FAA approved. The Airworthiness Limitations document must be used in its entirety at a specific
revision level, and maintenance requirements and limitations from different revision levels shall not be combined.
Where used in this document, the term “FAA Oversight Office” is defined as the FAA office that currently has oversight responsibility for the type certificate
of the Boeing model 787. At the time of publication, the FAA office with oversight responsibility for the type certificate of the 787 is the FAA Boeing Aviation
Safety Oversight Office (BASOO).
The Airworthiness Limitations in this document may make reference to Instructions for Continued Airworthiness which are included in other Boeing
documents.
• When a document is cited using the words "in accordance with", the cited document (or document section) must be followed to ensure that the critical
design feature is maintained. Any deviation from the cited document requires FAA Oversight Office approval.
• When a document is cited using the words "refer to”, the cited document (or document section) represents one method of complying with the airworthiness
limitation. An alternative procedure may be developed by an operator in accordance with its procedures in its maintenance program/manual.
NOTE: Where specifically indicated, some of the limitations defined in this document have unique requirements for BBJ 787 airplanes. BBJ airplanes are
defined to be those that accumulate less than 1200 Flight Hours per year and operate under Title 14 CFR 91 or Title 14 CFR 125 for private
carriage only.
AIRWORTHINESS LIMITATIONS (AWLS)
The Airworthiness Limitations may only be revised with the approval of the FAA Oversight Office.
If the inspections cannot be accomplished due to repairs and/or modifications, an alternate inspection must be approved by the FAA Oversight Office.
D011Z009-03-01
MAY 2018 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-22
B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITS
This section summarizes the airplane operational limits imposed on the 787 airplanes. The operational limitation imposed on each 787 is the lowest of the
individual limitations as defined in the Temporary Operational Limit subsection below.
TEMPORARY OPERATIONAL LIMIT
The FAA has agreed to the following three-stage approach for Boeing to compile and publish the information necessary to accomplish the supplemental
structural fatigue inspections.
• Stage 1 results in publishing the baseline inspection program which consists of the 787 Maintenance Planning Data (MPD) document, D011Z009-03,
Structures and Zonal Programs at the time of certification. Stage 1 is complete.
• Stage 2 results in publishing the Supplemental Structural Fatigue Inspection thresholds. Stage 2 is complete. Until Stage 3 is complete, an operational limit
is imposed on every 787 airplane equal to 75% of the lowest threshold defined in Table 1 for which the inspection procedures and DTR Check Forms are
not published.
• Stage 3 results in publishing the DTR Check Forms and the procedures necessary to accomplish the Supplemental Structural Fatigue Inspections. Once
Stage 3 is complete, the Stage 2 temporary operational limit will be removed.
D011Z009-03-01
AUG 2017 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-23
This approach is illustrated in the table below:
Stage Description Publication Date Details of Publication Threshold Temporary Operational Limit
1 Baseline Inspection Prior to issuance of the 787 TC. MPD Structures and Zonal Not Applicable. Not Applicable.
Program Data published. Programs at time of certification.
2 Supplemental structural 3,000 total flight cycles, 10,000 Thresholds for all PSEs Published in Table 1 for 75% of the lowest threshold
fatigue inspection total flight hours, or 18 months identified. each PSE requiring defined in Table 1 for which the
thresholds published. from issuance of the 787 TC, supplemental inspection inspection procedures and DTR
whichever comes first. Check Forms are not published.
3 DTR Check Forms and Prior to Stage 2 operational NDT Manual: Inspection Same as Stage 2. None.
NDT Manual Procedures limit. procedure details (including
published. inspection equipment,
standards, probes, etc.) are
developed and documented and
are validated and available to
the operators. DTR Check
Forms for items defined in
Table 1.
D011Z009-03-01
FEB 2014 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-24
C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS
INTRODUCTION
The Structural Maintenance Program and the Zonal Inspection Program approved in the 787 Maintenance Review Board Report (MRBR), Document
D011Z009-02, and contained in the 787 MPD, Document D011Z009-03, describe an initial baseline Structural Maintenance Program for all Structural
Significant Items (SSIs). These programs were developed based on the guidelines of MSG-3, Revision 2005.1 (for the 787-8), Revision 2011.1 (for the
787-9), and Revision 2015.1 (for the 787-10), and partially satisfy the requirements of Title14 CFR § 25.571 and § 25.1529 by providing accidental damage
and environmental deterioration detection opportunity, and in some cases fatigue damage detection opportunity, for all Principal Structural Elements (PSEs).
The Supplemental Structural Fatigue Inspections are to be accomplished in conjunction with the baseline Structural Maintenance Program and thereby fully
satisfies the requirements of Title 14 CFR § 25.571 and § 25.1529.
NOTE: Escalation of MPD Sections 2 and 3 Structures and Zonal tasks beyond the flight cycle repeat interval defined at initial type certification is not permitted
at this time as compliance to Title 14 CFR § 25.571 requirements for accidental damage to composite structure was based on the flight cycle repeat
interval defined at initial type certification. Escalation of the Structures and Zonal MPD tasks may be possible in the future subsequent to Boeing/FAA
discussions regarding parameters under which flight cycle escalation of 787 MPD Section 2 and 3 tasks is permissible.
The Supplemental Structural Fatigue Inspections listed in this document are for those PSEs that do not receive adequate fatigue damage detection
opportunity from the initial baseline Structural Maintenance and Zonal Inspection Programs. (Such 787 MPD Section 2 inspection tasks having
corresponding Supplemental Structural Fatigue Inspections will be identified by the letter "F" (for fatigue) in the Program (PGM) column.) The Supplemental
Structural Fatigue Inspections shall be accomplished in addition to the baseline Structural Maintenance Program.
The Supplemental Structural Fatigue Inspection Program, developed using the Boeing Damage Tolerance Rating (DTR) System, must be accomplished
prior to exceeding the defined threshold for each PSE. The Supplemental Fatigue Inspection threshold for each PSE is defined herein. The DTR System
defines a required DTR (a numerical value) that must be achieved for each PSE. Through the DTR System, the inspections and repeat intervals necessary
to provide adequate fatigue damage detection are determined. DTR Check Forms defining the inspection intervals, inspection options, and the required
DTR will be provided in D011Z009-04.
See Section D for PSEs certified per Title14 CFR § 25.571(c) as safe-life structure.
D011Z009-03-01
There is no separate 787 Corrosion Prevention and Control Program (CPCP) as each MPD Section 2 inspection requires that the structural areas being
inspected are also evaluated for corrosion. All tasks defined therein are necessary to maintain the aircraft to Corrosion Level 1 or better.
NOTE: Supplemental Structural Fatigue Inspections necessitated by major non-conformances occurring during airplane production are contained in Document
D011Z009-03-02, 787 Airworthiness Limitations (AWLs) – Line Number Specific. Revised inspection requirements and inspection intervals will be
listed in Document D011Z009-03-02 as applicable to individual production line number airplanes. These line number-specific inspections must be
included in the applicable operator's maintenance program.
THRESHOLD (787-8/-9/-10 AIRPLANES)
The Supplemental Structural Fatigue Inspections must be accomplished prior to accumulation of a certain number of flights (threshold). The threshold for
each PSE requiring Supplemental Structural Fatigue Inspections is defined in Table 1, "Airworthiness Limitations – Supplemental Structural Fatigue
Inspections". In addition to the stated flight cycle threshold, a calendar threshold of 22 years from date of aircraft delivery applies to all Supplemental
Structural Fatigue Inspections.
NOTE: For BBJ 787 airplanes only: If an initial inspection of an FAA approved Structural Maintenance Program containing tasks necessary to maintain the
aircraft to Corrosion Level 1 or better has occurred, thereby constituting implementation of a Corrosion Prevention and Control Program (CPCP), the 22
year calendar threshold does not apply.
NOTE: Supplemental inspection thresholds and repeat intervals are measured in flight cycles or flight hours that a particular PSE detail has accumulated
regardless of what the airframe as a whole has accumulated. Most PSE details will never be replaced and therefore have accumulated the same flight
cycles and flight hours as the airframe. Some PSE details will be replaced, such as when installing removable structural components (repairable/
rotable/expendables) or installing used structural parts as part of a repair. In these cases, the accumulated flight cycles and flight hours of the
replacement PSE details may be different from that of the airframe they have now been installed on. The operator must account for this in determining
when inspections must be done.
D011Z009-03-01
Each PSE requiring a Supplemental Structural Fatigue Inspection is categorized as either Group 1 or Group 2. Inspection thresholds are limited to a
maximum of 33,000 flight cycles for Group 1 and a maximum of 44,000 flight cycles for Group 2. The definition for each group is as follows:
Group 1:
• Single load path structure; or
• Multiple load path structure that provides insufficient opportunity for visual detection of a crack because the crack originates in a hidden structural element
and the majority of the crack growth period resides within the hidden (non-visible) member; or
• Multiple load path structure in which the lead crack would not be directly visible during internal or external normal maintenance inspections.
Group 2:
• Remaining unobstructed PSEs which require a Supplemental Structural Fatigue Inspection.
The Supplemental Structural Fatigue Inspections must be accomplished prior to exceeding the defined thresholds as stated in Table 1.
Some PSE details are sensitive to flight length; such details are identified by "FLS" (Flight Length Sensitive) in the Threshold column of Table 1. The
threshold for FLS Items must be determined from the FLS Threshold Curves of Figure 1, based upon the actual airplane utilization in terms of flight hours
and flight cycles.
Adjustments for training flights can be made by considering a full stop landing or two touch-and-go landings equivalent to one flight cycle.
D011Z009-03-01
NOTE: For reference, the PSE details listed below, as also indicated in Table 1, have a threshold less than 33,000 Flight Cycles.
PSE DTR Check Form Title DTR Location Threshold
53-41-05B MLG Hanger Link Aft Lug - BS 1209 Forward and Aft Flanges common to Wheel Well Longeron Extension 21,860
(L/N 4 - 70)
NOTE: The inspection requirement for the PSE 57-13-02A DTR Location listed below was previously listed in Table 1 for 787-8, and in the table above as
having a threshold less than 33,000 Flight Cycles. Design change has been incorporated either in production or by retrofit such that the inspection
associated with this DTR Location is no longer required. In-service airplane retrofit has been accomplished in accordance with Boeing Service Bulletin
B787-81205-SB530003-00-001 or -002 on all applicable units not reworked prior to delivery (787-8 L/Ns 8, 9, 23, 24, 31, 33, 37, 38, 40, 41, 42, 47, 48).
PSE DTR Check Form Title DTR Location
57-13-02A Overwing Beams Web Pocket at BL 11 BS 1021-1104, 1071-1104 BL 39 BS 1011-1031, 1071-1104, BL 66 BS

948-979, 1011-1041, 1081-1104
D011Z009-03-01
50,000
44,000FC 787Ͳ8/Ͳ9Group1
66,000FH
45,000 787Ͳ10Group1
787Ͳ8/Ͳ9Group2
40,000
33,000FC 787Ͳ10Group2
49,500FH
35,000
30,000
FlightCycles
11,500FC
25,000 115,000FH
20,000 7,500FC 10,000FC

101,250FH 135,000FH
15,000
10,000 8,625FC
86,250FH
5,000
0
0 20,000 40,000 60,000 80,000 100,000 120,000 140,000
FlightHours
Figure 1. FLIGHT LENGTH SENSITIVE (FLS) THRESHOLD CURVE
USE OF FLS THRESHOLD CURVES

(For FLS Items only; all non-FLS PSEs have flight cycle thresholds as listed in Table 1)
1. Determine the Group of the FLS PSE detail from Table 1.
2. Determine the total number of flight cycles and flight hours accumulated on the PSE detail.
3. Locate the intersection of Flight Hours and Flight Cycles for the PSE detail on the graph.
4. If the point determined by Step 3 lies inside the Threshold Curve for the group from Step 1, the detail has not reached the Inspection Threshold. If the
point falls outside the curve for the specified group, the threshold has been exceeded. Operators must accomplish the inspection prior to exceeding the
threshold. FLS related DTR Check Forms will be provided in D011Z009-04. Find the appropriate DTR Check Form for the FLS PSE detail based on the
average hours per flight for the detail.
D011Z009-03-01
REPEAT INSPECTION INTERVAL
The Supplemental Structural Fatigue Inspection program uses the Damage Tolerance Rating (DTR) System to determine the inspections (and repeat
intervals) necessary to provide adequate fatigue damage detection. The DTR System defines a required DTR (a numerical value) that must be achieved for
each PSE. DTR Check Forms, which define the inspection options and the required DTR, will be contained in the 787-8/9/10 Damage Tolerance Rating
(DTR) Check Form Document, D011Z009-04.
A repeat inspection interval for the fatigue inspections of a PSE is established from its DTR Check Form. Revision to the required DTR or DTR curve is not
allowed without approval from the FAA Oversight Office.
REPORTING RESULTS OF STRUCTURAL INSPECTIONS
Report of structural significant defects, as defined by the FAA Suspect Discrepancy Report (SDR) process (14 CFR Part 121.703), shall be submitted by
operators operating under FAA regulations. Operators who are not required to submit SDRs shall make equivalent reports to Boeing Commercial Airplanes
(BCA).
In addition to the above, all significant structural discrepancies found during scheduled fatigue related inspection tasks shall also be reported to BCA on a
Discrepant Structure Report form located in Appendix F of the Maintenance Planning Data, D011Z009-03.
D011Z009-03-01
REMOVAL OF EXCESS SEALANT WHEN INSPECTING
1. In areas where the inspection is prevented due to sealant, remove any fastener cap, fillet or brush sealant that extends beyond 0.20-inch around the
fastener at locations that are to be inspected. Remove any additional sealant which impairs visibility of the structure adjacent to the fastener cap, fillet
or brush sealant. This requirement applies to post-threshold inspection of PSEs for which the MPD Section 2 or 3 tasks satisfy the required DTR.
2. For PSEs requiring Supplemental Structural Fatigue Inspections, requirements to remove fastener cap, fillet or brush sealant will be defined on the DTR
Check Forms, D011Z009-04.
3. Sealant and corrosion protection finishes should be removed only when specified in the inspection task. Upon completion of the inspection task, restore
sealant per the AMM section or other reference noted below. Sealant restoration common to the fuel tanks is subject to airworthiness limitations
identified in Document D011Z009-03-04, Special Compliance Items/Airworthiness Limitations. Adherence to the airworthiness limitations requirements
of D011Z009-03-04 is required to prevent the development of an ignition source within the fuel tanks.
Refer to AMM 51-31-01 (and any applicable Service Bulletins or repair instructions) for general sealant removal and application.
Refer to AMM 28-11-00 (Task B787-A-28-11-00-14A-663A-A) for removal of sealant (BMS 5-45) inside the fuel tank. Application of sealant
(BMS 5-45) inside the fuel tank shall be performed in accordance with AMM 28-11-00 (Task B787-A-28-11-00-14A-663A-A). The application
requirements in the AMM are subject to airworthiness limitations identified in Document D011Z009-03-04. Adherence to these airworthiness
limitation requirements is required to prevent the development of an ignition source within the fuel tanks.
If sealant inside the fuel tank is removed for inspection, care must be taken to remove any sealant debris in the fuel tank.
Refer to AMM 28-11-00 (Task B787-A-28-11-00-15A-663A-A) for removal and application of secondary fuel barrier sealant (BMS 5-167 Type I
Coating – Heat Resistant Secondary Fuel Barrier) outside the fuel tank.
D011Z009-03-01
SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTION REQUIREMENTS
Table 1 lists the threshold for each Airworthiness Limitation Supplemental Structural Fatigue Inspection. The table identifies each PSE detail for which one
or more DTR Check Forms will be provided in D011Z009-04. Each item is listed by PSE Number, DTR Check Form Title, DTR Location, and Airplane
Applicability/Threshold. Where there is more than one listing for a given PSE Number, the DTR Check Form Title and location is the unique identifier.
Airplane applicability is listed as shown below (no entry implies all 787 airplanes):
ALL = All B787 Airplanes
787 = All B787 Airplanes
-8 = B787-8
-9 = B787-9
-10 - B787-10
RR = Rolls Royce Trent 1000 Series Engine
GE = General Electric GEnx-1B Series Engine
NOTE: C/L or L/N = Airplane Cumulative Line Number, where mentioned with DTR Check Form Title, identifies certain DTR Check Forms to specific airplane
line numbers.
D011Z009-03-01
TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS
APPLICABILITY THRESHOLDS
(1)(4)(5)(6)
PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP 787-8 787-9 787-10
27-41-16A HSTA (Horizontal Stabilizer Trim Actuator) C99145 Ballscrew Flange and Threads 1 33,000 33,000 33,000
Ballscrew Assy (CA39590)
27-41-16B HSTA (Horizontal Stabilizer Trim Actuator) C99145 Ballnut Trunnion 1 33,000 33,000 33,000
Ballscrew Assy (CA39590)
27-41-16C HSTA (Horizontal Stabilizer Trim Actuator) C99145-001 Section 48 1 33,000 33,000 33,000
Upper Gimbal Pin Assy (CA29233)
52-37-01c-1 Aft Large Cargo Door - Latch Cam Support and Shear Shear Fitting Lugs 2 44,000 44,000 44,000
Fittings
53-11-01-1 Skin/Stringer/Frame Assembly Forward of BS 232.5 EF Post Outer Chord 2 44,000
53-11-03-1 Lower Lobe Skin/Stringer/Frame/Lower Stanchion Fitting Nose Wheel Well Integration Strap at S-37, BS 276 1 33,000
Assembly Fwd of BS 338.5
53-11-07-1 Passenger Entry Door 1 - Cutout Surround Structure Edge Frame Inner Chord and Web 2 44,000 44,000 44,000
53-11-07-2 Passenger Entry Door 1 - Cutout Surround Structure Edge Frame Web at Door Stop Fittings 2 44,000 44,000 44,000
53-11-07-3 Passenger Entry Door 1 - Cutout Surround Structure Aft Edge Frame Web at Nutplates 1 33,000
53-11-07-4 Passenger Entry Door 1 - Cutout Surround Structure Edge Frame Outer Chord 2 44,000 44,000 44,000
53-11-10-1 Forward Large Cargo Door - Cutout Surround Structure Edge Frame Inner Chord and Web 2 44,000 44,000 44,000
53-11-10-2 Forward Large Cargo Door - Cutout Surround Structure Edge Frame Web at Attachment to Upper and Lower 1 33,000 33,000 33,000
Main Sills
53-11-10-3 Forward Large Cargo Door - Cutout Surround Structure Edge Frame Outer Chord 2 44,000 44,000 44,000
D011Z009-03-01
(1)(4)(5)(6)
53-11-12-1 Forward Large Cargo Door Cutout – Lower Main Sill & Lower Main Sill Inner Chord and Web 2 44,000 44,000 44,000
Latch Backup Structure
53-11-17-1 Crew Window Cutout #1 – Window Frame Window Frame along AB Post 2 44,000
53-11-17-2 Crew Window Cutout #1 – Window Frame Window Frame along CD post 1 33,000
53-11-19-1 Crew Window Cutout #2 – Window Frame Window Frame along EF Post, DQ Sill, and QF Sill 2 44,000
53-11-20-1 Crew Window Cutout #2 - Window Sills Window Sill Along EF Post, DQ Sill, and QF Sill 2 44,000
53-11-21-1 Crew Window Cutout - Left & Right Frames Window Frame Along AB Post 2 44,000 44,000 44,000
53-11-21-2 Crew Window Cutout - Left & Right Frames Window Frame Along CD Post 2 44,000 44,000 44,000
53-11-21-3 Crew Window Cutout - Left & Right Frames Window Frame Along BD Sill Inner Chord, and DQ Sill 1 33,000 33,000 33,000
and QT Sill Outer Chord
53-13-01-1 Forward Pressure Bulkhead – Bulkhead Web Web at Attachment to Angle Chord 2 44,000 44,000 44,000
53-13-02-1 Forward Pressure Bulkhead – Bulkhead Chord & Splices Angle Chord at Attachment to Dome Web and at 2 44,000 44,000 44,000
Attachment to Y-Chord
53-13-02-2 Forward Pressure Bulkhead – Bulkhead Chord & Splices Angle chord at Locations hidden by Chord Splices 1 33,000 33,000 33,000
53-13-02-3 Forward Pressure Bulkhead – Bulkhead Chord & Splices Angle Chord at Attachment to Y-Chord and Fuselage 2 44,000 44,000 44,000
Skin
53-17-01-1 Nose Wheel Well – Trunnion Support Fitting Fastener Locations Common to Trunnion Frame 1 FLS
53-17-01-2 Nose Wheel Well – Trunnion Support Fitting Trunnion Support Fitting Free Flange 2 FLS
D011Z009-03-01
(1)(4)(5)(6)
53-17-01-3 Nose Wheel Well – Trunnion Support Fitting Fastener Locations Common to Trunnion Frame & 2 FLS FLS FLS
Trunnion Fitting Free Flange
53-17-02-1 Nose Wheel Well – Drag Brace Fitting Grease Fitting Hole 1 33,000 33,000 33,000
53-18-01-1 Nose Wheel Well – Forward Bulkhead Panel Web at Door Stop Fittings 2 44,000
53-18-04-1 Nose Wheel Well – Side Panels Web at Attachment to Lower Chord & Web at 2 44,000 44,000 44,000
Attachment to Beam No. 4
53-18-06-1 Nose Wheel Well – Aft Bulkhead Beams Aft Bulkhead Beam No. 2 at Attachment to Aft 2 44,000 44,000 44,000
Bulkhead Web
53-18-06-2 Nose Wheel Well – Aft Bulkhead Beams Aft Bulkhead Beam No. 4 at Attachment to Aft 2 44,000
Bulkhead Web
53-18-07-1 Nose Wheel Well – Aft Bulkhead Web Bulkhead Frame Splice 2 44,000 44,000 44,000
53-31-34-1 Passenger Entry Door 2 – Cutout Surround Structure Upper Sill Inner Chord Splices 2 44,000 44,000 44,000
53-31-34-2 Passenger Entry Door 2 – Cutout Surround Structure Edge Frame Inner Chord and Web 2 44,000
53-31-34-3 Passenger Entry Door 2 – Cutout Surround Structure Edge Frame Web at Door Stop Fittings 2 44,000
53-31-34-4 Passenger Entry Door 2 – Cutout Surround Structure Edge Frame Web at Latch Fittings 1 33,000
53-31-34-5 Passenger Entry Door 2 – Cutout Surround Structure Edge Frame Outer Chord 2 44,000
53-41-03-1 Front Spar Bulkhead Frame – BS 873 Inner Chord and Web 2 44,000 44,000 44,000
53-41-03-2 Front Spar Bulkhead Frame – BS 873 Inner Chord, Outer Chord, and Web at Splice Located 2 44,000 44,000 44,000
Between S-16 and S-17
D011Z009-03-01
(1)(4)(5)(6)
53-41-03-3 Front Spar Bulkhead Frame – BS 873 Outer Chord 2 44,000 44,000
53-41-04-1 Aft Wheel Well Bulkhead Frame – BS 1209 Inner Chord and Web 2 44,000 44,000 44,000
53-41-04-2 Aft Wheel Well Bulkhead Frame – BS 1209 Inner Chord and Web Splice Angles at Splice Located 2 44,000
Between S-2 and S-3
53-41-04-3 Aft Wheel Well Bulkhead Frame – BS 1209 Splice Strap and Splice Angle at Splice Located 2 44,000 44,000 44,000
Between S-1L and S-1R
53-41-04-4 Aft Wheel Well Bulkhead Frame – BS 1209 Inner Chord at Splice Located Between S-16 and S-17 2 44,000
53-41-04-5 Aft Wheel Well Bulkhead Frame – BS 1209 Inner Chord, Outer Chord, and Web at Splice Located 2 44,000 44,000 44,000
Between S-16 and S-17
53-41-04-6 Aft Wheel Well Bulkhead Frame – BS 1209 Outer Chord 2 44,000 44,000 44,000
53-41-05B MLG Hanger Link Aft Lug – BS 1209 (L/N 4-70) Lug Base Corner Fillet Radius 2 44,000
53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 71 and on) Lug Base Corner Fillet Radius 2 44,000
53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 4-70) Forward and Aft Flanges common to Wheel Well 1 21,860
Longeron Extension
53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 71 and on) Forward and Aft Flanges common to Wheel Well 1 33,000
Longeron Extension
53-41-07 Wheel Well Longeron Rear Spar Overwing Longeron BS 1024-1128 (LHS/ 2 44,000
RHS) at Fasteners
53-41-07 Wheel Well Longeron Rear Spar Overwing Longeron BS 1111-1117 (LHS/ 1 33,000
RHS) at Fairing Strut Bracket
53-41-07 Wheel Well Longeron RS OWL BS 1024-1128 (LHS/RHS) at Edges 2 44,000
D011Z009-03-01
(1)(4)(5)(6)
53-41-07 Wheel Well Longeron Rear Spar Overwing Longeron Upper Edge, BS 1110 1 33,000
to BS 1116
53-41-07 Wheel Well Longeron BS 1194-1221 WWLE Vertical and Horizontal Flanges 1 33,000
Hidden Details
53-41-07 Wheel Well Longeron Vertical Flange Hidden Details at BS 1169, 1185 and 1 33,000 33,000
1195
53-41-07 Wheel Well Longeron Longeron Extension Flange Fillet Radius from 1 33,000 33,000
BS 1180 to 1195
53-41-07 Wheel Well Longeron Wheel Well Longeron Horizontal Flange, 1 FLS
BS 1121-1135
53-41-07 Wheel Well Longeron Wheel Well Longeron Horizontal Flange, 1 FLS
BS 1139-1141
53-41-07 Wheel Well Longeron Fillet Radius, from BS 1135 to BS 1155 2 44,000 44,000
53-41-07-A Wheel Well Longeron Vertical Flange at attachment to splice plate and uplock 1 33,000
fitting
53-41-07B Wheel Well Longeron BS 1190-1257 Visible Fastener Holes Vertical and 2 44,000
Horizontal Flanges
53-41-07-B Wheel Well Longeron Vertical & Horizontal Flanges, BS 1120-1190 2 44,000
Open Areas
53-41-07 Wheel Well Longeron Longeron Extension at Visible Fastener Locations 2 44,000 44,000
53-41-07-C Wheel Well Longeron Vertical Flange, BS 1137-1141 2 44,000
53-41-07-D Wheel Well Longeron Vertical and Horizontal Flanges, BS 1120-1201 Hidden 1 33,000
Areas
D011Z009-03-01
(1)(4)(5)(6)
53-41-08-1 Wheel Well Bulkhead Frames Inner Chord 2 44,000 44,000 44,000
53-41-11 Front Spar Underwing Longeron Fuselage and Wing Lower Panel Attachment 1 33,000 33,000 FLS
53-41-12 Front Spar Pickle Fork Fitting Pickle Fork Inner Chord, Outer Chord, and Web BS 1 33,000 33,000 33,000
873, S-17 splice
53-41-12 Front Spar Pickle Fork Fitting Fail-Safe Strap, S-18 to S-21 1 33,000
53-41-12 Front Spar Pickle Fork Fitting Outer Chord Attachment to Fail-Safe Strap and Skin – 1 33,000
Hidden Details – S-19 to S-21
53-41-12 Front Spar Pickle Fork Fitting Outer Chord Attachment to Skin – Hidden Details S-19 1 33,000
to S-20
53-41-12 Front Spar Pickle Fork Fitting Outer Chord Attachment to Fail-Safe Strap and Skin – 2 44,000
Stringer 22 to Stringer 19
53-41-12 Front Spar Pickle Fork Fitting Inner Chord from WL 184 to Top of Pickle Fork 2 44,000 44,000 44,000
53-41-12 Front Spar Pickle Fork Fitting Stringer 19 and 20 Mouse Holes 2 44,000 44,000 44,000
53-41-12 Front Spar Pickle Fork Fitting Front Spar and Skin Attachments WL 165 to WL 189.5 1 33,000 33,000 33,000
53-41-12 Front Spar Pickle Fork Fitting Front Spar Attachment at WL 189.5, Inboard Bolt 1 33,000
53-41-13 Trapezoidal Panel/Vertical Flex Tee Fastener Holes at Trapezoidal Panel/Vertical Shear Tie 1 33,000 33,000 33,000
Interface
53-41-13 Trapezoidal Panel/Vertical Flex Tee Trapezoidal Panel Aft Horizontal Flange Fastener 2 44,000
Holes, BS 1120 to 1140.4
53-41-13 Trapezoidal Panel/Vertical Flex Tee Upper Chord – Visible Fastener Holes at 2 44,000 44,000
BS 1086 - 1139
D011Z009-03-01
(1)(4)(5)(6)
53-41-13 Trapezoidal Panel/Vertical Flex Tee Lower Penetration, inspection applies to both 2 44,000
penetrations
53-41-13 Trapezoidal Panel/Vertical Flex Tee Penetrations 2 FLS FLS
53-41-13 Trapezoidal Panel/Vertical Flex Tee Trapezoidal Panel Stiffeners Inboard and Outboard 2 44,000 44,000 44,000
Surfaces
53-41-13 Trapezoidal Panel/Vertical Flex Tee Fastener Holes at Vertical Shear Tie/Trapezoidal Panel 1 33,000
Interface, (8) Fasteners Common to Splice Plate
53-41-13 Trapezoidal Panel/Vertical Flex Tee Vertical Shear Ties, rebate and radius area 2 44,000
53-41-13 Trapezoidal Panel/Vertical Flex Tee Trapezoidal Panel fastener holes at Flex-T, Horizontal 2 44,000
and Vertical flanges / Trap Stiffener Bracket
53-41-13 Trapezoidal Panel/Vertical Flex Tee Trapezoidal Panel fastener holes at Flex-T at BS 1089 2 44,000
and 1113 Frames
53-41-13 Trapezoidal Panel/Vertical Flex Tee Flex T-Chord Fastener Hole and Trap Panel Stiffener 1 33,000
Brackets (Hidden Locations)
53-41-13 Trapezoidal Panel/Vertical Flex Tee Upper Chord Hidden Fastener Holes from BS 1103 to 1 33,000 33,000
1108, Inboard Side
53-41-13 Trapezoidal Panel/Vertical Flex Tee Visible Fastener Holes in Vertical Shear Tie (both 2 44,000
upper and lower)
53-55-01 Pressure Deck – Stiffened Web Gutter – Hidden Fastener details, LBL 94.6 to 1 33,000
RBL 94.6 BS 1077 to BS 1081
53-55-01 Pressure Deck – Stiffened Web Gutter – Fastener Attachment (Hidden Detail) Forward 1 33,000 33,000
Flange at BS 1080, BL 0 to BL 100
53-55-01 Pressure Deck – Stiffened Web Gutter – Fastener Attachment (Non-Hidden Detail), BL 2 44,000 44,000
0 to BL 100
D011Z009-03-01
(1)(4)(5)(6)
53-55-01 Pressure Deck – Stiffened Web Drainage Gutter, BL 66 to BL 90 at approximately WL 2 44,000

180 and BS 1083
53-55-01 Pressure Deck – Stiffened Web Gutter Drain Hole at BL 30, BS 1082 2 44,000 44,000
53-55-01 Pressure Deck – Stiffened Web Outboard Pressure Pan framing member 1 33,000
53-55-01 Pressure Deck – Stiffened Web Forward and Outboard Pressure Pan framing members 2 44,000 44,000
53-55-01 Pressure Deck – Stiffened Web Inboard Pressure Pan framing member 2 44,000
53-55-01 Pressure Deck – Stiffened Web Inboard and Aft Pressure Pan framing members 2 44,000 44,000
53-55-01 Pressure Deck – Stiffened Web Gutter Doubler – Fastener Holes at BS 1086 - 2 44,000 44,000
BS 1089, BL 89 - BL 91
53-55-01 Pressure Deck – Stiffened Web Fastener Hole on Splice Fitting (BS 1080) 1 33,000
53-55-01 Pressure Deck – Stiffened Web Stiffener Splice Fittings at BS 1113, BL 11, 19, 25.75, 2 44,000
32.5, 46, 52.75, 59.5, 74, 82
53-55-01 Pressure Deck – Stiffened Web Splice Fittings at BS 1113, BL 39.5 & 66 1 33,000
53-55-01 Pressure Deck – Stiffened Web Closeout Panel – Stub Beam Joint at BS 1113, 1137, 2 44,000 44,000
1161 & 1185
53-55-01B Horizontal Pressure Deck to Wheel Well Longeron Splice BS 1137-1161, BL +/-108.2 1 33,000
Plate #3
53-55-01B Horizontal Pressure Deck to Wheel Well Longeron Splice BS 1137-1161, BL +/-108.2 2 44,000
Fitting #3 (L/N 7 and on)
53-55-02 Bulkhead Frame/Transverse Beam Splice Fitting Upper Chord 2 44,000
D011Z009-03-01
(1)(4)(5)(6)
53-55-02 Bulkhead Frame/Transverse Beam Splice Fitting Web 2 44,000
53-55-02 Transverse Beams – Attachment to Keel Beam at Upper Fittings BS 1113-1185, LBL 9, BL 0, RBL 9 1 33,000
H-Frames
53-55-03A Pressure Deck – Longitudinal Beams and Splice Fittings BL 90 Longitudinal Beam Intercostals at Lower Splice 1 33,000 33,000
Strap, BS 1113, 1137, 1161, & 1185
53-55-03A Pressure Deck – Longitudinal Beams and Splice Fittings BL 90 Longitudinal Beam Intercostals at Web 2 44,000 44,000
Penetration Forward of BS 1137
53-55-03B Pressure Deck – Longitudinal Beams and Splice Fittings Funnel Fitting at BS 1105-1113, BL90 1 33,000 33,000
53-55-03B Pressure Deck – Longitudinal Beams and Splice Fittings Funnel Fitting Lower Chord at BS 1093-1100, BL90 2 44,000
53-55-03B Pressure Deck – Longitudinal Beams and Splice Fittings Funnel Fitting Lower Chord at BS 1100-1110, BL90 1 33,000
53-55-03C Pressure Deck – Longitudinal Beams and Splice Fittings Longitudinal Beam to Seat Track attachment at 2 44,000 44,000
BS 1105 to 1201, BL 39.5 to 66
53-55-04A Pressure Deck – Stub Beam Runouts and Splice Fittings Stub Beam Runout Upper Chord, BL 92 2 44,000 44,000
53-55-04B Pressure Deck – Stub Beam Runouts and Splice Fittings Stub Beam Splice at Pedestal Fitting Chord, BL 96 2 FLS 44,000
53-55-05B Sloping Pressure Deck – BS 1089 Tie Rod Intercostal Upper Flange from BL 39 to BL 66 2 44,000 44,000
53-58-01B Wheel Well Bulkhead – Upper Chord Angle - BS 1209, LBL 92 to RBL 92 2 44,000
53-58-01B Wheel Well Bulkhead – Upper Chord Gusset - BL 19, 39.5 & 66 LH and RH sides 2 44,000
53-58-01C AWWB Stiffener Splice BS 1209, WL 130 to WL 151, LBL 16 to RBL 16 1 33,000
D011Z009-03-01
(1)(4)(5)(6)
53-58-01C AWWB Stiffener Splice BS 1209, WL 116 to WL 158, LBL 16 to RBL 16, 2 44,000
Typical Flange
53-58-01C AWWB BL 0 Vertical Chord – Lower Section, Section A- BS 1209, BL0, WL 106-120 2 44,000
A, Splice Straps
53-58-01C Wheel Well Bulkhead – BL 0 Splice Vertical Chord, Bay 5 at WL 157-164, Bay 10 at WL 2 44,000 44,000
123-130, & Bay 13 at WL less than 109
53-58-01C Wheel Well Bulkhead – BL 0 Splice Vertical Chord Hidden by Horizontal Stiffeners at WL 1 33,000 33,000
123 and WL 157
53-58-01C Aft Wheel Well Bulkhead - BL 0 Intercostals Cap and Web at WL130 and WL164 2 44,000
53-58-01D AWWB BL 0 Vertical Chord – Lower Section, Section B- BS 1209, BL0, WL 106-113 1 33,000
B, Chord Fitting
53-58-01E AWWB BL 0 Vertical Chord – Lower Section, Section C- BS 1209, BL0, WL 98-106 2 44,000
C, Chord Fitting
53-58-02 Pressure Deck Vertical Beam Extension Splice – Extension Beam Web 2 44,000
Extension Location
53-58-02 Pressure Deck Vertical Beam Extension Splice Doubler & Tripler, BS 1205 to BS 1216 1 33,000
WL 179.7 - 188, BL19, 39.5 & 66
53-58-02 Pressure Deck Vertical Beam Extension Extension Beam Upper Chord, BS1185-1209, BL19, 2 44,000
39.5 & 66
53-58-02 Wheel Well Bulkhead – Vertical Beam Intercostal Joints at Vertical Beams at BL 19, 39.5, & 2 44,000 44,000
66, WL 130, 164
53-58-02-4 Pressure Deck Splice Beam Extension Angle BL 19, 39.5 Wheel Well Bulkhead - Vertical Beams Scenario #1 2 44,000
& 66 LH and RH Sides Hole Crack
53-58-02-4 Pressure Deck Splice Beam Extension Angle BL 19, 39.5 Wheel Well Bulkhead - Vertical Beams Scenario #2 2 44,000
& 66 LH and RH Sides Edge Crack
D011Z009-03-01
(1)(4)(5)(6)
53-58-02A Wheel Well Bulkhead – Vertical Beam Vertical Beam Lower Clip – Base Flange Lower Joint at 2 44,000
BL 19.0 Clip
53-58-02B Wheel Well Bulkhead – Vertical Beam Vertical Beam Lower Clip – Base Flange Lower Joint at 2 44,000 44,000 44,000
BL 39.5 Clip
53-58-02C Wheel Well Bulkhead – Vertical Beam Vertical Beam Lower Clip – Base Flange Lower Joint at 2 44,000 44,000 44,000
BL 66.0 Clip
53-58-02C Wheel Well Bulkhead – Vertical Beam Vertical Beam Lower Joint at BL 66.0 Clip, at Flange 2 44,000 44,000
Fastener Hole
53-58-03 Wheel Well Bulkhead Side Fitting BS 1209 Side Fitting Outer Chord Splice Region at WL 1 33,000
238
53-58-03 Wheel Well Bulkhead Side Fitting Side Fitting Inner Chord BS 1209, S-17 splice 2 44,000
53-58-03 Wheel Well Bulkhead Side Fitting Side Fitting Web BS 1209, S-17 splice 2 44,000
53-58-03 Aft Wheel Well Bulkhead Lower Chord and Wheel Well Lower Chord and Side Fitting at splice details (Stringer 1 33,000
53-58-04 Bulkhead Side Fitting 28 and 37)
53-58-03A Wheel Well Bulkhead Side Fitting Outer Chord between WL 223 and the Lower Splice at 1 33,000
WL 150
53-58-03B Wheel Well Bulkhead Side Fitting (L/N 4 - 125) Outer Chord between WL 210 and WL 180 (Stringer 21 2 44,000
to Stringer 24)
53-58-03B Wheel Well Bulkhead Side Fitting (L/N 127 and on) Outer Chord between WL 210 and WL 180 (Stringer 21 2 44,000
to Stringer 24)
53-58-03B Wheel Well Bulkhead Side Fitting Outer Chord, Bifurcation Area – Hoop Loading – 1 33,000
Hidden Fasteners from WL 210 to WL 180 (Stringer 21
to Stringer 24)
D011Z009-03-01
(1)(4)(5)(6)
53-58-03C Wheel Well Bulkhead Side Fitting Outer Chord, Bifurcation Area – Longitudinal Loading – 2 FLS
Fastener Holes between WL 210 to WL 180
53-58-03C Wheel Well Bulkhead Side Fitting Outer Chord, Bifurcation Area – Longitudinal Loading – 1 FLS
Hidden Fasteners between WL 210 to WL 180
(Stringer 21 to Stringer 24)
53-58-03D Wheel Well Bulkhead Side Fitting Pressure Deck Flange, Details Hidden Under Stiffeners 1 33,000
at WL 186, BL 97 and BL 90
53-58-03E Wheel Well Bulkhead Side Fitting BS 1209 Web at Stringer 19 and 20, Lower 2 44,000
Mouse Holes
53-58-03F Wheel Well Bulkhead Side Fitting Fillet radii along Side Fitting Ribs at WLs 158, 165, 2 44,000
171, and 179
53-58-03G Wheel Well Bulkhead Side Fitting Upper Flap Fitting Interface Fastener Hole Bending 1 FLS
53-58-03H Wheel Well Bulkhead Side Fitting Inner Chord above the Pressure Deck at 2 44,000
WL 185 to WL 210
53-58-03K Wheel Well Bulkhead Side Fitting Fail-Safe Strap, Stringer 19 and 20 1 33,000
53-58-03L Wheel Well Bulkhead Side Fitting Fail-Safe Strap between Stringer 21 and Stringer 25 1 33,000
53-58-03M Wheel Well Bulkhead Side Fitting Outer Chord – Hidden by Stringer Splice, BS 1209 1 33,000
53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap – Visible Stringer 19 and 20, BS 1209 2 44,000
53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Outer Chord, between Stringer 1 33,000
18 - 18.5, BS 1209
53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Outer Chord, between Stringer 1 33,000
18.5 - 21, BS 1209
D011Z009-03-01
(1)(4)(5)(6)
53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Stringer Fitting, BS 1209 1 33,000
53-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Edge Crack, BS 1209 2 44,000
53-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Fillet Radius, BS 1209 2 44,000
53-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Stiffener Radius, BS 1209 2 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Outer Chord Between WL 209 and WL 190 2 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Outer Chord Between WL209 and WL190 – Hidden 1 33,000
Details
53-58-03 Wheel Well Bulkhead – Side Fitting Outer Chord – WL 163 to WL 190 2 44,000 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Pressure Deck Flange Attachment 2 44,000 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Mouse Holes at Stringer 19 and 20 2 FLS FLS
53-58-03 Wheel Well Bulkhead – Side Fitting Ribs at Interface with Flap Support Fitting 2 44,000 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Stiffener Fillet Radii at Interface with Flap 2 44,000 44,000
Support Fitting
53-58-03 Wheel Well Bulkhead – Side Fitting Inner Chord between Stringers 18 to 21 2 44,000 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Inner Chord between WL 191 and WL 209 2 44,000 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Lower Stringer 17 Splice, Outer Chord 2 44,000 44,000 44,000
D011Z009-03-01
(1)(4)(5)(6)
53-58-03 Wheel Well Bulkhead – Side Fitting Lower Stringer 17 Splice, Inner Chord 2 44,000 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Lower Stringer 17 Splice, Web 2 44,000 44,000
53-58-03 Wheel Well Bulkhead – Side Fitting Stringer 28 Splice 1 33,000 33,000
53-58-04A Wheel Well Bulkhead – Lower Chord Lower Chord at BL 39.5 Vertical Beam Attachment 1 33,000
53-58-04A Wheel Well Bulkhead – Lower Chord Stringer 28 through 36 1 33,000 33,000
53-58-04A Wheel Well Bulkhead – Lower Chord Stringer 36 through BL 0 1 33,000 33,000
53-58-04B Wheel Well Bulkhead – Lower Chord Lower Chord at BS 1209, LBL 91 to RBL 91 Typical 1 33,000
Lower Chord Section
53-58-04B Wheel Well Bulkhead – Lower Chord Stringer 27.5 and 37.5 Splice, Fastener Locations 1 33,000 33,000
53-58-04C Wheel Well Bulkhead – Lower Chord Lower Chord Splices at Stringer 28 and Stringer 37 2 44,000
53-58-04D Wheel Well Bulkhead – Lower Chord Lower Chord at BL 66.0 Vertical Beam Attachment - 1 33,000
Critical Hidden Detail
53-58-04E Wheel Well Bulkhead – Lower Chord Circumferential Cracking in the Chord Radius 2 44,000
53-58-05 Wheel Well Bulkhead – Flap Support #4 Fitting Upper Support Fitting Outer Clevis Lugs 1 33,000
53-58-05 Wheel Well Bulkhead – Flap Support #4 Fitting Upper Support Fitting Inner & Outer Fitting Clevis Lugs 1 33,000 33,000
53-58-05 Wheel Well Bulkhead – Flap Support #4 Fitting Upper Support Fitting Base Flange Outer Fillets and 2 FLS
Fasteners
D011Z009-03-01
(1)(4)(5)(6)
53-58-05 Wheel Well Bulkhead – Flap Support #4 Fitting Upper Support Fitting Base Flange Outer Fillets and 1 33,000 33,000
Fasteners
53-58-05 Wheel Well Bulkhead – Flap Support #4 Fitting Upper Support Fitting Base Flange Inner Fillets 1 FLS 33,000 33,000
53-58-05 Wheel Well Bulkhead – Flap Support #4 Fitting Lower Support Fitting at Aft Wheel Well Bulkhead BS 2 44,000
1208
53-58-05A Wheel Well Bulkhead – Flap Support #4 Fitting Inner Fitting Clevis Lugs 1 33,000
53-58-05 Wheel Well Bulkhead – Flap Support #4 Fitting Fillet Radius and Fastener Attachments 1 33,000 33,000
53-59-01 Keel Beam Upper BL0 Web Attachment BS 1089-1209 Upper Web Fastener Holes Hidden 1 33,000
Details
53-59-01 Keel Beam BL 0 Web Attachment to Upper Chord Bay 35 BS 1161-1185 2 44,000
53-59-01 Keel Beam – BL 0 Web (L/N 126 - 337) Upr Attachment, Exposed Web at Perimeter Fasteners 2 44,000
Around Panels 50, 51, and 52
53-59-01 Keel Beam – BL 0 Web Upr Attachment, Hidden Fastener Hole Details at Fwd 1 33,000
Edge of Panels 50 and 52
53-59-01 Keel Beam – BL 0 Web (L/N 126 - 337) Fillets and Fastener Holes Around Panels 10 and 53 2 44,000
53-59-01 Keel Beam – BL 0 Web (L/N 126 - 337) Fillets and Fastener Holes Around Panels 12, 54, 58, 2 44,000
59
53-59-01 Keel Beam – BL 0 Web (L/N 338 and on) Fillets and Fastener Holes Around Panels 10, 12, 50, 2 44,000
51, 52, 53, 54, 58 and 59
53-59-01 Keel Beam – BL 0 Web Attachment to Upper Chord and Rear Spar Beam at BS 2 44,000
1089-1161
D011Z009-03-01
(1)(4)(5)(6)
53-59-01 Keel Beam – BL 0 Web (L/N 4 - 6) All Penetrations from BS 1088 to BS 1209, 1 33,000
WL 97 to WL 185
53-59-01 Keel Beam – BL 0 Web (L/N 7 and on) All Penetrations from BS 1088 to BS 1209, 2 44,000
WL 97 to WL 185
53-59-01 Keel Beam BL0 Web Fillets and Fastener Holes Around Panel 1 and 44 2 44,000
through 63
53-59-01A Keel Beam – BL 0 Web Attachment to Upper Chord & Aft Wheel Well Bulkhead 2 44,000
Vertical Chord at BS 1185 - 1209
53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1089, LH and RH, Lower Fastener 1 33,000
Attachments (L/N 4-19) Row
53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1089, LH and RH, Lower Fastener 1 33,000
Attachments (L/N 20 and on) Row
53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1113, 1137, 1161 and 1185, LH and 2 44,000
Attachments (L/N 4-6) RH, Lower Fastener Row
53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1113, 1137, 1161 and 1185, 1 33,000
Attachments (L/N 7 and on) LH and RH, Lower Fastener Row
53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1089 WL 100 through WL 105 2 44,000
Attachments (L/N 4-19)
53-59-02 Keel Beam – A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1089 LH and RH, Upper Fastener 1 33,000
Attachments (L/N 20 and on) Row
53-59-02 Keel Beam – A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1113, 1137, 1161 and 1185, 2 44,000
Attachments (L/N 4-6) LH and RH, Upper Fastener Row
53-59-02 Keel Beam – A/H-Frame Outer Chord to Keel Chord A/H-Frames at BS 1113, 1137, 1161 and 1185, 2 44,000
Attachments (L/N 7-19) WL 100 through WL 105
D011Z009-03-01
(1)(4)(5)(6)
53-59-02 Keel Beam – A/H-Frame (L/N 20 and on) Outer Chord to Keel Chord Attachments at BS 1113, 2 44,000
1137, 1161 and 1185, LH and RH, Upper Fastener
Row
53-59-02 Keel Beam – A/H-Frame Outer Chord to Keel Chord Attachments at BS 1089, 2 44,000 44,000
1113, 1137, 1161 and 1185, LH and RH, Upper
Fastener Row
53-59-02 Keel Beam – A/H-Frame Inner Chord (L/N 4-19) BS 1089, BL0, WL 117 & 124 1 33,000
53-59-02 Keel Beam – A/H-Frame Inner Chord BS 1089, BL0, WL 117 & 124 1 33,000
(L/N 20 and on)
53-59-02 BL0 Web at Keel Beam H-Frame Inner Chord BS 1089 1 33,000
(L/N 4-19)
53-59-02 BL0 Web to Keel Beam A/H Frame Inner Chord BS 1089, WL 137 to WL 160 1 33,000
(L/N 20 and on)
53-59-02 BL0 Web at Keel Beam H-Frame Inner Chord BS 1113, 1137, 1161, and 1185 1 33,000
(L/N 4-19)
53-59-02 Keel Beam H-Frame Inner Chord (L/N 4-19) BS 1089 1 33,000
53-59-02 Keel Beam H-Frame Inner Chord (L/N 4-19) BS 1113, 1137, 1161, and 1185 1 33,000
53-59-02 Keel Beam – H-Frames – Attachment to Transverse Lower Fittings and H-Frame Upper Chords BS 1113- 1 33,000
Beams 1185, LBL 9, BL 0, RBL 9
53-59-03 Keel Beam – Rear Spar Fittings Pressure Deck Splice Ftg at BL 0, BS 1050-1100, WL 1 33,000
181 Base Flange
53-59-03 Keel Beam – Rear Spar Fittings Pressure Deck Splice Ftg at BL 0, BS 1050-1100, WL 1 33,000
181 Vertical Flange
D011Z009-03-01
(1)(4)(5)(6)
53-59-03 Keel Beam – Rear Spar Fittings BL0 Pressure Deck Splice Fitting, BS 1061 to BS 1097, 1 33,000 33,000
WL 181
53-59-03 Keel Beam – Rear Spar Fittings At Rear Spar Web (WL 131 to WL 180) and BL 0 Web 1 33,000 33,000 33,000
(WL 154 to WL 182/WL 183)
53-59-04 Main Landing Gear Torque Box Torque Box Forward and Aft Upper Chord and Side 1 33,000
Web Hand Hole
53-59-04 Main Landing Gear Torque Box Tension Fitting and Hinge Fitting 1 33,000 33,000 33,000
53-59-04 Main Landing Gear Torque Box (L/N 4-19) Lower Tension Fitting 1 33,000
53-59-04 Main Landing Gear Torque Box (L/N 20 and on) Lower Tension Fitting 1 33,000
53-59-04 Keel Beam – MLG Door Hinge Fittings Main Landing Gear Torque Box, Lower Tension Fitting 2 44,000 44,000
and Center Rib
53-59-04a Keel Beam – MLG Door Hinge Fittings Forward, Mid, and Aft Hinges Lower Lug on both sides 1 33,000 33,000 33,000
53-59-04a Keel Beam – MLG Door Hinge Fittings Mid Hinge Fitting, Upper Lugs 1 33,000 33,000
53-59-04b MLG Door Hinges Fittings Fillet Radius Details Mid, Forward and Aft Hinge Fillets @ BS 1145, 2 44,000
BS 1195, and BS 1089
53-59-04 Keel Beam – MLG Door Hinge Fittings Mid Hinge Fitting, Lower Tension Joint – Fillet Details 1 33,000 33,000
53-59-04 Keel Beam – MLG Door Hinge Fittings Mid Hinge Fitting, Lower Clevis Fillets 1 33,000 33,000
53-59-05A Underwing Vertical Webs Detail A Shear Web Boundaries BS 868-1075 Critical Location 2 44,000
Bay 4 Lower
53-59-05B Underwing Vertical Webs – Keel Beam Flange Keel flange under clip in Bay 1 2 44,000
Detail B
D011Z009-03-01
(1)(4)(5)(6)
53-59-05C Underwing Vertical Webs – Stiffeners, Keel Side Critical Location is #18 at BS 879 2 44,000
of Attachment
53-59-07-2 Keel Chord Splice BS 867.7 and 1209, LBL 14 and RBL 14 1 33,000
53-59-07-3 Keel Ladder Vertical Supports Keel to Vertical Support at Front Spar BS 868 & AWW 2 44,000
Bulkhead BS 1209 LH & RH Side
53-59-07-7 Rear Spar Lattice Fitting BS 1073.33 LBL 11.5 to RBL Lattice Fitting Lower Chord common to Vapor Barrier 1 FLS
11.5 Web
53-59-07-7 Rear Spar Lattice Fitting 12 End Pad at Keel Chord Attachment 1 FLS
53-59-07 Keel Beam – Ladder Assembly Keel Shear Tie at Front Spar, BS 867 Fillet Radius 2 44,000 44,000
Transition to Vertical Flange
53-59-07 Keel Beam – Ladder Assembly Keel Shear Tie at Front Spar, BS 867 Fastener Details 2 44,000 44,000
53-59-07 Keel Beam – Ladder Assembly Lugs, Keel Chord Splice at BS 1209, LBL 14 and RBL 1 33,000 33,000
14
53-59-07 Keel Beam – Ladder Assembly Keel Chord Attachments to A/H-Frame Outer Chord at 2 44,000 44,000
BS 1089, 1113, 1137, 1161, and 1185, Lower Fastener
Row
53-61-03-1 Circumferential Skin-Stringer Splice – BS 1209 Doubler Hidden by Longeron 1 33,000
53-61-07-1 Passenger Entry Door 3 – Cutout Surround Structure Edge Frame Web and Inner Chord 2 44,000
53-61-07-2 Passenger Entry Door 3 – Cutout Surround Structure Edge Frame Web at Door Stop Fittings 2 44,000
53-61-07-3 Passenger Entry Door 3 – Cutout Surround Structure Edge Frame Web at Hinge Programming Fitting 1 33,000
D011Z009-03-01
(1)(4)(5)(6)
53-61-07-4 Passenger Entry Door 3 – Cutout Surround Structure Edge Frame Web at Attachment to Lower Main Sill 1 33,000
53-61-07-6 Passenger Entry Door 3 – Cutout Surround Structure Edge Frame Outer Chord at Nutplates 1 33,000
53-61-07-7 Passenger Entry Door 3 – Cutout Surround Structure Edge Frame Outer Chord at Strip Nutplates 2 44,000
53-61-09-1 Aft Large Cargo Door – Cutout Surround Structure Lower Main Sill Inner Chord and Web 2 44,000 44,000 44,000
53-61-09-2 Aft Large Cargo Door – Cutout Surround Structure Edge Frame Inner Chord and Web 2 44,000 44,000 44,000
53-61-09-3 Aft Large Cargo Door – Cutout Surround Structure Edge Frame Outer Chord 2 44,000 44,000 44,000
53-71-07-1 Passenger Entry Door 4 – Cutout Surround Structure Edge Frame Inner Chord and Web 2 44,000
53-71-07-2 Passenger Entry Door 4 – Cutout Surround Structure Edge Frame at Door Stop Fittings 2 44,000
53-71-07-3 Passenger Entry Door 4 – Cutout Surround Structure Edge Frame Web at Attachments to Upper and Lower 1 33,000
Main Sills
53-71-08-1 Bulk Cargo Door – Cutout Surround Structure Lower Sill Inner Chord 2 44,000 44,000 44,000
53-71-08-2 Bulk Cargo Door – Cutout Surround Structure Edge Frame Inner Chord and Web 2 44,000 44,000 44,000
53-71-08-3 Bulk Cargo Door – Cutout Surround Structure Forward Edge Frame Inner Chord and Web Hidden at 1 33,000 33,000 33,000
Latch Fitting
D011Z009-03-01
(1)(4)(5)(6)
53-71-08-4 Bulk Cargo Door – Cutout Surround Structure Aft Edge Frame Web at Door Stop Fittings 1 33,000
53-71-08-5 Bulk Cargo Door – Cutout Surround Structure Edge Frame Outer Chord 2 44,000 44,000 44,000
53-81-04-1 Aft Pressure Bulkhead Assembly Y-Chord at Attachment to Aft Pressure Bulkhead 2 44,000
53-81-04-2 Aft Pressure Bulkhead Assembly Y-Chord at Attachment to Fuselage Skin and Splice 2 44,000
Strap
53-81-04-3 Aft Pressure Bulkhead Assembly T-Chord Radius Detail 2 44,000 44,000 44,000
53-81-06-1 Circumferential Splice at Pivot Bulkhead Side Chord at Attachment to Pivot Backup Fittings 2 44,000 44,000 44,000
53-81-06-2 Circumferential Splice at Pivot Bulkhead Side Chord at Attachment to Longeron Fittings 1 33,000 33,000 33,000
53-81-08-1 Pivot Fitting Assembly, Side Load Fittings, and Pivot Pivot Fitting Fastener Locations 2 44,000 44,000 44,000
Fitting Assembly Gussets
53-81-08-2 Pivot Fitting Assembly, Side Load Fittings, and Pivot Pivot Fitting Lug 1 33,000 33,000 33,000
Fitting Assembly Gussets
53-81-10-1 Horizontal Stabilizer Trim Actuator Fitting Assembly Pins 1 33,000 33,000 33,000
53-81-10-2 Horizontal Stabilizer Trim Actuator Fitting Assembly Fitting Lugs 1 33,000 33,000 33,000
53-81-11-1 Horizontal Stabilizer Cutout – Upper and Longeron Tension Bolts 1 33,000 33,000 33,000
Lower Longeron
54-51-01 Pylon To Wing Fittings – Rolls Royce Engine Pylon 2 FLS FLS
54-51-01 Pylon To Wing Fittings – Rolls Royce Engine Pylon 2 FLS

(L/N 1 - 478)
D011Z009-03-01
(1)(4)(5)(6)
54-51-01 Pylon To Wing Fittings – Rolls Royce Engine Pylon 2 FLS

(L/N 479 and on)
54-51-02-A Upper Spar Assembly - Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bay 0 2 44,000
54-51-02-C Upper Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 0 - 3, Inboard Side 2 FLS FLS
Only
54-51-02-C Upper Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 1-3 1 FLS
54-51-02-D Upper Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface at Frames 1 & 2 1 FLS FLS FLS
54-51-02-F Upper Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 4 & 5, Inboard Side 2 FLS FLS
Only
54-51-02-F Upper Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 4 & 5 1 FLS
54-51-02-G Upper Spar Assembly – Rolls Royce Engine Pylon R1 Upper Spar Fitting 1 33,000 FLS
54-51-02-G Upper Spar Assembly – Rolls Royce Engine Pylon R1 Upper Spar Fitting 2 44,000
54-51-03-B Side Skins – Rolls Royce Engine Pylon Side Skin Cutouts 2 FLS FLS FLS
54-51-04-A1 Lower Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 1 - 3 2 FLS
54-51-04-A1 Lower Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 1 - 5 2 FLS
54-51-04-A1 Lower Spar Assembly - Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 1-5 1 FLS
54-51-04-A2 Lower Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 1 - 3 at Brackets 1 FLS
D011Z009-03-01
(1)(4)(5)(6)
54-51-04-A2 Lower Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 1 - 5 at Brackets 1 FLS FLS
54-51-04-B1 Lower Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 4 and 5 2 FLS
54-51-04-B2 Lower Spar Assembly – Rolls Royce Engine Pylon Chord/Skin/Web Interface – Bays 4 and 5 at Brackets 1 FLS
54-51-04-C1 Lower Spar Assembly - Rolls Royce Engine Pylon R2 Fitting – Fastener Row 5 1 FLS
54-51-04-C2 Lower Spar Assembly - Rolls Royce Engine Pylon R2 Fitting – Fastener Rows 3, 4 and 6 2 FLS
54-51-05-A Forward Engine Mount Bulkhead – Rolls Royce Tension Bolt Attachments 2 FLS FLS 44,000
Engine Pylon
54-51-07-A Aft Engine Mount Bulkhead - Rolls Royce Engine Pylon Aft Upper Center Rib 2 44,000
54-51-08-B Aft Engine Mount Shear Fittings – Rolls Royce Engine 2 44,000 44,000
Pylon
54-51-09-A Aft Engine Mount Tension Fittings – Rolls Royce Engine 2 FLS FLS FLS
Pylon
54-51-10-A Aft Strut Bulkhead – Rolls Royce Engine Pylon Upper Mid Stiffener 2 44,000 44,000 44,000
54-51-11 Rolls Royce Forward Engine Mount Installation Mount Fitting, Mount Links, Engine Lugs, Attach Bolts 2 FLS FLS FLS
54-51-13 Rolls Royce Aft Engine Mount Installation Engine Serial Thrust Links, Fitting, Mount Links, Evener Bar, Engine 2 FLS
Numbers: 10025 -10047 Lugs, Attach Bolts
54-51-13 Rolls Royce Aft Engine Mount Installation Thrust Links, Fitting, Mount Links, Evener Bar, Engine 2 FLS FLS FLS
Lugs, Attach Bolts
54-51-01-B Pylon To Wing Attachments – General Electric Engine Fittings, Links, Brace & Pins 2 FLS FLS FLS
Pylon
D011Z009-03-01
(1)(4)(5)(6)
54-51-02-A Upper Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface - Bays 1 - 3 2 FLS FLS
54-51-02-A Upper Spar Assembly - General Electric Engine Pylon Chord/Skin/Web Interface - Bays 1 - 3 1 FLS
54-51-02-D Upper Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface at Frames 1 & 2 1 FLS FLS FLS
54-51-02-F Upper Spar Assembly – General Electric Engine Pylon R3/R4 Upper Spar Chord 1 FLS FLS FLS
54-51-02-G Upper Spar Assembly – General Electric Engine Pylon R1 Upper Spar 1 FLS 33,000
54-51-02-G Upper Spar Assembly – General Electric Engine Pylon R1 Upper Spar 2 44,000
54-51-03 Side Skins – General Electric Engine Pylon Side Skin Cutouts 2 FLS FLS FLS
54-51-04-A1 Lower Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface – Bays 1 - 3 2 FLS FLS FLS
54-51-04-A2 Lower Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface – Bays 1 - 3 at Brackets 1 FLS FLS FLS
54-51-04-A3 Lower Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface – Bays 1 - 3 at Partial 1 FLS
Bracket Locations
54-51-04-B1 Lower Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface – Bays 4 and 5 2 FLS
54-51-04-B2 Lower Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface – at Shear Fittings 1 FLS
54-51-04-B3 Lower Spar Assembly – General Electric Engine Pylon Chord/Skin/Web Interface – at Heat Shield 1 FLS
54-51-04-C1 Lower Spar Assembly - General Electric Engine Pylon R2 Fitting – Fastener Row 4 1 FLS
54-51-04-C2 Lower Spar Assembly - General Electric Engine Pylon R2 Fitting – Fastener Rows 3, 5, 6, 7 and 8 2 FLS
D011Z009-03-01
(1)(4)(5)(6)
54-51-05-A Forward Engine Mount Bulkhead – General Electric Tension Bolt Attachments 2 FLS FLS
Engine Pylon
54-51-06-B Frame 3 – General Electric Engine Pylon Tension Bolt Attachments 2 44,000 44,000
54-51-08-A Aft Mount Bulkhead Shear Fittings – General Electric 2 44,000 44,000
Engine Pylon
54-51-09-A Aft Engine Mount Bulkhead Side Fittings – General 2 FLS FLS FLS
Electric Engine Pylon
54-51-10-A Aft Bulkhead Assembly – General Electric Engine Pylon Upper Mid Stiffener 2 44,000 44,000 44,000
54-51-12 Forward Engine Mount Assembly – General Electric Mount Fitting, Mount Links, Engine Lugs, Attach Bolts 2 FLS FLS FLS
54-51-14 Aft Engine Mount Assembly – General Electric Thrust Links, Fitting, Mount Links, Evener Bar, Engine 2 FLS FLS FLS
Lugs, Attach Bolts
55-10-01 T-Chord Upper Center Box Side (787-8 L/N 1 - 820) Rear Spar - Pivot Strap 1 33,000
55-10-01 Upper T-Chord, Multispar Box Side (787-8 L/N 4 - 6) Front Spar 1 33,000
55-10-01 T-Chord Upper Multispar Box Side (787-8 L/N 4 - 6) Rear Spar – Pivot Strap 1 33,000
55-10-01 T-Chord Upper Center Box (787-8 L/N 4 - 6) Front Spar – Jackscrew Plate 1 33,000
55-10-01 T-Chord Upper Front Spar Zone Multispar Box Side Front Spar 2 44,000
(787-8 L/N 7 - 820)
55-10-01 T-Chord Upper Front Spar Center Box Side Jackscrew Front Spar 2 FLS
Plate (787-8 L/N 7 - 820)
D011Z009-03-01
(1)(4)(5)(6)
55-10-01 T-Chord Upper Front Spar Center Box Side Front Spar 2 44,000
(787-8 L/N 7 - 820)
55-10-02 T-Chord Lower Center Box Side (787-8 L/N 1 - 820) Rear Spar – Pivot Strap 1 33,000
55-10-02 Lower T-Chord, Multispar Box side (787-8 L/N 4 - 6) Front Spar 1 33,000
55-10-02 T-Chord Lower Multispar Box Side (787-8 L/N 4 - 6) Rear Spar 1 33,000
55-10-02 T-Chord Lower Center Box (787-8 L/N 4 - 6) Front Spar – Jackscrew Plate 1 33,000
55-10-02 T-Chord Lower Front Spar Zone Multispar Box Side Front Spar 2 44,000
(787-8 L/N 7 - 820)
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 4 - 6) Upper Flange 1 33,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 7 - 820) Upper Flange 2 44,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 4 - 6) Lower Flange 1 33,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 7 - 820) Pivot Fitting Lower Flange 2 44,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 821 and on) Upper and Lower Flanges of I/B & O/B Pivot Fittings 1 33,000 33,000 33,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 4 - 6) Web 1 33,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 7 - 820) Pivot Fitting Angle Web bolt 2 44,000
55-10-10 Pivot Fitting, I/B & O/B Web fastener holes common to I/B & O/B Pivot Fittings 1 33,000 33,000 33,000
55-10-13 Pivot Fitting, O/B Angle and O/B Pivot Fitting Angle
(787-8 L/N 821 and on)
D011Z009-03-01
(1)(4)(5)(6)
55-10-10 Pivot Fitting I/B & O/B (787-8 L/N 4 - 6) Lug 1 33,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 7 - 820) Pivot Fitting Lug 1 33,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 821 and on) Lugs 1 33,000 33,000 33,000
55-10-10 Pivot Fitting, I/B & O/B (787-8 L/N 821 and on) I/B Pivot Fitting Vertical Flange, adjacent to fasteners 1 33,000 33,000 33,000
common to Rear Spar
55-10-12 Upper Strap Pivot Side (787-8 L/N 4 - 6) Pivot Side 2 44,000
55-10-12 Upper Strap Pivot side – Transversal Stress Upper Strap – Pivot Side – Horizontal Stabilizer Center 2 44,000
(787-8 L/N 7 - 820) Box
55-10-12 Upper Strap Pivot Side Long Stress (787-8 L/N 7 - 820) Pivot Side 2 44,000
55-10-12 Upper Strap (787-8 L/N 7 - 820) T-Chord 2 44,000
55-10-12 Pivot Fitting Upper & Lower Straps Upper Strap, adjacent to fasteners common to upper 2 44,000 44,000 44,000
(787-8 L/N 821 and on) Skin Panel
55-10-12 Pivot Fitting Upper & Lower Straps (787-8 L/N 4 - 6) Lower Strap, Pivot Side 2 FLS
55-10-12 Pivot Lower Strap Crack Growth-FX (787-8 L/N 7 - 820) Pivot Strap Lower LHS – Horizontal Stabilizer Center 2 44,000
Box
55-10-12 Lower Strap Pivot Side Longitudinal Stress Pivot Side 2 44,000
(787-8 L/N 7 - 820)
55-10-12 Lower Strap T-Chord Side (787-8 L/N 7 - 820) T-Chord Zone 2 44,000
55-10-12 Pivot Fitting Upper & Lower Straps Lower Strap, adjacent to fasteners common to lower 2 44,000 44,000 44,000
D011Z009-03-01
(1)(4)(5)(6)
55-10-13 Pivot Fitting Outboard Angle (787-8 L/N 4 - 6) Pivot Side 2 44,000
55-10-13 Rear Spar Splice Pivot Side Vertical Stress Pivot Web Side 2 44,000
(787-8 L/N 7 - 820)
55-10-13 Rear Spar Splice Pivot Side Horizontal Stress Pivot Web Side 2 44,000
(787-8 L/N 7 - 820)
55-10-13 Rear Spar Splice Multispar Box Side Vertical Stress Multispar Box Side 2 44,000
(787-8 L/N 7 - 820)
55-10-13 Rear Spar Splice Multispar Box Side Horizontal Stress Multispar Box Side 2 44,000
(787-8 L/N 7 - 820)
55-10-13 Pivot Fitting Outboard Angle Vertical Flange, adjacent to fasteners common to Rear 1 33,000 33,000 33,000
(787-8 L/N 821 and on) Spar Web
55-10-14 Pivot Fitting, Outer Pin Inner & Outer Pins 1 33,000 33,000 33,000
55-10-15 Pivot Fitting, Inner Pin
55-10-17 Pivot Fitting, Forward & Aft Rib Posts Forward Rib Post Flange common to 2 44,000
(787-9 L/N 126 - 478) Mid-Spar 3 Web
55-10-17 Pivot Fitting, Forward & Aft Rib Posts Forward Rib Post Flange common to Riblet 4 Web and 2 44,000
(787-9 L/N 126 - 478) Riblet 4 Upper & Lower Angles
55-10-17 Pivot Fitting, Forward & Aft Rib Posts Aft Rib Post Flange common to Riblet 4 Web and 1 33,000 33,000 33,000
(787-8 L/N 821 and on) Riblet 4 Upper & Lower Angles
55-10-17 Pivot Fitting, Forward & Aft Rib Posts Aft Rib Post Flange common to Rear Spar Web 1 33,000 33,000 33,000
(787-8 L/N 821 and on)
55-12-01 BL0 Center Splice, Upper Splice Straps 1, 2, 3 Splice Strap 2, aft end of Splice Strap adjacent to each 1 33,000 33,000 33,000
(787-8 L/N 821 and on) O/B row of fasteners
55-12-01 BL0 Center Splice, Upper Splice Straps 1, 2, 3 Splice Strap 3, aft end of Splice Strap 1 33,000 33,000 33,000
(787-8 L/N 821 and on)
D011Z009-03-01
(1)(4)(5)(6)
55-12-02 BL0 Center Splice, Lower Splice Straps 1, 2, 3 Splice Strap 1, adjacent to fasteners common to Jack 2 44,000 44,000
Screw Fitting
55-12-03 BL0 Center Splice, Upper T-Chord Bay 4 Outboard fastener row 1 33,000 33,000 33,000
(787-8 L/N 821 and on)
55-12-03 BL0 Center Splice, Upper T-Chord T-Chord Vertical Flange, common to 1 33,000 33,000 33,000
55-12-04 BL0 Center Splice, Lower T-Chord Mid-Spar Cleats
(787-8 L/N 821 and on)
55-12-03 BL0 Center Splice, Upper T-Chord T-Chord Vertical Flange, common to BL0 Web in Bays 2 44,000 44,000 44,000
55-12-04 BL0 Center Splice, Lower T-Chord 3 and 4
(787-8 L/N 821 and on)
55-12-03 BL0 Center Splice, Upper T-Chord T-Chord Vertical Flange, common to BL0 Web, Rear 1 33,000 33,000 33,000
55-12-04 BL0 Center Splice, Lower T-Chord Spar Terminal Fitting, and Clip
(787-8 L/N 821 and on)
55-12-05 BL0 Center Splice, Internal Splice Fitting Vertical Flange common to BL0 Web 1 33,000 33,000 33,000
(787-8 L/N 821 and on)
55-12-05 BL0 Center Splice, Internal Splice Fitting Vertical Flange common to Rear Spar Web 1 33,000 33,000 33,000
(787-8 L/N 821 and on)
55-12-05 BL0 Center Splice, Internal Splice Fitting Upper Horizontal Flange adjacent to I/B chordwise 1 33,000 33,000 33,000
(787-8 L/N 821 and on) fastener row
55-12-06 BL0 Center Splice, Upper External Splice Fitting Horizontal Flange, common to Rear Spar Chord and 1 FLS 33,000 33,000
(787-8 L/N 821 and on) Upper Skin Panel
55-12-06 BL0 Center Splice, Upper External Splice Fitting Vertical Flange common to Rear Spar Web 1 33,000 33,000 33,000
(787-8 L/N 821 and on)
55-15-01 Jackscrew Fitting Upper Plate Front Side Front Side 2 FLS
(787-8 L/N 1 - 820)
D011Z009-03-01
(1)(4)(5)(6)
55-15-01 Jackscrew Fitting Upper Plate Multispar Box Side Jackscrew Fitting Upper Plate Multispar Box Side 2 44,000
(787-8 L/N 4 - 6)
55-15-01 Jackscrew Upper Plate (787-8 L/N 7 - 820) Jackscrew Upper Plate Middle Side 2 44,000
55-15-01 Jackscrew Upper Plate (787-8 L/N 7 - 820) Jackscrew Upper Plate Multispar Box Side 2 44,000
55-15-02 Jackscrew Fitting Lower Plate Front Spar Side Jackscrew Fitting Lower Plate Front Spar Side 2 44,000
(787-8 L/N 4 - 6)
55-15-03A Jackscrew Front Spar Web Splice (787-8 L/N 4 - 6) Center Box Side Flange 2 44,000
55-15-03A Jackscrew Web Splice (787-8 L/N 7 - 820) Center Box Side (y direction) 2 44,000
55-15-03A Jackscrew Web Splice (787-8 L/N 7 - 820) Web Splice Multispar Box Side (y direction) 2 44,000
55-15-03A Jackscrew – Front Spar Splice, Web Splice Front Spar Splice Fitting Vertical Leg, common to Front 1 FLS FLS FLS
(787-8 821 and on) Spar Web & Jackscrew Ftg
55-15-03A Jackscrew – Front Spar Splice, Web Splice Front Spar Splice Fitting Vertical Leg, common to 1 FLS FLS FLS
(787-8 821 and on) Upper & Lower Front Spar Splice Angles at locations
not hidden under the BL0 Rib Post or the Front Spar
Corner Fittings
55-15-03A Jackscrew – Front Spar Splice, Web Splice Front Spar Splice Fitting Vertical Leg, common to 1 FLS FLS FLS
(787-8 821 and on) Upper & Lower Front Spar Splice Angles at locations
hidden under the BL0 Rib Post and the Front Spar
Corner Fittings
55-15-03B Jackscrew Front Spar Upr/Lwr Splice Angle 1 33,000

(787 L/N 4 - 6)
55-15-03B Jackscrew Upper Splice Angle (787-8 L/N 7 - 820) Upper Angle (Bolt UH1) Center Box Horizontal 2 44,000
Stabilizer
D011Z009-03-01
(1)(4)(5)(6)
55-15-03B Jackscrew – Front Spar Splice, Upper Splice Angle Adjacent to fasteners common to Upper Splice Angle 1 FLS FLS FLS
(787-8 L/N 821 and on) horizontal flange, Front Spar Chord, and Upper Skin
55-15-03B Jackscrew – Front Spar Splice, Upper Splice Angle Central and Lateral Flanges common to Front Spar 1 FLS FLS FLS
(787-8 L/N 821 and on) Splice
55-15-03B Jackscrew – Front Spar Splice, Upper Splice Angle Common to Jackscrew Fitting I/B and O/B 1 FLS FLS FLS
(787-8 L/N 821 and on) Vertical Flange
55-15-03B Jackscrew – Front Spar Splice, Upper Splice Angle Horizontal Flange at BL0, common to Upper Skin 1 FLS FLS FLS
(787-8 L/N 821 and on) Panel and Upr Splice Strap 1
55-15-03C Jackscrew Lower Angle (787-8 L/N 7 - 820) Upper Angle (Bolt LH1) Center Box 2 44,000
Horizontal Stabilizer
55-15-03C Jackscrew – Front Spar Splice, Lower Splice Angle Horizontal Flange, common to Lwr Spar Chord and Lwr 1 33,000 33,000 33,000
55-15-03C Jackscrew – Front Spar Splice, Lower Splice Angle Lower Splice Angle, adjacent to fasteners common to 2 44,000 44,000 44,000
(787-8 L/N 821 and on) Jack Screw Fitting
55-15-04 Jackscrew Terminal Fitting (787-8 L/N 7 - 820) Web Splice Side y-direction Center Box Horizontal 2 44,000
Stabilizer
55-15-04 Jackscrew Terminal Fitting (787-8 L/N 7 - 820) Web Splice Side x-direction Center Box Horizontal 2 44,000
Stabilizer
55-15-04 Horizontal Stabilizer Center Box (787-8 L/N 7 - 820) Jackscrew Terminal Fitting Rib Side (fy) 2 44,000
55-15-05 Jackscrew – Front Spar Rib Post (787-8 L/N 821 and on) Flange common to BL0 Web, adjacent to fasteners 1 33,000 33,000 33,000
55-15-05 Jackscrew – Front Spar Rib Post (787-8 L/N 821 and on) Flange common to BL0 Web, fastener holes common 1 33,000 33,000 33,000
to Lower T-Chord
55-15-05 Jackscrew – Front Spar Rib Post (787-8 L/N 821 and on) Flange common to BL0 Web, fastener holes common 1 33,000 33,000 33,000
to Upper T-Chord
D011Z009-03-01
(1)(4)(5)(6)
55-18-01 Jackscrew Inboard/Outboard Fittings (787-8 L/N 4 - 6) Upper Horizontal Flange 2 44,000
55-18-01 Jackscrew Inboard/Outboard Fittings (787-8 L/N 7 - 820) Upper Horizontal Flange 2 44,000
55-18-01 Jackscrew Inboard/Outboard Fittings BL0 Ctr Splice, Upper Horizontal Flange, fastener holes common to 1 FLS FLS FLS
55-12-01 Upper Splice Straps 1, 2, 3 Jackscrew Upper Angle Jackscrew Ftg, Upr Splice Angle, and BL0 Upr Splice
55-15-03b (787-8 L/N 821 and on) Strap 1
55-18-01 Jackscrew Inboard/Outboard Fittings (787-8 L/N 4 - 6) Lower Horizontal Flange 2 44,000
55-18-01 Jackscrew Inboard/Outboard Fittings (787-8 L/N 7 - 820) Lower Horizontal Flange 2 44,000
55-18-01 Jackscrew Inboard/Outboard Fittings BL0 Ctr Splice, Lower Horizontal Flange, fastener holes common to 1 33,000 33,000 33,000
55-12-02 Lower Splice Straps 1, 2, 3 Jackscrew Lower Angle Jackscrew Ftg, Lwr Splice Angle, and BL0 Lwr Splice
55-15-03C (787-8 L/N 821 and on) Strap 1
55-18-01 Jackscrew Inboard/Outboard Fittings (787-8 L/N 4 - 6) Lug 2 44,000
55-18-01 Jackscrew Inboard/Outboard Fittings (787-8 L/N 7 - 820) Lug 1 33,000
55-18-01 Jackscrew Inboard/Outboard Fittings Lug 1 FLS FLS FLS

(787-8 L/N 821 and on)
55-18-01 Jackscrew Inboard/Outboard Fittings Vertical Flange 1 33,000 33,000 33,000

(787-8 L/N 821 and on)
55-18-02 Jackscrew Inner Gimbal Nut Inner & Outer Pin 1 FLS FLS FLS
55-18-03 Jackscrew Outer Gimbal Nut
55-33-06 Main Torque Box – Spanwise Splice at Front Spar Fitting, Front Spar Splice Strap, adjacent to fasteners 2 44,000 44,000
Left & Right
D011Z009-03-01
(1)(4)(5)(6)
55-33-07 Main Torque Box – Inspar Rib 1 Shear Tie common to Front Spar attach fastener 2 44,000 44,000
55-33-10 Main Torque Box – Closure Rib 15 1st Forward 0.25" dia. fastener common to the Main 2 FLS
Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 (L/N 4 - 6) Forward 0.25" Dia Chord Fasteners common to the 2 FLS
Main Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 (L/N 7 and on) Forward 0.25" Dia Chord Fasteners common to the 2 FLS
Main Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 Aft 0.25" Dia. Chord Fastener common to the Main Box 2 FLS
Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 Aft 0.3125" dia. chord fastener common to the Main 2 FLS
Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 (L/N 4 - 6) Forward 0.19" Dia Chord Field Fastener common to 2 FLS
Main Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 (L/N 7 and on) Forward 0.19" Dia Chord Field Fastener common to 2 FLS
Main Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 (L/N 4 - 6) Aft 0.19" Dia Chord Field Fastener Common to the 2 FLS
Main Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 (L/N 7 and on) Aft 0.19" Dia Chord Field Fastener Common to Main 2 FLS
Box Skin Panel
55-33-10 Main Torque Box – Closure Rib 15 Lower Flange of Rib Chord common to Main Box Skin 2 44,000 44,000
Panel
55-37-01 Root Attach Fittings, Rear Spar, Left & Right Forward & Aft Tension Bolt Lugs 2 FLS FLS FLS
55-37-01 Root Attach Fittings, Rear Spar, Left & Right Fitting web and stiffeners below Rib 1 WL 325 to WL 2 FLS
327
D011Z009-03-01
(1)(4)(5)(6)
55-37-01 Root Attach Fittings, Rear Spar, Left & Right Fitting web and stiffeners below Rib 1 WL 317 to WL 2 FLS
325
55-37-01 Root Attach Fittings, Rear Spar, Left & Right Flange common to Fin Deck Attachment 2 FLS 44,000 44,000
Shear Fasteners
55-37-02 Root Attach Fittings, Stringer 3 Left & Right Forward & Aft Tension Bolt Lug 2 FLS
55-37-02 Root Attach Fittings, Stringer 3 Left & Right Stringer 3 Root Splice between WL 325 and WL 331 2 FLS
55-37-02 Root Attach Fittings, Stringer 3, Left & Right 10.41 inches below Rib 1 centerline along center 2 FLS
stiffener centerline (cut 3)
55-37-02 Root Attach Fittings, Stringer 3, Left & Right Flange common to Fin Deck Fasteners 2 FLS
55-37-02 Root Attach Fittings, Stringer 3, Left & Right At Splice attachment to Stringer 3 2 FLS
55-37-03 Root Attach Fittings, Stringer 6, L/R Rib #1 centerline along center stiffener centerline 2 FLS
(cut 5)
55-37-03 Root Attach Fittings, Stringer 6, Left & Right Forward & Aft Tension Bolt Lug 2 FLS
55-37-03 Root Attach Fittings, Stringer 6, Left & Right Stringer 6 Root Splice Between WL 328 and WL 333 2 FLS
55-37-03 Root Attach Fittings, Stringer 6, Left & Right 8.27" below Rib #1 centerline along center stiffener 2 FLS
centerline (cut 3)
55-37-03 Root Attach Fittings, Stringer 6, Left & Right Flange Common to Fin Deck Fasteners 2 FLS
55-37-04 Root Attach Fittings, Front Spar, Left & Right Forward & Aft Tension Bolt Lug 2 FLS
55-37-04 Root Attach Fittings, Front Spar, Left & Right Fitting 1 Web and Flange adjacent to the Front Spar 2 FLS
Root Strap, WL 329 to WL 333
D011Z009-03-01
(1)(4)(5)(6)
55-37-04 Root Attach Fittings, Front Spar, Left & Right Flange common to Fin Deck Fasteners 2 FLS
55-37-04 Root Attach Fittings, Front Spar, Left & Right Fitting 1 Web and Stiffener below Forward Torque Box 2 FLS
(L/N 4 - 6) Rib 1 attachment (cut 3)
55-37-04 Root Attach Fittings, Front Spar, Left & Right Fitting 1 Web and Spar Flange Aft of the Front Spar 2 FLS
(L/N 4 - 6) (cut 1)
55-37-04 Root Attach Fittings, Front Spar, Left & Right Fitting 1 Web and Spar Flange Aft of the Front Spar, 2 FLS
(L/N 7 and on) WL 321 to WL 333
55-37-04 Root Attach Fittings, Front Spar, Left & Right Fitting 1 Web and Stiffener below Forward Torque Box 2 FLS
(L/N 7 and on) Rib 1 attachment (Cut 3) WL 323 to WL 325
55-37-04 Root Attach Fittings, Front Spar, Left & Right Fitting 1 Web and Spar Flange Aft of the Front Spar, 2 FLS
(L/N 7 and on) WL 317 to WL 321
55-37-04 Root Attach Fittings, Front Spar, Left & Right Fitting 1 Web & Stiffener below Forward Torque Box 2 FLS
(L/N 7 and on) Rib 1 Forward of the Front Spar, WL 320 to WL 323
55-37-05 Root Attach Tension Bolts Frame 4 - Fwd Tension Bolt - V-Fin 2 FLS 44,000
(787-8 LN 1 - 732 & 787-9 LN 126 and on)
55-37-05 Root Attach Tension Bolt Frame 4 – Fwd Tension Bolt – V-Fin 1 FLS FLS
(787-8 LN 733 and on & 787-10)
57-10-01A Side of Body Splice – Upper Surface Critical Surface Upper Splice Plate – BS 1026.5 - 1076.5 Rear Spar to 2 FLS
Inspection Areas Stringer 4
57-10-01A Side of Body Splice – Upper Surface Upper Splice Plate – BS 873 - 1076.5 1 33,000 33,000
57-10-01B Side of Body Splice – Upper Surface General Surface Upper Splice Plate – BS 873.0 - 1026.5 Front Spar to 2 44,000
Inspection Areas Stringer 5
57-10-01C Side of Body Splice – Upper Surface Upper Splice Plate – BS 873.0 - 1076.5 Areas Hidden 1 FLS 33,000 33,000
by Pi Fittings – Section 11
D011Z009-03-01
(1)(4)(5)(6)
57-10-01D Side of Body Splice – Upper Surface Tee Chord and Upper Splice Plate – BS 873.0 - 1076.5 areas hidden 1 FLS
57-10-01E Splice Plate by Flex Tee at Pi Fittings
57-10-01D Side of Body Splice – Upper Surface Tee Chord and Upper Splice Plate – BS 873.0 - 1076.5 areas hidden 1 FLS 33,000 33,000
57-10-01E Splice Plate by Flex Tee
57-10-01F Side of Body Splice – Upper Surface T-Chord Flange Radius 1 33,000 33,000
57-10-01G Side of Body Splice – Upper Surface Stringer Splice Fittings at all Section 11 Stringers and 2 44,000 44,000
Section 12 S-7 through S-18
57-10-02 Side of Body Splice – Lower Surface Jack Pad Fitting bolt holes 2 44,000
57-10-02 Side of Body Splice – Lower Surface Side of Body Rib Lower Chord visible fasteners at Web 1 33,000
attachment
57-10-02 Side of Body Splice – Lower Surface Outboard Wing, Lower Chord and Splice Plate from 1 33,000
LHS (L/N 4-21), RHS (L/N 4-20) Front Spar to Rear Spar
57-10-02 Side of Body Splice – Lower Surface Outboard Wing, Lower Chord and Splice Plate from 1 33,000
LHS (L/N 22 and on), RHS (L/N 21 and on) Front Spar to Rear Spar
57-10-02 Side of Body Splice – Lower Surface Lower Chord and Splice Plate, Front Spar to Rear Spar 1 33,000 FLS
57-10-02 Side of Body Splice – Lower Surface Lower Chord and Splice Plate, Section 11, at Spanwise 1 FLS FLS
Beam Fittings
57-10-02 Side of Body Splice – Lower Surface Lower Chord and Splice Plate, Section 11, at S-1 1 33,000 33,000
57-10-02 Side of Body Splice – Lower Surface Jack Pad Fitting at Front Spar Terminal Ftg, Splice 1 33,000 33,000
Plate at Rear Spar Terminal Ftg
57-10-02 Side of Body Splice – Lower Surface Lower Chord – Attachment to Rib Web, Front Spar to 2 44,000 44,000
Rear Spar
D011Z009-03-01
(1)(4)(5)(6)
57-10-02 Side of Body Splice – Lower Surface Sections 11 & 12 - Enhanced Radius Filler Ftgs at 2 44,000 FLS
Upper and Lower Flange Fillets
57-10-02 Side of Body Splice – Lower Surface Section 12 - Enhanced Radius Filler Fitting at 1 33,000 33,000
Upper Tab Flange Attachments at S-3, S-4, S-5
57-10-02 Side of Body Splice – Lower Surface Section 11 S-1 Fitting 2 44,000 44,000
57-10-03-1 Side of Body Splice – Front Spar Terminal Fitting, Lower Cap Horizontal Flange 1 FLS
57-10-03-2 Side of Body Splice – Front Spar Terminal Fitting Vertical Flanges 1 33,000
57-10-03-5 Side of Body Splice – Front Spar Terminal Fitting, Upper Cap Flange Common to Side of 1 33,000
Body Rib
57-10-03-9 Side of Body Splice – Front Spar Terminal Fitting, Upper Cap Flange Common to Front 1 33,000
Spar Web
57-10-03 Side of Body Splice – Front Spar Front Spar Terminal Fitting, BS 873 1 FLS FLS
57-10-04 Side of Body Splice – Rear Spar Rear Spar Terminal Fitting at attachment Side of Body 1 FLS
Rib Web – Hidden Areas
57-10-04 Side of Body Splice – Rear Spar Rear Spar Terminal Fitting at attachment Side of Body 1 33,000
Rib Web – Non-Hidden Areas
57-10-04 Side of Body Splice – Rear Spar Rear Spar Terminal Fitting lower horizontal & vertical 1 FLS
flanges
57-10-04 Side of Body Splice – Rear Spar Lower Splice Plate holes common to rear spar lower 2 44,000
chord
57-10-04 Side of Body Splice – Rear Spar Rear Spar Terminal Fitting 1 FLS FLS
D011Z009-03-01
(1)(4)(5)(6)
57-10-05 Side of Body Rib Side of Body Rib Web at Front & Rear Spar Terminal 1 FLS
Ftg & Upper and Lower Chords
57-10-05 Side of Body Rib Web penetration holes with satellite holes 2 44,000
57-10-05 Side of Body Rib Web penetration holes without satellite holes 2 44,000
57-10-05 Side of Body Rib Web penetrations 2 44,000 44,000
57-10-05 Side of Body Rib (L/N 4-6) Web to Access Door Detail (LHS/RHS) 1 33,000
57-10-05 Side of Body Rib (L/N 7 and on) Web to Access Door Detail (LHS/RHS) 2 44,000
57-10-05 Side of Body Rib (L/N 4-6) Vertical stiffeners No.1-12 to web joints 2 44,000
(LHS/RHS)
57-10-05 Side of Body Rib (L/N 34 and on) Web at Base of Integral Horizontal Stiffeners – Group 1 2 44,000
57-10-05 Side of Body Rib Vertical Stiffener No. 1 Attachment 1 33,000 33,000
57-10-05 Side of Body Rib Web to Front Spar Terminal Fitting Joint 1 33,000
57-10-05 Side of Body Rib Web to Rear Spar Terminal Fitting Joint 1 33,000
57-10-06A Overwing Flex-Tee Flex-Tee Fastener Holes at Trapezoidal Panel, Visible 2 44,000
Locations
D011Z009-03-01
(1)(4)(5)(6)
57-10-06A Overwing Flex-Tee Flex-Tee Fastener Holes at Trapezoidal Panel – 1 33,000

Hidden Locations
57-10-06A Overwing Flex-Tee Flex-Tee No. 1 Base Flange Fastener Row 1 at 2 44,000 44,000
BS 1186
57-10-06A Overwing Flex-Tee Flex-Tee No. 1 Base Hidden Fastener Holes at 1 33,000 33,000
BS 1088 to BS 1095
57-10-06A Overwing Flex-Tee Flex-Tee Web fastener holes hidden by FSOWL & 1 33,000
RSOWL and locations in Note 2
57-10-06A Overwing Flex-Tee Flex-Tee Web fastener holes at hidden locations 1 33,000 33,000
57-10-06A Overwing Flex-Tee Flex-Tee Web fastener holes at visible locations 2 44,000 44,000
57-10-06A Overwing Flex-Tee Flex-Tee rebate edge at BS 933 Forward edge of #4 2 44,000
and Aft edge of #5 Flex-Tees
57-10-06A Overwing Flex-Tee Flex-Tee rebate edges 2 44,000 44,000 44,000
57-10-06A Overwing Flex-Tee Flex-Tee rebate, from BS 883 to BS 1120 except Flex- 2 44,000 44,000 44,000
Tee rebate edges
57-10-06A Overwing Flex-Tee No. 1 Flex Tee Clevis Bore – BL 113, BS 1076/ BS 1 33,000 33,000 33,000
1080
57-10-06A Overwing Flex-Tee No. 1 Flex Tee Clevis Neck – BL 113, BS 1076/BS 2 44,000 44,000 44,000
1082
57-10-06A Overwing Flex-Tee No. 2 Flex Tee Lug Bore – BL 113, BS 1076/BS 1080 1 33,000 33,000 33,000
57-10-06A Overwing Flex-Tee No. 2 Flex Tee Lug Neck at BL 113, BS 1080 2 44,000 44,000
D011Z009-03-01
(1)(4)(5)(6)
57-10-06B Pi-Fitting – Frame BS 897-1089 Upper Flange Joint, Pi-Fittings #1-9 (LHS/RHS) 2 44,000
57-10-06B Pi-Fitting – Frame BS 897-1089 Upper flange radius, Pi-Fittings #1-9 (LHS/RHS) 2 44,000
57-10-06B Pi-Fitting – Frame BS 897-1089 Wall Flange Joint 2 FLS

L/N 1-6: BS 897, 945, 1017, 1041, 1065
L/N 7 and on: BS 945, 1017, 1041, 1065
57-10-06B Pi-Fitting – Frame BS 897-1089 Wall Flange, Fitting Base Radius Pi Fittings #1 - 9 2 44,000
(LHS/RHS)
57-10-06B Pi-Fitting – Frame BS 897-1089 All Base Joint Fasteners, Pi Fittings #1 - 9 1 33,000
57-10-06B Pi-Fitting – Frame BS 897-1089 Pi-Fittings #1 through #9 at Radius Fillet 1 33,000 33,000
57-10-06C Shear Fitting – Frame BS 897-1089 Vertical & Base Flange Radius 2 44,000
57-12-01A Rear Spar BL 11 Stiffener at Edge of Flange (LHS/RHS) at WL 2 44,000

130 to 147
57-12-01A Rear Spar Stiffener, Free Flange Fasteners BL 11 1 33,000

(LHS/RHS) at WL 140 to WL 157
57-12-01a Rear Spar Stiffener, Hole Section BL 11 (LHS/RHS) at WL 94.5 - 2 44,000

98
57-12-01A Rear Spar BL11 Stiffener, at Free Flange Edge and Fastener 2 44,000 44,000
Holes, WL 94 to WL 181
57-12-01A Rear Spar Manufacturing Door Horizontal Stiffener 1 33,000
57-12-01A Rear Spar Manufacturing Door Horizontal Stiffener Edge & Web 1 33,000 33,000
Joint, BL 0 to RBL 46, WL 161
D011Z009-03-01
(1)(4)(5)(6)
57-12-01B Rear Spar Access Doors Manufacturing Door Fastener Hole (Hidden Locations) 1 33,000
57-12-01C Rear Spar – Miscellaneous Fittings Bracket, BL 74 and BL 59.5 (LHS/RHS) RBL 32.5, RBL 2 44,000
19 at WL 181.7
57-12-01C Rear Spar – Miscellaneous Fittings T Clip @ BL 82, 52.8 46, 25.8 (LHS/RHS) LBL 32.5, 2 44,000
LBL 19 at WL 181.7
57-12-01C Rear Spar – Miscellaneous Fittings Inboard/Outboard OWB Fittings, BL 66 1 33,000

(LHS/RHS) at WL 181.7
57-12-01C Rear Spar – Miscellaneous Fittings (L/N 4-19) T-Clip at MLG Door Support Intercostal, LBL 90 and 2 44,000
RBL 90, WL 135
57-12-01C Rear Spar – Miscellaneous Fittings (L/N 4-19) Lug - R/S MLGD Support Ftg, LBL 90, RBL 90, LBL 1 33,000
102, RBL 102 Lug Area
57-12-01C Rear Spar – Miscellaneous Fittings (L/N 20 and on) Lug - R/S MLG Door Support Upper Fittings, LBL 90, 1 33,000
RBL 90, LBL 102, RBL 102 Lug Area
57-12-01C Rear Spar – Miscellaneous Fittings (L/N 4-19) Upper Flange Detail - R/S MLG Door Support Ftg, LBL 2 44,000
90 and RBL 90
57-12-01C Rear Spar – Miscellaneous Fittings (L/N 4-19) R/S MLG Door Support Fitting Joint LBL 90, RBL 90, 1 FLS
LBL 102, RBL 102 Joint Area
57-12-01C Rear Spar – Miscellaneous Fittings Rear Spar Back-up Angles, LBL and RBL 46 and 82, 2 44,000
WL 146
57-12-01C Rear Spar – Miscellaneous Fittings Lower Beam Lug and Clevis Fitting, LBL and RBL 46 1 33,000
and 82, WL 144
57-12-01C Rear Spar – Miscellaneous Fittings MLG Door Uplock Support Fitting Lug Detail, BL90 and 1 33,000 33,000
100 at WL 146
D011Z009-03-01
(1)(4)(5)(6)
57-12-01C Rear Spar – Miscellaneous Fittings MLG Door Uplock Support Fitting Joint Details, BL 90 2 44,000 44,000
and 100 at WL 146
57-12-01C Rear Spar – Miscellaneous Fittings Internal Lower Beam Attachment Fittings at BL 46 and 1 33,000 33,000
82, Fwd and Aft Side of Rear Spar Web
57-12-02A Front Spar Stiffener, BL 82, BL 90 (LHS/RHS) WL 136 to WL 192 2 44,000
57-12-02A Front Spar BL 82, BL 90 Vertical Stiffener, Base Flange, WL146 to 2 44,000 44,000
WL 192
57-12-02A Front Spar Stiffener, Gage Steps at BL 82, BL 90 (LHS/RHS) WL 2 44,000

136 to WL 192
57-12-02A Front Spar Horizontal Stiffener between BL 90 to BL 114 1 33,000 33,000 33,000
57-12-02B Front Spar – Miscellaneous Fittings Overwing Beam Fitting @ BL 11, 39.5, 66, 90, (LHS/ 2 44,000
RHS) at Front Spar Attachment
57-12-02B Front Spar – Miscellaneous Fittings (L/N 7 - 45) Overwing Beam Fitting @ BL 11, 39.5, 66, 90, (LHS/ 1 33,000
RHS) where hidden by doublers
57-12-02B Front Spar – Miscellaneous Fittings Overwing Beam Fitting, Upper Flange @ BL 11, 39.5, 2 44,000
66, 90, (LHS/RHS) at WL 194
57-12-02B Front Spar – Miscellaneous Fittings Stiffener End Fitting @ BL 3, 11, 25, 39.5, 52, 59, 65, 2 44,000 44,000 44,000
and 74 (LHS/RHS) WL 98 to WL 133
57-12-02B Front Spar – Miscellaneous Fittings Stiffener End Ftg, Radius Section @ BL 3, 11, 25, 39.5, 2 44,000
52, 59, 65, 74 (LHS/RHS), WL 98 to WL 133
57-12-02B Front Spar – Miscellaneous Fittings Lower Beam Lugs and Clevis Fittings LBL and RBL 46 1 33,000
and 82, WL 144
57-12-02B Front Spar – Miscellaneous Fittings Internal Lower Beam Attachment Fittings at BL 46 and 1 33,000 33,000
82 at Fwd and Aft Side of Front Spar Web
D011Z009-03-01
(1)(4)(5)(6)
57-12-02B Front Spar – Miscellaneous Fittings Stiffener Runout Fittings at Overwing Beams at BL 11, 2 44,000 44,000
39.5, and 66
57-12-02B Front Spar – Miscellaneous Fittings Keel Outboard Vertical Support at BL 11, from WL 96 2 44,000 44,000
to 108
57-12-02B Front Spar – Miscellaneous Fittings Keel Inboard Vertical Support at BL 11, from WL 96 to 1 33,000 33,000
142
57-12-03a Front Spar Body Chord Skin Flange BL 30 - BL 104 1 FLS
57-12-03a Front Spar Body Chord Skin Flange, Hidden Flange at BL 95 - 98 1 33,000
57-12-03a Front Spar Body Chord Web Side Flange BL 30 - BL 104 1 33,000
57-12-03a Front Spar Body Chord Web Side Flange, Hidden Fastener Details 1 33,000
BL 30 - BL 104
57-12-03a Front Spar Body Chord Web Flange @ BL 0 - BL 30 Hidden Details 1 33,000
57-12-03a Front Spar Body Chord Radius 2 44,000
57-12-03a Front Spar Body Chord Web and Skin Flange Fastener Details from 1 33,000 FLS
BL 4.5 to BL 100.7
57-12-03a Front Spar Body Chord Skin Flange at BL 0 - BL 30 1 33,000

57-12-03b
57-12-03a Front Spar Body Chord Web Flange at BL 0 - BL 30 1 33,000

57-12-03b
57-12-03b Front Spar Body Splice Chord Details Body Chord at BL 0 Splice – Skin Flange at Stiffener 1 33,000
End Fittings
D011Z009-03-01
(1)(4)(5)(6)
57-12-03b Front Spar Body Chord Splice Details Body Chord at BL 0 Splice - Web Flange at Stiffener 1 33,000
End Fittings
57-12-03b Front Spar Body Chord Splice Details BL 0 Body Chord Splice – Skin Flange 2 44,000
(LBL 5.3 to RBL 5.3)
57-12-03b Front Spar Body Chord Splice Details BL 0 Body Chord Splice – Web Flange 2 44,000
(LBL 5.3 to RBL 5.3)
57-12-03b Front Spar Body Chord Splice Details Pickle Fork and Front Body Chord at Outboard Splice – 1 33,000
Skin Flange
57-12-03b Front Spar Body Chord Splice Details Pickle Fork and Front Body Chord at Outboard Splice – 1 33,000
Web Flange
57-12-03b Front Spar Body Chord Splice Details Pickle Fork to Body Chord Splice Fitting 2 44,000
57-12-03b Front Spar Body Splice Chord Details Pickle Fork and Body Chord Web and Skin Flanges at 1 33,000 33,000
Outboard Splice, from WL 167.3 to WL 179.5
57-12-03b Front Spar Body Chord Splice Details Splice Web and Skin Flanges, BL 0 Splice, from BL 0 2 44,000 FLS
to BL 1.8, and Pickle Fork Splice, from WL 167.3 to WL
179.5
57-13-01a Spanwise Beams Stiffeners, Spanwise Beams 1, 2, 3 at BL 46, BL 82 2 44,000

(LHS/RHS)
57-13-01a Spanwise Beams Internal Lower Beam Stiffeners, Spanwise Beams 1, 2, 2 44,000 44,000
3 at BL 46, BL 82 (LHS/RHS)
57-13-01a Spanwise Beams Stiffeners, Base Flange Radius Spanwise Beam #1, 2 44,000
#2, #3 at BL 46, BL 82 (LHS/RHS) at Top End
57-13-01b Spanwise Beam – Corner Fittings Forward and Aft Corner Fittings at Lower Chord of 2 FLS 44,000 44,000
Spanwise Beams 1, 2, & 3
D011Z009-03-01
(1)(4)(5)(6)
57-13-01c Spanwise Beams – Miscellaneous Fittings Internal Lower Beam Splice Fittings at Spanwise 2 44,000 44,000
Beams 1, 2, and 3 at BL 46 and 82
57-13-02A Overwing Beams Aft Lower Chord, BL 90, (LHS and RHS) Fastener 2 44,000
holes common to Aft Lower Chord and Splice Fitting
BS 1113
57-13-02A Overwing Beams Lwr Chord – Hidden Detail, RS Splice Fittings at BL 11, 1 33,000
39.5, 66, and 90. Fastener Holes Common to RS
Splice Fitting and Lwr Chord
57-13-02A Overwing Beams Seat Track at BS 1113 Splice Fitting, BL 11, BL 39.5, 1 33,000
BL 66 (LHS/RHS)
57-13-02A Overwing Beams Overwing Beam Web, BS 1113 Splice Fittings 1 33,000
- BL 11, 39.5, 66 (LHS and RHS)
57-13-02B Overwing Beams – Miscellaneous Fittings Rear Spar Splice Fittings - Horizontal Flange, BS 1072 1 FLS
to 1087 (LHS and RHS)
57-13-02B Overwing Beams – Miscellaneous Fittings Splice Fitting, BS 1113 - BL 11, 39.5, 66, and 90 (LHS 2 44,000
and RHS)
57-13-02B Overwing Beams – Miscellaneous Fittings Drain Hole – BS 1113 Splice Ftg at BL66, Outboard BS 1 33,000
1113 splice fitting at RBL 66 and LBL 66
57-13-02C Overwing Beam – Tie Rods Aluminum Clevis Fittings – BS 1017, 1041, 1065, 1077, 1 33,000
1089, and 1113, at BL 66 and 90
(LHS and RHS)
57-13-02C Overwing Beam – Tie Rods BL 66 Tie Rod Fitting Lugs at BS 1017, 1041, 1065, 1 33,000 33,000
and 1089
57-13-02C Overwing Beam – Tie Rods Rod end shaft – BS 1017, 1041, 1065, 1077, 1089, and 1 33,000
1113 at inboard and outboard rod ends
(LHS/RHS)
D011Z009-03-01
OCT 2018 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-77
(1)(4)(5)(6)
57-13-02C Overwing Beam – Tie Rods Inboard Rod End Lugs – BS 1017, 1041, 1065, 1077, 1 FLS
1089 1113 at BL 66 and 90 (LHS and RHS) (L/N 6-780)
57-13-02C Overwing Beam – Tie Rods Tie Rod Inboard and Outboard Lugs at BS 1017, 1041, 1 33,000 33,000
1065, and 1089
57-13-02C Overwing Beam – Tie Rods Outboard Rod End Clevis at Frames – Clevis Base, BS 2 44,000
1017, 1041, 1065, 1089 (LHS and RHS)
57-13-02C Overwing Beam – Tie Rods Outboard Rod End Clevis at Frames – Lug Hole, BS 1 33,000
1017, 1041, 1065, 1089 (LHS and RHS) (L/N 6-780)
57-13-02C Overwing Beam – Tie Rods Tie Rod Flanges, Lugs, and Clevises 1 12,000
(L/N 781
and on)
57-15-01 Lower Panel Keel Attach Chord at Bays 1, 2, 3 (BS 1039 to 1075), 2 44,000
and 19 (BS 870 to 882) (LHS/RHS)
57-15-01 Lower Panel Keel Attach Chord at BS 871 - 882, 912, and 1 33,000 33,000
946 - 1074
57-15-01 Lower Panel (L/N 4 - 6) Section 11 Lower Panel Stringer 1 Forward/Aft LHS/ 1 33,000
RHS fittings, all 5 fasteners per fitting
57-15-01 Lower Panel (L/N 4 - 6) Section 11 Lower Panel Stringer 1, End Fitting 2 44,000
57-21-02 Front Spar Splice (L/N 4-6) Wing Front Spar at Rib 14 1 FLS
57-21-02 Front Spar Splice (L/N 4-6) Wing Front Spar at Rib 30 1 FLS
57-21-02 Front Spar Splice Wing Front Spar at Rib 39.5 (wing tip) 1 FLS FLS FLS
57-21-04 Rear Spar Splice (L/N 4-6) Wing Rear Spar at Rib 19 1 FLS
D011Z009-03-01
(1)(4)(5)(6)
57-21-04 Rear Spar Splice (L/N 4-6) Wing Rear Spar at Rib 30 1 FLS
57-21-04 Rear Spar Splice Wing Rear Spar at Rib 39.5 (wing tip) 1 FLS FLS FLS
57-22-01A Wing Tip Inspar Rib 40 Bay #3 Upper Chord 1 33,000
57-22-01B Wing Tip Inspar Rib 40 Bay #1 Front Spar Attachment 1 33,000
57-22-01C Wing Tip Inspar Ribs 41, 42, and 43 Bay #2 Upper Chord 1 33,000
57-22-01D Wing Tip Inspar Ribs 41, 42, and 43 Bay #2 Lower Chord 1 33,000
57-22-01E Wing Tip Inspar Ribs 41, 42, and 43 Bay #1 Front Spar Attachment 1 33,000
57-24-01 R4 Inboard Side Load Fitting Strut Joint Lug 1 FLS FLS FLS
57-24-02 R3 Outboard Side Load Fitting Strut Joint Lug 1 FLS FLS FLS
57-24-03 R2 Aft Pitch Load Fitting Diagonal Brace Joint Lug 1 FLS FLS FLS
57-24-04 R1 Inboard/Outboard Forward Pitch Load Fittings Upper Link Joint Lug 1 FLS FLS FLS
57-24-05 R7/R8 Side Load Fitting Side Link Joint Lug 1 FLS FLS FLS
57-24-06C R3 Forward Backup Fitting at Rib 12 Fitting attachment to Rib 12 Web 1 FLS FLS FLS
57-25-02J Lower Stringer Splice at Rib 35 Stringer L-13 and L-15 Fastener LBF-7 and LBF-8 1 FLS
57-25-02L Lower Stringer-8 @ Rib 17 (L/N 4-6) Fastener Rows 7 and 8 (hidden details) Both fittings 1 FLS
are used in the analysis
D011Z009-03-01
(1)(4)(5)(6)
57-27-01 MLG Forward Trunnion Side Load Backup Fitting Lower flange attachments to lower skin panel 2 44,000 44,000
57-27-01A MLG FWD Trunnion Side Load Backup Fitting Spar attachment flange free edge 2 44,000
57-27-01B MLG FWD Trunnion Side Load Backup Fitting Lower flange attachments to lower skin panel 2 44,000
57-27-02 MLG Drag Brace Lower Backup Fitting Upper Flange of cross-section H-H 2 FLS
57-27-02 MLG Drag Brace Lower Backup Fitting Attachment to Lower Skin at cross-section X1-X1 1 FLS
57-27-02 MLG Drag Brace Lower Backup Fitting Upper Flange at cross-section X2-X2 2 FLS
57-27-02 MLG Drag Brace Lower Backup Fitting Attachment to Lower Skin at Section X1-X1 1 FLS
57-27-02 MLG Drag Brace Lower Backup Fitting Attachment to Lower Skin at Section X2-X2 1 FLS
57-27-03 MLG Drag Brace Upper Backup Fitting Lower flange of cross-section F-F 2 FLS
57-27-03 MLG Drag Brace Upper Backup Fitting Attachment to Upper Skin at cross-section X3-X3 1 FLS
57-27-03 MLG Drag Brace Upper Backup Fitting Lower Flange of cross-section X4-X4 2 FLS
57-27-03 MLG Drag Brace Upper Backup Fitting Attachment to Upper Skin at Section X3-X3 1 FLS
57-27-03 MLG Drag Brace Upper Backup Fitting Lower Flange of Cross Section X4-X4 2 FLS
57-27-05 MLG Drag Brace Upr/Lwr Rib 2 Attach Clips Drag Brace Lower Backup Fitting to Rib 2 Attachment 2 FLS
Clip
57-27-06 MLG Drag Brace Backup Shear Web Fitting Upper Backup Fitting Attachment 2 FLS FLS
D011Z009-03-01
(1)(4)(5)(6)
57-30-01A Wing Tip Inboard Closure Rib Front and Rear Spar Lower Splice Joints 1 33,000 33,000 33,000
57-30-01B Wing Tip Inboard Closure Rib Barrel Nut Housing 1 FLS 33,000 33,000
57-51-01A Fixed Trailing Edge Inboard Flap Supports – Inboard Inboard & Outboard Lower Flange Attachment to Wing 2 FLS FLS FLS
Flap Support #3 Skin and Hinge Lugs
57-51-01B Fixed Trailing Edge Inboard Flap Supports –Auxiliary Auxiliary Support C Structure 2 44,000 44,000 44,000
Support C
57-51-01C1A Fixed Trailing Edge Inboard Flap Supports –Auxiliary Auxiliary Support D to Mini-Cantilever Fitting Lower 1 33,000 33,000 33,000
Support D Joint (Lug)
57-51-01C1B Fixed Trailing Edge Inboard Flap Supports –Auxiliary Auxiliary Support D to Mini-Cantilever Fitting Lower 1 33,000 33,000 33,000
Support D Joint (Pin)
57-51-01C1C Fixed Trailing Edge Inboard Flap Supports –Auxiliary Auxiliary Support D to Mini-Cantilever Fitting Lower 1 33,000 33,000 33,000
Support D Joint (Link Lug)
57-51-01C2 Fixed Trailing Edge Inboard Flap Supports –Auxiliary Auxiliary Support D Backup Rib Lower Chord 2 44,000 FLS FLS
Support D
57-51-01C3 Fixed Trailing Edge Inboard Flap Supports –Auxiliary Auxiliary Support D Roller Rib (Aft of Backup Rib) 2 44,000 44,000 44,000
Support D
57-51-01D Fixed Trailing Edge Inboard Flap Supports – Lower Wing Skin Attachment 2 44,000 44,000 44,000
Spoiler 5 Main Support
57-51-02 Fixed Trailing Edge Flaperon Support Structure Hinge Ribs, Cam Track Ribs, and Cam Track 2 44,000 44,000 44,000
57-51-03A Fixed Trailing Edge Outboard Flap Supports – Outboard Flap Support #1 Lower Flange / Wing Skin attachments 2 44,000 44,000 44,000
Flap Support #1 (Inboard + Outboard) Ribs
57-51-03B Fixed Trailing Edge Outboard Flap Supports – Outboard Flap Support #2 Lower Flange / Wing Skin attachments 2 44,000 44,000 44,000
Flap Support #2 (Inboard + Outboard Ribs)
D011Z009-03-01
(1)(4)(5)(6)
57-51-04A Fixed Trailing Edge Aileron Hinge & Actuator Fittings – Hinge Rib #1 with failed Rib #2 2 44,000 44,000 44,000
Aileron Hinge Rib #1
57-51-04C Fixed Trailing Edge Aileron Hinge & Actuator Fittings – Hinge Rib #2 with failed Rib #3 2 44,000 44,000 44,000
57-51-04D Fixed Trailing Edge Aileron Hinge & Actuator Fittings – Hinge Rib #3 with failed Rib #4 2 44,000 44,000 44,000
57-51-04E Fixed Trailing Edge Aileron Hinge & Actuator Fittings – Hinge Rib #4 with failed Rib #3 2 44,000 44,000 44,000
57-51-04F Fixed Trailing Edge Aileron Hinge & Actuator Fittings – Hinge Rib #5 with failed Rib #4 2 44,000 44,000 44,000
57-53-02 Inboard Flap Support #3 Carrier Fitting Carrier Fitting and Internal Fitting Bathtub Bolt Holes 1 33,000 33,000 33,000
(qty. 6)
57-53-02 Inboard Flap Support #3 Carrier Fitting All BACB30LE9K Attachment Bolts (Qty 6) 1 33,000 33,000 33,000
57-53-02 Inboard Flap Support #3 Carrier Fitting Lower Flange Edges 2 44,000 44,000 44,000
57-53-03A Inboard Flap Torque Tube Carrier Beam Attachment Lug 1 33,000 33,000 33,000
57-53-03A Inboard Flap Torque Tube Outer Torque Tube, at Fitting 5 Attachment Lugs 1 33,000 33,000 33,000
57-53-03A Inboard Flap Torque Tube Inner Torque Tube, at Pad-Up at Fitting 5 1 33,000 33,000 33,000
57-53-03A Inboard Flap Torque Tube Inner Torque Tube, at Collar Fitting Attachment Lugs 1 33,000 33,000 33,000
57-53-03A Inboard Flap Torque Tube Outer Torque Tube, at Drain Holes 1 33,000 33,000 33,000
57-53-03A Inboard Flap Torque Tube Outer Torque Tube, at Flange at Fitting 5 1 33,000 33,000 33,000
D011Z009-03-01
(1)(4)(5)(6)
57-53-03A Inboard Flap Torque Tube Outer Torque Tube, at Pad-Up at attachment to Fitting 1 33,000 33,000 33,000
5
57-53-03B Inboard Flap Torque Tube – Fitting 4 Shear Rib, at fastener holes at Collar attachment 1 33,000 33,000 33,000
57-53-03B Inboard Flap Torque Tube – Fitting 4 Shear Rib, at Torque Tube cut out 1 33,000 33,000 33,000
57-53-03B Inboard Flap Torque Tube – Fitting 4 Shear Rib, at Upper Skin Flange fastener holes 1 33,000 33,000 33,000
57-53-03C Inboard Flap Torque Tube – Fitting 5 Lower Flange to Lower Skin fastener holes (quantity 8) 1 33,000 33,000 33,000
57-53-03C Inboard Flap Torque Tube – Fitting 5 Outer Torque Tube attachment bolt hole 1 33,000 33,000 33,000
57-53-03D Inboard Flap Torque Tube Inner Torque Tube Collar Flange 1 33,000 33,000 33,000
57-53-03D Inboard Flap Torque Tube Inner Torque Tube Collar, at Inner Torque Tube 1 33,000 33,000 33,000
attachment lugs
57-53-03E Inboard Flap Torque Tube Torque Tube Support Pin 1 33,000 33,000 33,000
57-53-04A Inboard Flap Drive Fittings – Support 3 Carrier Fitting and Bathtub fillet radii and flange edges 1 33,000 33,000 33,000
Internal Fitting
57-53-04B Inboard Flap Drive Fittings – Support 4 Carrier Beam Carrier Beam Hinge Lug (B Joint lugs) 1 33,000 33,000 33,000
Assembly
57-53-04B Inboard Flap Drive Fittings – Support 4 Carrier Beam Carrier Beam Torque Tube Aft Attachment Lugs 1 33,000 33,000 33,000
Assembly (138Z4041 & 138Z4044)
57-53-04B Inboard Flap Drive Fittings – Support 4 Carrier Beam Carrier Beam Lower Flange 1 33,000 33,000 33,000
Assembly
D011Z009-03-01
(1)(4)(5)(6)
57-53-04B Inboard Flap Drive Fittings – Support 4 Carrier Beam Support 4 Carrier Beam Aft Lug field fastener holes 1 33,000 33,000 33,000
Assembly
57-53-04B Inboard Flap Drive Fittings – Support 4 Carrier Beam Carrier Beam Drain Holes 1 33,000 33,000 33,000
Assembly
57-53-04C Inboard Flap Drive Fittings – Support 4 Actuator Support Forward Flange edges 2 44,000 44,000 44,000
Assembly
57-53-04C Inboard Flap Drive Fittings – Support 4 Actuator Support Upper Bulkhead/K-Joint Lugs 1 33,000 33,000 33,000
Assembly
57-53-04C Inboard Flap Drive Fittings – Support 4 Actuator Support Actuator Support Fitting Hinge Joint (B-Joint) Boss 2 44,000 44,000 44,000
Assembly
57-53-04C Inboard Flap Drive Fittings – Support 4 Actuator Support Pyramid Section 1 33,000 33,000 33,000
Assembly
57-53-04C Inboard Flap Drive Fittings – Support 4 Actuator Support Actuator Support Torque Box Panel 138Z4058 2 44,000 44,000 44,000
Assembly Fastener Holes
57-53-04E Inboard Flap Drive Fittings – Support #4 B-Joint Hinge Inner and Outer Pins 1 33,000 33,000 33,000
Pin
57-53-04F Inboard Flap Drive Fittings – Support #4 Upper Inner and Outer Pins 1 33,000 33,000 33,000
Bulkhead/K-Joint Pin
57-53-04G Inboard Flap Drive Fittings – Support #4 Torque Tube Torque Tube to Carrier Beam Inner and Outer 1 33,000 33,000 33,000
Attachment Pins Attachment Pins
57-53-06A Inboard Flap Auxiliary Supports & Tracks Internal Fittings and Tracks, Auxiliary Support C & 2 44,000 44,000 44,000
Auxiliary Support D
57-53-09A Outboard Flap Drive Fittings – Support #1 Carrier Fitting BACB30LE8K Attachment Bolts (Qty 6) 1 33,000 33,000 33,000
Attachment Bolts
57-53-09A Outboard Flap Drive Fittings – Support 1 Carrier Fitting Lower Flange edges 2 44,000 44,000 44,000
D011Z009-03-01
(1)(4)(5)(6)
57-53-09A Outboard Flap Drive Fittings – Support 1 Carrier Fitting C-Joint Clevis Lugs 2 44,000 44,000 44,000
57-53-09B Outboard Flap Drive Fittings – Support #2 Carrier Fitting BACB30US8K Attachment Bolts (Qty 6) 1 33,000 33,000 33,000
57-53-09B Outboard Flap Drive Fittings – Support 2 Carrier Fitting Lower Flange edges 2 44,000 44,000 44,000
57-53-09B Outboard Flap Drive Fittings – Support 2 Carrier Fitting C-Joint Clevis Lugs 2 44,000 44,000 44,000
57-53-09B Outboard Flap Drive Fittings – Support 2 Carrier Fitting Carrier Fitting and Internal Fitting Bathtub Bolt Holes, 1 33,000 33,000 33,000
Qty. 6
57-53-10A Outboard Flap Internal Fittings – Support 1 Carrier Fitting to Internal Fitting Tension Bolt Holes, 1 33,000 33,000 33,000
Internal Fitting Qty. 6
57-53-10A Outboard Flap Internal Fittings – Support 1 Bathtub fillets radii and edges of Carrier Fitting and 1 33,000 33,000 33,000
Internal Fitting Internal Fitting
57-53-10B Outboard Flap Internal Fittings – Support 2 Bathtub fillets radii and edges of Carrier Fitting and 1 33,000 33,000 33,000
Internal Fitting Internal Fitting
57-53-12A Outboard Flap Auxiliary Supports & Tracks Internal Fittings and Tracks, Auxiliary Support A, 2 44,000 44,000 44,000
Auxiliary Support B, and Deflection Control Support
57-53-13A Aileron Hinges – Hinge Fitting 1 Fitting edges in radius 2 44,000 44,000 44,000
57-53-13A Aileron Hinges – Hinge Fitting 1 Lug 1 33,000 33,000 33,000
57-53-13A Aileron Hinges – Hinge Fitting 1 Fastener holes common to Aileron Spar attachment 2 44,000 44,000 44,000
57-53-13B Aileron Hinges – Hinge Fitting 2 Fastener holes common to Aileron Spar attachment 2 44,000 44,000 44,000
57-53-13B Aileron Hinges – Hinge Fitting 2 Fitting edges in radius 2 44,000 44,000 44,000
D011Z009-03-01
(1)(4)(5)(6)
57-53-13B Aileron Hinges – Hinge Fitting 2 Lug 1 33,000 33,000 33,000
57-53-13C Aileron Hinges – Hinge Fitting 3 Lug 1 33,000 33,000 33,000
57-53-13C Aileron Hinges – Hinge Fitting 3 Fitting edges in radius 2 44,000 44,000 44,000
57-53-13C Aileron Hinges – Hinge Fitting 3 Fastener holes common to Aileron Spar attachment 2 44,000 44,000 44,000
57-53-13D Aileron Hinges – Hinge Fitting 4 Lug 1 33,000 33,000 33,000
57-53-13D Aileron Hinges – Hinge Fitting 4 Fitting edges in radius 2 44,000 44,000 44,000
57-53-13D Aileron Hinges – Hinge Fitting 4 Fastener holes common to Aileron Spar attachment 2 44,000 44,000 44,000
57-53-13E Aileron Hinges – Hinge Fitting 5 Lug 1 33,000 33,000 33,000
57-53-13E Aileron Hinges – Hinge Fitting 5 Fitting edges in radius 2 44,000 44,000 44,000
57-53-13E Aileron Hinges – Hinge Fitting 5 Fastener holes common to Aileron Spar attachment 2 44,000 44,000 44,000
57-53-14A Aileron Actuator Fittings – Inboard Actuator Fitting Actuator Lug 1 33,000 33,000 33,000
57-53-14A Aileron Actuator Fittings – Inboard Actuator Fitting Link Lug 1 33,000 33,000 33,000
57-53-14A Aileron Actuator Fittings – Inboard Actuator Fitting Fitting edges in radius 2 44,000 44,000 44,000
57-53-14A Aileron Actuator Fittings – Inboard Actuator Fitting Fastener holes common to Aileron Spar attachment 2 44,000 44,000 44,000
57-53-14B Aileron Actuator Fittings – Outboard Actuator Fitting Actuator Lug 1 33,000 33,000 33,000
D011Z009-03-01
(1)(4)(5)(6)
57-53-14B Aileron Actuator Fittings – Outboard Actuator Fitting Link Lug 1 33,000 33,000 33,000
57-53-14B Aileron Actuator Fittings – Outboard Actuator Fitting Fitting edges in radius 2 44,000 44,000 44,000
57-53-14B Aileron Actuator Fittings – Outboard Actuator Fitting Fastener holes common to Aileron Spar attachment 2 44,000 44,000 44,000
57-54-07A MLG Mini-Cantilever Fitting Auxiliary-D Lower Lug 1 FLS 33,000 33,000
57-54-07B MLG Mini-Cantilever Fitting Lower Skin Attachment 2 FLS FLS FLS
57-54-08 MLG Beam Bridge Fitting Mini-Cantilever Fitting Attachment 1 FLS
57-54-08A MLG Beam Bridge Fitting Mini-Cantilever Fitting Attachment 1 FLS FLS
(Fastener #127 and #128)
57-54-08B MLG Beam Bridge Fitting Mini-Cantilever Fitting Attachment 2 FLS FLS
(Fastener #120 - #126)
57-54-14 MLG Forward Trunnion Outboard Vertical Fitting Rear Spar Web attachment between Ribs 7 and 8 2 FLS FLS FLS
57-54-15 MLG FWD Trunnion Side Load Fitting Tension Strap Attachment 2 44,000 44,000
57-54-20 MLG Drag Brace Down Lock Support Fitting Outboard Main Lug 2 FLS FLS FLS
57-54-21A MLG Drag Brace Shackle Support Fitting Critical Cross Section B-B 2 FLS FLS FLS
57-54-21B MLG Drag Brace Shackle Support Fitting Critical Cross Section G-G 2 FLS FLS FLS
57-54-21C MLG Drag Brace Shackle Support Fitting Tension fastener attaching to lower backup fitting 1 FLS FLS FLS
D011Z009-03-01
(1)(4)(5)(6)
57-70-01A Inboard Spoiler Beam Upper Chord 1 33,000 33,000 33,000
57-70-01B Inboard Spoiler Beam Inboard joint 2 44,000 44,000 44,000
57-70-01C Inboard Spoiler Beam Outboard joint, Load Distribution Plates 2 FLS 44,000 44,000
57-70-01D Inboard Spoiler Beam Load Distribution Plate attachment to Auxiliary Support 1 33,000 33,000 33,000
D Backup Rib
57-70-02A Mid Spoiler Beam Upper Chord 1 33,000 33,000 33,000
57-70-02B Mid Spoiler Beam Attachments to Auxiliary Support D Backup Rib and 1 33,000 33,000 33,000
Flap Support 3 Rib
TABLE NOTES:
1. Blank entries in table indicate field is not applicable for that PSE/Check Form.
2. Multiple listings under a single PSE are uniquely identified by DTR Check Form Title, DTR Location, and Model-Series information. All inspections
listed under a single PSE Number for a given model must be performed.
3. C/L or L/N in DTR Check Form Title indicates forms pertaining only to specific airplane line numbers.
4. Thresholds designated as "FLS" are sensitive to flight length; see Figure 1. All other values shown are in flight cycles.
5. No airplane may be operated beyond 75% of the stated threshold (or operational limit) until the applicable inspection procedures are published in the
appropriate manual, validated, and accepted by the FAA. If the applicable published inspection procedure cannot be accomplished, an alternative FAA
accepted procedure must be used.
D011Z009-03-01
6. In addition to the stated flight cycle threshold, a calendar threshold of 22 years from date of aircraft delivery applies to all Supplemental Structural
Fatigue Inspections.
For BBJ 787 airplanes only: If an initial inspection of an FAA approved Structural Maintenance Program containing tasks necessary to maintain the
aircraft to Corrosion Level 1 or better has occurred, thereby constituting implementation of a Corrosion Prevention and Control Program (CPCP), the 22
year calendar threshold does not apply.
D011Z009-03-01
D. AIRWORTHINESS LIMITATIONS – LIFE LIMITS
STRUCTURAL SAFE-LIFE PARTS
The 787 landing gear and some of its support structure is certified per Title 14 CFR § 25.571(c) as safe-life structure. The data presented in this subsection
defines the safe life limits, as a function of accumulated flight cycles and flight hours, for the main and nose landing gear and support structure.
Nomenclature for applicability of landing gear parts is given in Table 2.
TABLE 2. AIRPLANE APPLICABILITY NOMENCLATURE
Airplane Applicability Maximum Taxi Weight (MTW, Reference)
787-8 486,000 LB
220,446 KG
787-8MI (Mission Improvement) 503,500 LB

228,383 KG
787-9 561,500 LB
254,692 KG
787-10 561,500 LB
254,692 KG
D011Z009-03-01
SAFE-LIFE LIMIT
LANDING GEAR AND SUPPORT STRUCTURE FAA EASA
787-8, 787-9, 787-10 Nose Landing Gear Figure 2A and 2B (FAA and EASA)
Figures 3, 4, 5A, 5B, 5C, and 5D

787-8, 787-9, 787-10 Main Landing Gear
(FAA and EASA)
787-8, 787-9, 787-10 Main Landing Gear Support Fittings Figures 6 and 7 (FAA and EASA)
Instructions for using Safe Life Charts (Figure 2 through Figure 7):
1. For each safe life part, determine the accumulated flight cycles and flight hours.
2. Enter the Safe Life Limit Curve at the appropriate flight cycles and flight hours and locate the intersection.
3. If the point determined in Step 2 lies inside the Safe Life Limit Curve, the part has not reached the safe life limit. If the point is on, above, or to the right
of the Safe Life Limit Curve, then the safe life limit has been exceeded. Operators must replace parts prior to exceeding the safe life limits.
4. Where indicated by "(TESTING IN PROGRESS)", the safe life limits presented in Figure 2 through Figure 7 are interim values. These values will be
periodically updated as the testing progresses. Final values will be published upon completion of the testing.
5. Safe Life parts that are common for the -8/-9 and -10 will require tracking minor model usage as well as flight hours (FH) and flight cycles (FC). Miner's
hypothesis for cumulative damage shall be applied for the evaluation of the damage incurred during the life of any given part. For a part that can be
used interchangeably on aircraft having different certified minor model, the safe-life limit (SLL) determination must consider the accumulation of all
damage incurred during the operation on each certified minor model that the aircraft is operated. Below is an example of the equation used to track
accumulation of damage on each minor model.
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෎ ௌ௅௅ி஼ǡிு ൅ ௌ௅௅ி஼ǡிு ൑ ͳǤͲ
͹ͺ͹ െ ͺǡȀെͻ ͹ͺ͹ െ ͳͲ
D011Z009-03-01
Interchangeability Document 520Z0001 provides a complete list of 787-8 / 787-9 / 787-10 nose landing gear related components subject to life limitations.
Figure 2A. NOSE LANDING GEAR SAFE-LIFE LIMITS - 787-8, 787-9
D011Z009-03-01
787NoseLandingGearSafeLifeLimits
AllComponents
60000
50000
0,44000 66000,44000
40000
FLIGHTCYCLES
30000
20000
115000,11500
10000
115000,0
0
0 20000 40000 60000 80000 100000 120000 140000
FLIGHTHOURS
Interchangeability Document 520Z0001 provides a complete list of 787-8 / 787-9 / 787-10 nose landing gear related components subject to life limitations.
Figure 2B. NOSE LANDING GEAR SAFE-LIFE LIMITS - 787-10

D011Z009-03-01
60000
55000
50000
45000
40000
0,33000 49500,33000
FLIGHTCYCLES
35000
AllComponents
30000
25000
20000
15000
10000 101250,7500
5000
101250,0
0
0 20000 40000 60000 80000 100000 120000 140000
FLIGHTHOURS
Interchangeability Document 510Z0001 provides a complete list of 787-8 / 787-9 / 787-10 main landing gear related components subject to life limitations.
Figure 3. MAIN LANDING GEAR TRUCK ASSEMBLY SAFE-LIFE LIMITS (TESTING IN PROGRESS)
D011Z009-03-01
60000
55000
50000
45000
40000
FLIGHTCYCLES
35000 0,33000 49500,33000

AllComponents
(1)
30000
25000
20000
15000
10000 101250,7500
5000
101250,0
0
0 20000 40000 60000 80000 100000 120000 140000
FLIGHTHOURS
1
Note: The Retract Actuator Head End Fuse Pin (P/N 511Z3022) has a life limit of 55,000 Flight Cycles (there is no Flight Hour limitation associated with this part).
Figure 4. MAIN LANDING GEAR SHOCK STRUT ASSEMBLY SAFE-LIFE LIMITS (TESTING IN PROGRESS)
D011Z009-03-01
60000
TitaniumBraceAssemblyMembers
55000 513Z3003Ͳ51/Ͳ52
513Z3301Ͳ1
50000 513Z3302Ͳ1
66000,44000 513Z3103Ͳ51
45000 0,44000
514Z3301Ͳ501
514Z3302Ͳ501
40000
FLIGHTCYCLES
35000
0,28600 42900,28600
30000
25000
20000
AllOtherBrace
15000 Components
10000 135000,10000
87750,6500
5000
87750,0 135000,0
0
0 20000 40000 60000 80000 100000 120000 140000
FLIGHTHOURS
AllOtherBraceComponents TiBraces
Figure 5A. 787-8 MAIN LANDING GEAR SIDE AND DRAG BRACE ASSEMBLIES SAFE-LIFE LIMITS (TESTING IN PROGRESS)
D011Z009-03-01
60000
TitaniumBraceAssembly
55000
Members
513Z3003Ͳ501/Ͳ502
50000
513Z3301Ͳ501
0,44000 513Z3302Ͳ501
45000
66000,44000 513Z3103Ͳ501
514Z3301Ͳ501
40000
514Z3302Ͳ501
FLIGHTCYCLES
35000
0,28600 42900,28600
30000
25000
20000
AllOtherBrace
15000 Components
10000
135000,10000
87750,6500
5000
135000,0
0 87750,0
0 20000 40000 60000 80000 100000 120000 140000
FLIGHTHOURS
AllOtherBraceComponents TiBraces
Figure 5B. 787-9 MAIN LANDING GEAR SIDE AND DRAG BRACE ASSEMBLIES SAFE-LIFE LIMITS (TESTING IN PROGRESS)
D011Z009-03-01
60000
55000
50000
0,44000
TitaniumBraceAssembly
45000 66000,44000 Members
513Z3003Ͳ501/Ͳ502
40000 513Z3301Ͳ501
513Z3302Ͳ501
513Z3103Ͳ501
35000
FLIGHTCYCLES
514Z3301Ͳ501
514Z3302Ͳ501
30000 0,28600 42900,28600
25000
20000
15000
AllOtherBrace
Components 115000,11500
10000
87750,6500
5000
115000,0
0 87750,0
0 20000 40000 60000 80000 100000 120000 140000
FLIGHTHOURS
Figure 5C. 787-10 MAIN LANDING GEAR SIDE AND DRAG BRACE ASSEMBLIES SAFE-LIFE LIMITS (TESTING IN PROGRESS)
D011Z009-03-01
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Figure 5D. 787-9/-10 MAIN LANDING GEAR STEEL DRAG BRACE ASSEMBLIES SAFE-LIFE LIMITS (TESTING IN PROGRESS)
D011Z009-03-01
50000
0,44000 66000,44000 594000,44000

45000
40000 787Ͳ8/Ͳ9/Ͳ10AllComponents
35000 787Ͳ8/Ͳ9RetractActuatorSupportFitting,
126Z2503
30000 787Ͳ8/Ͳ9/10AllComponentsExcept787Ͳ8/Ͳ9Retract
FlightCycles
ActuatorSupportFitting,126Z2503
25000
20000
15000
166969,12368
10000
5000
594000,0
166969,0
0
0 100,000 200,000 300,000 400,000 500,000 600,000 700,000
FlightHours
Interchangeability Doc.126Z0007 provides a complete list of 787-8 / 787-9 / 787-10 main landing gear wing box support fitting related components subject to life limitations.
<1> Note: MLG Beam Outboard Support, MLG Forward Trunnion Support, MLG Drag Brace Support
Figure 6. MAIN LANDING GEAR SUPPORT FITTINGS SAFE-LIFE LIMITS
D011Z009-03-01
50000
0,44000 66000,44000 787Ͳ8/Ͳ9

45000
787Ͳ10
40000
35000
30000
FlightCycles
25000
20000
202043,14966
15000
115000,11500
10000
5000
115000,0 202043,0
0
0 50,000 100,000 150,000 200,000 250,000
FlightHours
Interchangeability Document 151Z0000 provides a complete list of 787-8 / 787-9 / 787-10 main landing gear trailing edge support fitting related components
subject to life limitations.
Figure 7. MAIN LANDING GEAR BEAM ASSEMBLY SAFE-LIFE LIMITS
D011Z009-03-01
787 NOSE LANDING GEAR (NLG) PART LIST
Boeing 787 Nose Landing Gear Structure Interchangeability Document, 520Z0001 provides a complete list of 787-8 / 787-9 / 787-10 landing gear related
components subject to life limitations.
D011Z009-03-01
787 MAIN LANDING GEAR (MLG) PART LIST
Boeing 787 Main Landing Gear Structure Interchangeability Document, 510Z0001 provides a complete list of 787-8 / 787-9 / 787-10 main landing gear
related components subject to life limitations.
Boeing 787 Trailing Edge Main Landing Gear Structure Interchangeability Document, 151Z0000 provides a complete list of 787-8 / 787-9 / 787-10 main
landing gear trailing edge support fitting related components subject to life limitations.
Boeing 787 Wing Box Main Landing Gear Structure Interchangeability Document 126Z0007, provides a complete list of 787-8 / 787-9 /787-10 main landing
gear wing box support fitting related components subject to life limitations.
D011Z009-03-01
STRUCTURES LIFE-LIMITED PARTS
The replacement times established for the life-limited parts listed below result from Model 787-8 airplane certification activities with the FAA and are part of
the Airworthiness Limitations section of the Instructions for Continued Airworthiness. These maintenance actions are mandatory. These life limits may only
be revised with the approval of the FAA Oversight Office.
COMPONENT LIFE LIMIT
Horizontal Stabilizer Pivot Pins (LH & RH) as configured per Boeing Installation
Requirements Model (IR044Z0001-3): 12,000 landings or 2,200 days, whichever comes first
Inner Pivot Pin (311Z6401-3)
Outer Pivot Pin (311Z6402-3)
NOTE: Life-limited parts are installed on 787-8 Line Numbers 7 through 55. Prior to exceeding the specified life limit, the parts shall be replaced with
P/Ns 311Z6401-5 (Inner Pivot Pin) and 311Z6402-5 (Outer Pivot Pin). The P/N 311Z6401-5 and 311Z6402-5 pivot pins, and the corresponding
Installation Requirements Model P/N IR044Z0001-5 are not life-limited. Refer to AMM 55-17-01 for instructions for replacement of the pivot pins.
Service Bulletin 787-55-0001 provides warranty information and replacement instructions. The calendar life limit applies from date of airplane delivery.
D011Z009-03-01
SYSTEMS LIFE-LIMITED PARTS
The replacement times established for the life-limited parts listed below result from Model 787 airplane certification activities with the FAA and are part of the
Airworthiness Limitations section of the Instructions for Continued Airworthiness. These maintenance actions are mandatory. These life limits may only be
revised with the approval of the FAA Oversight Office.
Some of the component life limits in this listing will be temporary, due to qualification testing or endurance testing inadequacies at the time of airplane
certification, and will be removed when Boeing has satisfied the certification requirements for these components. Service Bulletins will be issued for some
items that will allow retrofit of a new component that does not have a life limit.
Calendar-based life limits apply from date of airplane delivery, unless otherwise noted.
ITEM QUANTITY
NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMIT PER AIRPLANE
1. Electrical Subsystems
1a. RPDU Differential Protection Current 7001044H02 Boeing is seeking a design solution for this component 8 Years 9
Transformer that will remove the life limit requirement. When
available, a Service Bulletin will be issued
recommending installation of the new part.
1b. Main and APU Battery Enclosure JS-0-0089-000 All 787 Airplanes/Incorporation of Service Bulletin 5,000 Flight Cycles 2
Vent Burst Disc B787-81205-SB500003-00
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ITEM QUANTITY
2. Environmental Controls
2a. Supplemental Cooling Unit (SCU) 7011015H02 Limited to production LN 6-9, 11-15, 17, 20-481, 5.8 Years/70 Months Up to 4 maximum
483-488, 490-491. The life limit is imposed due to the (2 basic, 2 optional)
condenser unit within the SCU. Prior to exceeding the
defined life limit, and if replacing according to one of
the two options listed below, the life limit shall be as
follows:
1. Replace with Part Number 7011015H02 SCU;
2. Replace with Part Number 7011015H02 SCU
refurbished with zero-time condenser per
UTC Aerospace Systems Service Bulletin
7011015-21-3.
Option (1) is subject to the defined life limit, measured
from date of original installation of the replacement
part on an airplane.
Option (2) is subject to the defined life limit, measured
from date of installation of the refurbished part on
the airplane.
If the installation date of the replacement or
refurbished part is not known, or if it is known or
suspected that the replacement or refurbished part
was previously installed on another aircraft, the date
of part manufacture or the delivery date of the airplane
the part was previously installed on can be used to
conservatively determine the part life relative to the
defined life limit.
NOTE: SCUs with no life limit are available for
retrofit; refer to Fleet Team Digest
787-FTD-21-14004 for information.
3. Flight Controls
3a. Electro Mechanical Spoiler Actuator C99144-004 Service Bulletin (SB 787-27-0003) to be released for 12,000 Flight Cycles 4
new part which will not have this life limitation.
3b. Power Drive Unit Gearbox P667A4001-01 Service Bulletin (SB 787-27-0002) to be released for 24,000 Flight Cycles 2
new part which will not have this life limitation.
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ITEM QUANTITY
4. Hydraulics
4a.(i) Static-Dissipative Hydraulic Isolator CA489-06B Line Number (LN) 7-34. Full life expected rather than 54,000 Flight Hours 1 LW Main Tank
the life limit listed pending completion of system 2 RW Main Tank
endurance tests. 1 RW Surge Tank
4a.(ii) Static-Dissipative Hydraulic Isolator CA489-06D LN 35-54. Full life expected rather than the life limit 54,000 Flight Hours 1 LW Main Tank
listed pending completion of system endurance tests. 2 RW Main Tank
1 RW Surge Tank
LN 55 and on (787-8 only). Full life expected rather 1 LW Main Tank
than the life limit listed pending completion of system
endurance tests.
4b.(i) Static-Dissipative Hydraulic Isolator CA489-08C LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 5 LW Main Tank
2 Center Tank
4b.(ii) Static-Dissipative Hydraulic Isolator CA489-08D LN 35-54. Full life expected rather than the life limit 54,000 Flight Hours 5 LW Main Tank
2 Center Tank
LN 55 and on (787-8 only). Full life expected rather 5 LW Main Tank
than the life limit listed pending completion of system 6 RW Main Tank
2 Center Tank
LN 126-478 (787-9 only). Full life expected rather 6 LW Main Tank
than the life limit listed pending completion of system 6 RW Main Tank
2 Center Tank
LN 479 and on (787-9 and 787-10). Full life expected 5 LW Main Tank
rather than the life limit listed pending completion of 5 RW Main Tank
system endurance tests. 1 RW Surge Tank
1 Center Tank
4c.(i) Static-Dissipative Hydraulic Isolator CA489-12B LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 1 LW Main Tank
3 Center Tank
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ITEM QUANTITY
4c.(ii) Static-Dissipative Hydraulic Isolator CA489-12D LN 35 and on (787-8); LN 126-478 (787-9) 54,000 Flight Hours 1 LW Main Tank
Full life expected rather than the life limit listed 1 RW Main Tank
pending completion of system endurance tests. 3 Center Tank
LN 479 and on (787-9 and 787-10). Full life expected 1 LW Main Tank
rather than the life limit listed pending completion of 1 RW Main Tank
system endurance tests. 2 Center Tank
4d.(i) Static-Dissipative Hydraulic Isolator CA490-06B LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 1 LW Main Tank
4d.(ii) Static-Dissipative Hydraulic Isolator CA490-06D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 1 LW Main Tank
expected rather than the life limit listed pending 1 RW Main Tank
completion of system endurance tests.
4e.(i) Static-Dissipative Hydraulic Isolator CA490-08C LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 1 Center Tank
listed pending completion of system endurance tests.
4e.(ii) Static-Dissipative Hydraulic Isolator CA490-08D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 1 Center Tank
expected rather than the life limit listed pending
4f.(i) Static-Dissipative Hydraulic Isolator CA490-10B LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 1 Center Tank
4f.(ii) Static-Dissipative Hydraulic Isolator CA490-10D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 1 Center Tank
4g.(i) Static-Dissipative Hydraulic Isolator CA491-04B LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 1 LW Main Tank
4g.(ii) Static-Dissipative Hydraulic Isolator CA491-04D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 1 LW Main Tank
4h.(i) Static-Dissipative Hydraulic Isolator CA491-06B LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 6 LW Main Tank
4h.(ii) Static-Dissipative Hydraulic Isolator CA491-06D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 6 LW Main Tank
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ITEM QUANTITY
4j.(i) Static-Dissipative Hydraulic Isolator CA491-08C LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 1 LW Main Tank
4j.(ii) Static-Dissipative Hydraulic Isolator CA491-08D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 1 LW Main Tank
4k.(i) Static-Dissipative Hydraulic Isolator CA491-10B LN 7-33. Full life expected rather than the life limit 54,000 Flight Hours 2 Center tank
4k.(ii) Static-Dissipative Hydraulic Isolator CA491-10D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 2 Center tank
4l.(i) Static-Dissipative Hydraulic Isolator CA491A-06B LN 7-34. Full life expected rather than the life limit 54,000 Flight Hours 2 LW Surge Tank
listed pending completion of system endurance tests. 1 RW Surge Tank
1 RW Dry Bay
4l.(ii) Static-Dissipative Hydraulic Isolator CA491A-06D LN 35 and on (787-8, 787-9, and 787-10). Full life 54,000 Flight Hours 2 LW Surge Tank
expected rather than the life limit listed pending 1 RW Surge Tank
completion of system endurance tests. 1 RW Dry Bay
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ITEM QUANTITY
5. Landing Gear
5a.(i) Nose Wheel Steering Valve module 2-8300-4 Service Bulletin to be released for new part long 13,750 Flight Cycles 1
before life limit. Will only impact a few early airplanes.
5a.(ii) Nose Wheel Steering Valve module 2-8300-5 Service Bulletin to be released for new part long 13,750 Flight Cycles 1
before life limit. Will only impact a few early airplanes.
5b. Main Landing Gear Door Uplock 2-8325-4 (LH) Limited to production LN 4-19. Boeing Service Bulletin 13,750 Flight Cycles 2
Mechanism 2-8326-4 (RH) B787-81205-SB320003-00 provides warranty (1 for each Part No.)
information and instructions for replacement of life-
limited part with non-life-limited part.
5c. Main Landing Gear Door Uplock 2-8325-50 (LH) Limited to production LN 20 and on. Boeing Service 13,750 Flight Cycles 2
Mechanism 2-8326-50 (RH) Bulletin B787-81205-SB320004-00 provides warranty (1 for each Part No.)
information and instructions for replacement of life-
limited part with non-life-limited part.
5d. Main Landing Gear Door Uplock 2-8309-3 P/N 2-8309-4, which is not life-limited, is the preferred 3,500 Flight Cycles 2
Actuator spare for P/N 2-8309-3. Boeing Service Bulletins
B787-81205-SB320003-00 and B787-81205-
SB320004-00 provide warranty information and
replacement instructions.
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ITEM QUANTITY
6. Propulsion – Exhaust System – Rolls-Royce Trent 1000
6a. Primary Exhaust Nozzle 725Z4100-9 P/N 725Z4100-11, which is not life-limited, is the 5,300 Flight Cycles 2
preferred spare for P/N 725Z4100-9. Boeing Service
Bulletin B787-81205-SB780006 provides warranty
information and replacement instructions.
6b. Primary Exhaust 725Z4200-7 P/N 725Z4200-11, which is not life-limited, is the 5,300 Flight Cycles 2
Forward Centerbody preferred spare for P/N 725Z4200-7. Boeing Service
6c. Primary Exhaust Nozzle – 725Z4100-5 P/N 725Z4100-11, which is not life-limited, is the 5,300 Flight Cycles 2
Lightweight preferred spare for P/N 725Z4100-5. Boeing Service
6d. Primary Exhaust 725Z4200-9 P/N 725Z4200-11, which is not life-limited, is the 5,300 Flight Cycles 2
Forward Centerbody – Lightweight preferred spare for P/N 725Z4200-9. Boeing Service
7. Propulsion – Thrust Reverser Actuation System (TRAS) – Rolls-Royce Trent 1000
7a.(i) Actuator, Locking 725Z3161-175 Service Bulletin to be released for new part which will 5,500 Flight Cycles 8
not have this life limitation.
7a.(ii) Actuator, Locking 725Z3161-215 Service Bulletin to be released for new part which will 5,500 Flight Cycles 8
7e. Stow Tube 725Z3161-123 Part to remain life limited. However it is no longer 5,500 Flight Cycles 2
used/installed on any aircraft.
7g. Stow Tube 725Z3161-125 Part to remain life limited. However it is no longer 5,500 Flight Cycles 2
used/installed on any aircraft.
7n. Feedback Unit 725Z3161-151 Service Bulletin to be released for new part which will 5,500 Flight Cycles 2
not have this limitation.
7p. Feedback Unit 725Z3161-153 Service Bulletin to be released for new part which will 5,500 Flight Cycles 2
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ITEM QUANTITY
7q. Manual Drive Unit 720Z3161-167 Service Bulletin to be released for new part which will 5,500 Flight Cycles 4
7r. Hydraulic Control Unit 720Z3161-213 Service Bulletin to be released for new part which will 5,500 Flight Cycles 2
8. Propulsion – Thrust Reverser Actuation System – General Electric GEnx-1B
8a. Actuator, Locking 721Z3161-215 Service Bulletin to be released for new part which will 5,500 Flight Cycles 8
8l. Feedback Unit 721Z3161-151 Service Bulletin to be released for new part which will 5,500 Flight Cycles 2
8m. Feedback Unit 721Z3161-153 Service Bulletin to be released for new part which will 5,500 Flight Cycles 2
8n. Manual Drive Unit 720Z3161-167 Service Bulletin to be released for new part which will 5,500 Flight Cycles 4
8p. Hydraulic Control Unit 720Z3161-213 Service Bulletin to be released for new part which will 5,500 Flight Cycles 2
9. Propulsion – Power Door Opening System (PDOS) – Rolls-Royce Trent 1000
9a. PDOS Power Pack 725Z3191-27 Additional testing scheduled to develop full life design. 27,500 Flight Cycles 2
9c. Thrust Reverser Hold Open Rod 725Z3192-9 Additional testing scheduled to develop full life design. 5,500 Flight Cycles 4
10. Propulsion – Power Door Opening System (PDOS) – General Electric GEnx-1B
10a. PDOS Power Pack 725Z3191-27 Additional testing scheduled to develop full life design. 27,500 Flight Cycles 2
10c. Thrust Reverser Hold Open Rod 721Z3192-9 Additional testing scheduled to develop full life design. 5,500 Flight Cycles 4
11. Pressurized Doors
11a. Emergency Power Assist System 41004654-4 P/N 41004654-5, which provides the intended design 2 Years 8
(EPAS) Pressure Reservoir life, is the preferred spare for P/N 41004654-4.
Assembly
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E. OTHER AIRWORTHINESS LIMITATIONS – SYSTEMS AND STRUCTURES
These System and Structures Airworthiness Limitations are a result of Model 787 airplane certification activities with the U.S. FAA and are part of the
Airworthiness Limitations section of the Instructions for Continued Airworthiness. These maintenance actions are mandatory. These Airworthiness
Limitations may only be revised with the approval of the FAA Oversight Office.
SYSTEM AIRWORTHINESS LIMITATION NO. 1

INSPECTION OF THE FUEL OIL HEAT EXCHANGER FOLLOWING FUEL TANK ENTRY – 787-8 AIRPLANES WITH TRENT 1000 ENGINES
(FAA EXEMPTION 10199B, EASA CRI E-20 Issue 3)
Operation of a Model 787-8 airplane after the following dates is prohibited unless a modification to provide indication to the flight crew of gross fuel
contamination is installed:
1. April 30, 2017: In accordance with FAA Exemption No. 10199B, as referenced in FAA Type Certificate Data Sheet (TCDS) T00021SE.
2. December 31, 2016: In accordance with EASA Deviation CRI E-20 Issue 3, as referenced in EASA Type Certificate Data Sheet (TCDS)
EASA.IM.A.115.
• Airplane Applicability:
787 Production Line Numbers 7, 8, 9, 24, 31, 40, 41, 42, 47, 48, 51, 56, 59, 61, 63, 66, 67, 68, 69, 74, 78, 80, 83, 86, 87, 88, 97, 101, 102, 107, 108, 110,
111, 112, 113, 114, 118, 120, 121, 128, 130, 132, 136, 140, 147, 148, 149, 153, 156, 161, 165, 166, 173, 177, 178, 179, 183, 185, 187, 190, 193, 195, 197,
and 199.
• Engine Applicability:
Rolls-Royce Trent-1000 Engine Serial Numbers 10047 - 10225.
D011Z009-03-01
Unless the design change noted below has been made to the applicable airplanes, the following maintenance actions must be performed:
1. Following center wing tank purging and maintenance activity inside the center wing fuel tank, perform the following tasks if fuel has been added to the
center tank:
a. Prior to accumulating 20 flight hours after fuel has been added to the center tank, perform a borescope inspection for abnormal or significant
contamination of the left engine Fuel/Oil Heat Exchanger front face in accordance with Boeing AMM 79-21-11, Task 79-21-11-00A-280C-A. If
abnormal or significant fuel system contamination is found, troubleshoot the source of the fuel system contamination.
b. Prior to accumulating 40 flight hours after fuel has been added to the center tank, perform a borescope inspection for abnormal or significant
contamination of the right engine Fuel/Oil Heat Exchanger front face in accordance with Boeing AMM 79-21-11, Task 79-21-11-00A-280C-A. If
abnormal or significant fuel system contamination is found, troubleshoot the source of the contamination and remove unacceptable contaminates
from the fuel system.
2. Following a left or right engine low pressure fuel filter replacement due to the ENG FUEL FILTER L(R) EICAS message, perform the following task:
a. Perform a borescope inspection for abnormal or significant contamination of the corresponding engine Fuel/Oil Heat Exchanger front face in
accordance with Boeing AMM 79-21-11, Task 79-21-11-00A-280C-A. If abnormal or significant fuel system contamination is found, troubleshoot
the source of the fuel system contamination.
This limitation is removed from the applicable airplanes when:
Boeing production change CN-AA28953 or Service Bulletin B787-81205-SB730005-00 is incorporated. Delivered 787-8 airplanes with Trent 1000 engines
cannot be operated after the following dates, unless the design change listed above is incorporated:
EASA.IM.A.115.
D011Z009-03-01
If an engine installed on-wing is the Trent 1000- 2 model (e.g., Trent 1000-A2, Trent 1000-C2, Trent 1000-D2, Trent 1000-E2, Trent 1000-G2, Trent 1000-
H2, Trent 1000-J2, Trent 1000-K2, Trent 1000-L2), or has Rolls-Royce Modifications 73-H605 and 73-H684 incorporated, it is prohibited for it to be replaced
with an engine that is not the Trent 1000- 2 model, or does not have Rolls-Royce Modifications 73-H605 and 73-H684 incorporated.

ENGINE OIL CONSUMPTION RATES – 787-8 AIRPLANES WITH TRENT 1000 ENGINES
The approved maximum normal oil consumption rate for the Trent 1000 engine installed on the Model 787-8 airplane has been established as 0.63 quart
(0.60 liter) per hour.
The maximum oil consumption rate is used to show compliance with Title14 CFR § 25.1011(b), and is a limitation to ensure the maximum airplane fuel
endurance does not exceed each installed engine's usable oil quantity, thereby preventing a common mode loss of all engine thrust. The maximum airplane
fuel endurance is 24.5 flight hours and is calculated with the minimum crew, minimum equipment, no payload and the maximum quantity of usable fuel
without reserves. The engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity of oil consumed by the
total number of flight hours; oil consumption calculations over less than 10 flights can give an incorrect value.
Operation of a Model 787-8 airplane with an engine oil consumption rate higher than these limits is not authorized, except as allowed under a special flight
permit authorized under Title 14 CFR § 21.197 and § 21.199.
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INSPECTION OF THE FUEL PUMP STRAINER FOLLOWING CENTER WING FUEL TANK ENTRY – 787-8 AIRPLANES WITH GEnx-1B ENGINES
(FAA EXEMPTION 10268B, EASA CRI E021 Issue 3)
Operation of a Model 787-8 airplane after the following dates is prohibited unless a modification to provide indication to the flight crew of gross fuel
contamination is installed:
EASA.IM.A.115.
787 Production Line Numbers 20, 21, 23, 25, 26,27, 28, 29, 30, 32, 33, 34, 35, 36, 37, 38, 39, 43, 44, 45, 46, 49, 50, 52, 53, 54, 55, 57, 58, 60, 62, 64, 65,
70, 71, 72, 73, 75, 76, 77, 79, 81, 82, 84, 85, 89, 90, 91, 92, 93, 94, 95, 96, 98, 99, 100, 103, 104, 105, 106, 109, 115, 116, 117, 119, 122, 123, 124, 125,
127, 129, 131, 134, 135, 137, 138, 141, 142, 143, 144, 145, 150, 151, 152, 154, 155, 157, 158, 159, 160, 162, 163, 164, 167, 168, 170, 171, 172, 175, 182,
184, 186, and 191.
• Engine Applicability:
GE GEnx-1B Engine Serial Numbers 956101 - 956293, 956295, 956297-956329, 956331, 956333-956340, 956343, 956344, 956347, 956349, 956350,
956354-956356, 956361, 956363, 956364, and 956367.
These engines must have GE Service Bulletin 79-0018 incorporated, prior to installation on any airplane after the following dates:
EASA.IM.A.115.
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Unless the modification has been made to the applicable airplanes and engines, the following maintenance actions must be performed:
1. Following center wing fuel tank purging and maintenance activity inside the center wing fuel tank, perform the following tasks if fuel has been added to
the center tank:
a. After the next flight check for the presence of the ENG FUEL STRAINER L(R) EICAS status message and interrogate the Central Maintenance
Computing Function (CMCF) to check for the presence of the FUEL BOOST STRAINER L(R) impending bypass maintenance message.
Troubleshoot the source of the fuel system contamination if the messages are present.
b. Prior to accumulating 20 flight hours after fuel has been added to the center tank, perform the Main Fuel Pump Strainer Inspection procedure on
the left engine in accordance with Boeing AMM 73-11-04, Task 73-11-04-00B-280A-A. Collect any material removed from the fuel pump strainer to
troubleshoot the source of the fuel system contamination.
c. Prior to accumulating 40 flight hours after fuel has been added to the center tank, perform the Main Fuel Pump Strainer Inspection procedure on
the right engine in accordance with Boeing AMM 73-11-04, Task 73-11-04-00B-280A-A. Collect any material removed from the fuel pump strainer
to troubleshoot the source of the fuel system contamination.
The limitation is removed from the airplane when airplane has CN-AA32218 or Boeing Service Bulletin B787-81205-SB790002-00 incorporated.
For any airplane, it is prohibited to replace an on-wing engine that has the new MFOHX (P/N 2550M15P01) with an engine that contains one of the serial
numbers: 956101 - 956293, 956295, 956297 - 956329, 956331, 956333 - 956340, 956343, 956344, 956347, 956349, 956350, 956354 - 956356, 956361,
956363, 956364, 956367 without GE Service Bulletin 79-0018 incorporated.
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ENGINE OIL CONSUMPTION RATES – 787-8 AIRPLANES WITH GEnx-1B ENGINES
The approved maximum normal oil consumption rate for the GEnx-1B engine installed on 787-8 airplanes has been established as 0.42 US quart (0.40 liter)
per hour.
The maximum oil consumption rate is used to show compliance with Title 14 CFR § 25.1011(b), and is a limitation to ensure the maximum airplane fuel
fuel endurance is calculated with the minimum crew, minimum equipment, no payload and the maximum quantity of usable fuel without reserves. The
engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity of oil consumed by the total number of flight
hours; oil consumption calculations over less than 10 flights can give an incorrect value.
Operation of 787-8 airplanes with an engine oil consumption rate higher than these limits is not authorized, except as allowed under a special flight permit
authorized under Title 14 CFR § 21.197 and § 21.199.

ENGINE POST-SHUTDOWN FUEL VAPOR VENTING – 787-8 AIRPLANES WITH GEnx-1B ENGINES
Operation of a Model 787-8 airplane with GEnx-1B engine after December 31, 2014 is prohibited unless a modification to eliminate Engine Post-shutdown
Fuel Vapor Venting is installed in accordance with GE’s GEnx-1B S/B 73-0011.
787 Production Line Numbers 23, 27, 29, 33, 35, 37, 38, 44, 45, 46, 49, 50, 52, 53, 54, 55, 57, 58, 60, 62, 64, 65, 70, 71, 75, 77, 82, and 84 were delivered
with engines that must have GE’s GEnx-1B S/B 73-0011 incorporated before December 31, 2014.
• Engine Applicability
GEnx-1B Engines that must have GE’s GEnx-1B S/B 73-0011 incorporated prior to December 31, 2014: GEnx-1B Engines Serial Numbers 956102 through
956106, 956109 through 956130, 956140 through 956151, 956154, 956155, 956157, 956160 through 956169, 956171 through 956178, 956181 through
956188, 956192, 956194 through 956196.
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ENGINE OPERATING LIMITATION FOR ICE CRYSTAL ICING – 787-8, 787-9, AND 787-10 AIRPLANES WITH GEnx-1B ENGINES
For GEnx-1B powered airplanes, following flight crew report of Engine Rollback, or ENG THRUST X EICAS Caution message in Ice Crystal Icing conditions,
perform borescope of all HPC Stage 1 blade airfoils with borescope prior to the next revenue service flight for both engines. Refer to Boeing AMM Task
B787-A-G71-00-00-24A-280A-A.

ENGINE OIL CONSUMPTION RATES – 787-9 AIRPLANES WITH TRENT 1000 ENGINES
fuel endurance is 23.5 flight hours and is calculated with the minimum crew, minimum equipment, no payload and the maximum quantity of usable fuel
without reserves. The engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity of oil consumed by the
total number of flight hours; oil consumption calculations over less than 10 flights can give an incorrect value.
Operation of a Model 787-9 airplane with an engine oil consumption rate higher than these limits is not authorized, except as allowed under a special flight
permit authorized under Title 14 CFR § 21.197 and § 21.199.
D011Z009-03-01
SYSTEM AIRWORTHINESS LIMITATION NO. 8 - WING UPPER PANEL VENT STRINGER INNER FLANGE
This AWL was deleted in January 2017 following successful lightning testing and analysis which confirmed that adhesive fillet cracking will not create a
hazardous condition.

RAM AIR TURBINE GENERATOR CONTROL UNIT – 787-9 AIRPLANES
Operation of a Model 787-9 airplane with Ram Air Turbine (RAT) Generator Control Unit (GCU) Part Number 7000013H02 after August 31, 2015 is
prohibited. Boeing will release service data providing instructions for installation of a superseding Part Number 7101704H01 prior to that date.
(Reference Time Limited Grant of Exemption, Exemption No. 11002).

MODE CONTROL PANEL – 787-9 AIRPLANES
Operation of a Model 787-9 airplane with Mode Control Panel (MCP) Part Number 4091640-902 after November 30, 2015 is prohibited. Boeing will release
service data providing instructions for installation of a superseding Part Number 4091640-903 prior to that date. (Reference Time Limited Grant of
Exemption, Exemption No. 11002).
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SEP 2016 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-120

787-8/9 FLIGHT DECK ANNUNCIATION OF GEnx-1B ENGINE VARIABLE BLEED VALVE ICE PROTECTION SYSTEM
Operation of a Model 787-8/9 Series airplane equipped with GEnx-1B engines after March 31, 2016 is prohibited unless a modification to provide flight-deck
annunciation of operation of the engine variable bleed valve ice protection system is installed in accordance with a method approved by the FAA Oversight
Office. The FAA Oversight Office approval must specifically reference this airworthiness limitation.

UNCONTROLLABLE HIGH THRUST DUE TO THRUST CONTROL MODULE FAILURES - 787-8 AND 787-9 AIRPLANES WITH GEnx-1B ENGINES
Operation of a Model 787-8/9 airplane equipped with GEnx-1B engines, produced and delivered before December 31, 2018, is prohibited after December
31, 2020, unless a modification is incorporated to fully accommodate single failures of the Thrust Control Module that result in Uncontrollable High Thrust
while the airplane is on the ground. The modification must use a method approved by the FAA Oversight Office and the service information must specifically
reference this airworthiness limitation.

REPORTING UNCONTROLLABLE HIGH THRUST FAILURE CONDITIONS:
Title 14 CFR § 121.703, § 125.409, and § 135.415 state operator requirements for service difficulty reports. Included in the requirements is a clarification
that service difficulty reports include any "failure, malfunction, or defect in an aircraft that occurs or is detected at any time if, in its opinion, that failure,
malfunction, or defect has endangered or may endanger the safe operation of an aircraft". In many cases a reportable failure or malfunction will be obvious,
but there are some failure modes related to uncontrollable high thrust that are reportable but may not be obvious. The following information is provided to
assist the operators in identifying reportable malfunctions related to uncontrollable high thrust.
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The FAA has concluded that the loss of capability to control thrust due to a failure of the engine thrust control system may endanger the aircraft. This
includes any malfunctions having one or more of the following characteristics:
• Auto-acceleration or uncommanded thrust change to higher power
• Stuck thrust lever above idle power
• Inability to reduce thrust
Although some of these incidents may not appear to be safety related, documenting the events is important to ensure the present level of safety is
maintained and/or to identify failure conditions that must be corrected.
When filing a report of such an event with the FAA, the operator is requested to include in the description of the event one or more of the following phrases:
• "thrust control"
• "no response to thrust lever"
• "auto-acceleration"
• "uncontrolled high thrust"
In addition, the following information should be included in the report:
• Event description
• Flight Crew action
• Maintenance action
• List of affected or removed components
Reports should be submitted to the local FAA Administrator that handles the appropriate reporting responsibility for Title 14 CFR § 121.703, § 125.409, and
§ 135.415. In addition to filing reports with the FAA, it is recommended that a copy be sent to Boeing and to the engine manufacturer.
D011Z009-03-01

ENGINE SMOKE NUMBER EMISSIONS - 787-8, 787-9, AND 787-10 AIRPLANES WITH TRENT 1000-TEN ENGINES:
Airplanes equipped with a Trent 1000-TEN engine marked EXEMPT on the engine identification plate for compliance to §34.21(e)(2) as identified in their
permanent powerplant record per FAA exemption 17613 may not be operated after December 31, 2022.

ENGINE OIL CONSUMPTION RATES - 787-10 AIRPLANES WITH TRENT 1000 ENGINES:
The maximum oil consumption rate is used to show compliance with 14 CFR 25.1011(b), and is a limitation to ensure the maximum airplane fuel endurance
does not exceed each installed engine's usable oil quantity, thereby preventing a common mode loss of all engine thrust. The maximum airplane fuel
endurance is 24.5 flight hours and is calculated with the minimum crew, minimum equipment, no payload and the maximum quantity of usable fuel without
reserves. The engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity of oil consumed by the total
number of flight hours; oil consumption calculations over less than 10 flights can give an incorrect value. Any alternative method of calculating the oil
consumption rate must be approved by the FAA Oversight Office.
Operation of a Model 787-10 with an engine oil consumption rate higher than these limits is not authorized, except as allowed under a special flight permit
authorized under 14 CFR 21.197 and 21.199.
D011Z009-03-01

ENGINE OIL CONSUMPTION RATES - 787-9 AND 787-10 AIRPLANES WITH GEnx-1B ENGINES
The approved maximum normal oil consumption rate for the GEnx-1B engine installed on 787-9 and 787-10 airplanes has been established as 0.45 US
quart (0.43 liter) per hour.
fuel endurance is calculated with the minimum crew, minimum equipment, no payload and the maximum quantity of usable fuel without reserves. The
engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity of oil consumed by the total number of flight
hours; oil consumption calculations over less than 10 flights can give an incorrect value.
Operation of 787-9 and 787-10 airplanes with an engine oil consumption rate higher than these limits is not authorized, except as allowed under a special
flight permit authorized under Title 14 CFR § 21.197 and § 21.199.

ENGINE OPERATING LIMITATION IN ICE CRYSTAL ICING CONDITIONS – 787-10 AIRPLANES WITH GEnx-1B/P2 ENGINES
Operation of Boeing Model 787-10 airplanes equipped with GEnx-1B/P2 engine model is prohibited after December 19, 2019 unless the General Electric
GEnx-1B electronic engine control (EEC) software version B200 or later is installed on both engines. Installation of the software in-service must use a
method approved by the FAA Oversight Office and the service information must specifically reference this airworthiness limitation.
D011Z009-03-01
STRUCTURES AIRWORTHINESS LIMITATION NO. 1
Background: The 787 fuel tank access doors are compliant with 25.963 as impact resistant doors are installed in locations where they could be subject to
tire or engine fragment impacts. In addition to clear marking, the 787 doors were designed to have a physical barrier preventing non-impact doors being
installed in locations requiring impact resistant doors. Due to a design change, early 787-8 Line Numbers had the physical features omitted. These physical
features are being reincorporated into production units, beginning at Line Number 60. All units have the stenciling and correct door installation at time of
delivery. This occurs on the lower wing surface where high impact concerns are located.
Main and Center Fuel Tank Access Doors Installations
• Interval: 6 YR/12,000 Flight Cycles (whichever comes first) and following main and center fuel tank access door removal and re-installation.
• Airplane Applicability: 787-8 Production Line Numbers 7 through 59.
Main Fuel Tank Access Panel Inspection
Concern: Potential installation of a non-impact resistant fuel tank access door in a location where an impact resistant fuel tank access door is required.
Mitigations: At the specified inspection interval and when fuel tank access doors have been removed and installed:
1. Identify required main tank impact resistant door locations (refer to Boeing AMM B787-A-28-11-01-00A-520A-A, all door locations inboard of the engine
nacelle).
2. Verify that all impact resistant doors have the stencil "IMPACT RESISTANT DOOR" applied to the exterior surface
(refer to Boeing AMM B787-A-28-11-01-00A-520A-A).
3. Verify that all impact resistant doors each have 24 fastener holes (refer to Boeing AMM B787-A-28-11-01-00A-520A-A).
NOTE: All fuel tank access hole locations outboard of the engine nacelle contain non-impact resistant doors that have 23 fastener holes or less.
D011Z009-03-01
Center Fuel Tank Access Panel Inspection
Concern: Potential installation of a non-impact resistant fuel tank access door in a location where an impact resistant fuel tank access door is required.
Mitigations: At the specified inspection interval and when fuel tank access doors have been removed and installed:
1. Identify required center tank impact resistant door locations (refer to Boeing AMM B787-A-28-11-02-00A-520A-A, all door locations inboard of the
engine nacelle).
2. Verify that all impact resistant doors have the stencil "IMPACT RESISTANT DOOR" applied to the exterior surface (refer to Boeing AMM B787-A-28-11-
02-00A-520A-A).
3. Verify that all impact resistant doors each have 24 fastener holes (refer to Boeing AMM B787-A-28-11-02-00A-520A-A).
NOTE: All fuel tank access hole locations outboard of the engine nacelle contain non-impact resistant doors that have 23 fastener holes or less.
D011Z009-03-01
Background: The main landing gear forward trunnion support upper housing increases the vertical fusing capability of the forward trunnion of the main
landing gear. Four bearing pads are located between the main landing gear forward trunnion upper housing and the main landing gear forward trunnion
housing and are attached to the upper housing. During fatigue testing, at approximately 22,000 flight-cycles, the bearing pads were found partially migrated
and retaining features were found fractured. The loss of the bearing pads from between the main landing gear forward trunnion upper housing and the main
landing gear forward trunnion housing will reduce the vertical fusing capability of the forward trunnion of the main landing gear. This could result in the
premature fusing and loss of the main landing gear during a take-off roll with an airplane at maximum take-off weight. The highest vertical loads
experienced by the landing gear are during take-off roll with an airplane at maximum take-off weight and certain runway conditions. The loss of the main
landing gear would result in significant damage to the surrounding structure.
Support Fitting Bearing Pad, Main Landing Gear Forward Trunnion Inspection
• Threshold: 2 YR/3,500 Flight Cycles (whichever comes first)
• Interval: 2 YR/3,500 Flight Cycles (whichever comes first)
• Airplane Applicability: 787-8 Production Line Numbers 7, 8, 9, 23, 24, 29, 31, 33, 35, 37, 38, 40, 41, 42, 46, 47, 48, 51, 54, 56, and 60, unless terminating
action of Service Bulletin 787-57-0006 has been done.
Concern: Potential migration of main landing gear forward trunnion support upper housing bearing pads.
Mitigations: At the specified interval:
1. Do a detailed inspection of the bearing pads located between the main landing gear forward trunnion upper housing and forward trunnion housing for
migrated or missing bearing pads. For inspection zone and access information, refer to MPD Section 2, Item Number 57-522-00
(Task Card 57-522-01).
D011Z009-03-01
AUG 2017 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-127

Wing Upper Panel Vent Stringer Cutout Inspection
This AWL was deleted in August 2017, as it was determined that vent stringer cutouts will maintain ultimate load capability with barely visible impact
damage, thus rendering the inspection unnecessary.

787-9 General Electric Forward Engine Mount Barrel Nut Replacement
Background: The forward engine mount on the 787 with General Electric engines is very similar to the 747-8 in configuration and loading. Barrel nuts are
located in the forward engine mount and are used to fasten the forward engine mount to the pylon forward mount bulkhead. Boeing Service Bulletin 747-
71A2329 was issued to inspect the barrel nuts on the 747-8 forward engine mounts. A total of 8 barrel nuts have been found with cracks. A newly designed
barrel nut certified on the 747-8 has new features that improve durability. A lower installation torque is also used to reduce the preload stress in the
barrel nut.
• Threshold: Within three years of airplane delivery.
• Interval: Not applicable
• Airplane Applicability: 787-9 airplanes with General Electric engine and forward engine mount installations 711Z4010-5, 711Z4010-6, 711Z4010-7 and
711Z4010-8 with barrel nuts SL4081C14SP1.
Concern: If the existing barrel nuts on the forward engine mount are not replaced, the existing barrel nuts could become cracked. A crack on both sides of
the barrel nut will cause complete failure of the barrel nut. A complete failure of two or more barrel nuts on the same engine reduces the load capacity of the
forward engine mount and could result in separation of an engine from the airplane.
Mitigation: By the specified threshold:
1. Replace the forward engine mount barrel nuts per Boeing Service Bulletin B787-81205-SB710026-00. No airplane may be operated beyond the stated
threshold (or operating limit) until the service bulletin is approved by the FAA and the barrel nut replacement is accomplished. After the newly designed
barrel nuts are installed per Service Bulletin B787-81205-SB710026-00, the installation of barrel nut SL4081C14SP1 is prohibited.
D011Z009-03-01
787 Forward Engine Mount Barrel Nut Limited Interchangeability
• Airplane Applicability: All 787 airplanes.
• Limitation: Forward engine mount barrel nut Part Number SL4750NA can replace but cannot be replaced by barrel nut Part Number SL4081C14SP1.

787-10 and 787-8 at LN 733 and-on: Vertical Stabilizer Fin Root Tension Bolts
Background: The 787 vertical stabilizer is attached to the aft fuselage through eight root attachment fittings and 16 tension bolts. The 787 fin root joint is
similar to that used on the Boeing Model 777 with the exception of the composite CFRP fin deck. To address aspects associated with the use of a composite
fin deck, replacement of the instrumented fin root tension bolts at or prior to fatigue threshold is required.
Prior to the specified fatigue threshold per PSE # 55-37-05 or bolt replacement:
1. Inspect the instrumented fin root tension bolts (Refer to Boeing MPD Item Number 55-508-00 and Boeing Task Card 55-508-00-1).
2. Threshold: No later than 6,000 flight cycles or 3 years from the date of aircraft delivery (whichever comes first).
3. Interval: Repeat the inspection at intervals not to exceed 6,000 flight cycles or 3 years (whichever comes first).
4. This pre-threshold repeated inspections shall be replaced by the bolt replacement specified below at or prior to the fatigue threshold.
At or prior to the specified fatigue threshold:
1. Remove and replace the instrumented fin root tension bolts (Refer to Boeing AMM B787-A-55-37-04-00A-520A-A, Tension Bolt Removal and AMM
B787-A-55-37-04-00A-720A-A for Vertical Fin Tension Bolt Installation procedures).
a. Threshold: As defined in Table 1, "Airworthiness Limitations - Supplemental Structural Fatigue Inspections", PSE item: 55-37-05.
b. Interval: Not Applicable
D011Z009-03-01
2. In lieu of instrumented tension bolt removal and replacement, at or before fatigue threshold perform torque verification:
a. Threshold: As defined in Table 1, "Airworthiness Limitations - Supplemental Structural Fatigue Inspections", PSE item: 55-37-05.
b. Interval: Post-Threshold repeat interval not to exceed 1500 flight cycles.
c. Perform torque verification of the instrumented tension bolts, refer to Boeing Task Card 55-508-00-01, Section 1.C.(6) Table 2.
• Airplane Applicability: All 787-10 airplanes, 787-8 at LN 733 and-on.
D011Z009-03-01

Side of Body Rib Web Inspection at System Penetrations with Satellite Holes
Background: The Side of Body Rib Web is a machined aluminum web with mechanically fastened stiffeners that carries vertical loads introduced by wing
dihedral as well as FWD/AFT loads introduced by the Trapezoidal Panel. During 787 Full Scale Fatigue Testing, cracking was found common to the left and
right hand side of body rib webs at system penetration satellite holes. Fatigue cracking allowed to progress undetected, can grow to weaken the wing
structure such that it cannot sustain limit load, which could adversely affect the structural integrity of the airplane.
Airplane Applicability: 787-8, Line Number 6 Only
Concern: Potential for an undetected cracking condition may affect the side of body rib webs ability to sustain limit load.
Mitigation: At the specified threshold and interval conduct a High Frequency Eddy Current (HFEC) inspection in accordance with 787 NDT Manual, Part 6,
51-00-01 of the left and right hand side of body rib webs at all system penetrations with satellite holes. Inspection shall be completed from the outboard side
of the rib web, common to the rib web surface around the entire periphery of the attached bulkhead fitting. Prior to inspection, removal of sealant common
to the periphery of the bulkhead fitting and adjacent side of body rib web surfaces is required.
Threshold: 6,000 Total Flight Cycles
Interval: 6,000 Flight Cycles
Refer to AMM 28-11-00 (Task B787-A-28-11-00-14A-663A-A) for removal of sealant inside the fuel tank. Refer to Document D011Z009-03-04 and
associated AMM tasks for sealant application information. Adherence to these airworthiness limitation requirements is required to prevent the development
of an ignition source within the fuel tanks.
D011Z009-03-01
F. AWLs - STRUCTURAL LIMIT OF VALIDITY (LOV)
This section provides the Limit of Validity (LOV) in accordance with the requirements of Title 14 CFR § 26.21(b)(1) Amendment 26-5 (787-8, 787-9) and
14 CFR § 25.571(b) Amendment 25-132 (787-10). This regulation requires the establishment of an airplane level limit of validity of the engineering data that
supports the structural maintenance program that corresponds to the period of time, stated as a number of total accumulated flight cycles or flight hours or
both, during which it is demonstrated that widespread fatigue damage will not occur in the airplane. The LOVs listed in the following table support operator
compliance with Title 14 CFR § 121.1115 and § 129.115 for the 787 airplane models.
LIMIT OF VALIDITY
MODEL FLIGHT CYCLE LOV FLIGHT HOUR LOV
787-8
787-9 76,000 230,000
787-10
D011Z009-03-01
APPENDIX A. POST-THRESHOLD INTERVALS FOR STRUCTURES AND ZONAL TASKS
The post-threshold repeat interval table for structures and zonal tasks has been removed. As noted in Section C, escalation of MPD Section 2 and Section
3 structural and zonal tasks is not currently allowed. As there is currently no allowance to escalate the structural and zonal tasks, there is no necessity to
de-escalate these same tasks to the original intervals defined at type certification. Therefore, this data has been removed.
D011Z009-03-01
D011Z009-03-01

2019 Jan 787 - AWL

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Ms. Elizabeth Pasztor

Dear Ms. Pasztor:

Subject: Approval of Alternative Method of Compliance (AMOC) to Airworthiness

Reference: (1) Boeing letter RA-19-00066, dated January 10, 2019

In accordance with FAA Order 8110.103, the following conditions apply:

3. This FAA AMOC is transferable with the aircraft to another owner/operator.

5. The preceding paragraph also applies to any applicable foreign-registered aircraft

COMPILED AND PUBLISHED BY:

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REVISIONS .................................................................................................................................................................................................................................. 1.0-5

LIST OF EFFECTIVE PAGES .................................................................................................................................................................................................... 1.0-19

REFERENCES ........................................................................................................................................................................................................................... 1.0-20

TERMS AND ACRONYMS ......................................................................................................................................................................................................... 1.0-21

A. SCOPE ................................................................................................................................................................................................................................... 1.0-22

B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITS.............................................................................................................................. 1.0-23

C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS ....................................................................................... 1.0-25

D. AIRWORTHINESS LIMITATIONS – LIFE LIMITS .................................................................................................................................................................. 1.0-90

E. OTHER AIRWORTHINESS LIMITATIONS – SYSTEMS AND STRUCTURES.....................................................................................................................1.0-113

F. AWLS - STRUCTURAL LIMIT OF VALIDITY (LOV).............................................................................................................................................................. 1.0-132

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APPLICABLE FEDERAL AVIATION REGULATIONS:

FAA Advisory Circular 25-19, Certification Maintenance Requirements

FAA Advisory Circular 121-22A, Maintenance Review Board (MRB) Procedures

FAA Advisory Circular 20-114, Manufacturers Service Documents

Boeing Document D634Z301, Non Destructive Testing (NDT) Manual

TERMS AND ACRONYMS

BBJ Boeing Business Jet

BCL Bottom Centerline

CFR Code of Federal Regulations

CFRP Carbon Fiber Reinforced Plastic

DTR Damage Tolerance Rating

FLS Flight Length Sensitive

LHS Left-hand Side

PSE Principal Structural Element

RHS Right-hand Side

TCL Top Centerline

AIRWORTHINESS LIMITATIONS (AWLS)

B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITS

TEMPORARY OPERATIONAL LIMIT

This approach is illustrated in the table below:

C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS

THRESHOLD (787-8/-9/-10 AIRPLANES)

• Single load path structure; or

• Remaining unobstructed PSEs which require a Supplemental Structural Fatigue Inspection.

PSE DTR Check Form Title DTR Location Threshold

PSE DTR Check Form Title DTR Location

57-13-02A Overwing Beams Web Pocket at BL 11 BS 1021-1104, 1071-1104 BL 39 BS 1011-1031, 1071-1104, BL 66 BS