787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-1787AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02FEBRUARY 2015This document has EAR data with an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 fordevelopment, 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 thisdocument on to the extent that the pagecontains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collectivework. This document includes proprietary information owned by the Boeing Company and/or one or more third parties. Treatment ofthe document and the information it contains is governed by contract withBoeing. 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,DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-blue Boeing livery are all trademarks owned by The Boeing Company; no trademark license is granted in connection with thisdocument unless provided in writing by Boeing.COMPILED AND PUBLISHED BY:MAINTENANCE PROGRAMS ENGINEERINGCOMMERCIAL AVIATION SERVICESBOEING COMMERCIAL AIRPLANE GROUPSEATTLE, WASHINGTONFEB 2015D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-2787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICTHIS PAGE INTENTIONALLY LEFT BLANKBLANK787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3TABLE OF CONTENTSREVISIONS .................................................................................................................................................................................................................................. 1.0-5LIST OF EFFECTIVE PAGES ...................................................................................................................................................................................................... 1.0-8A. INDIVIDUAL AIRPLANE (LINE NUMBER SPECIFIC) AIRWORTHINESS LIMITATIONS....................................................................................................... 1.0-9B. ACRONYMS........................................................................................................................................................................................................................... 1.0-12C. ADDITIONAL INSPECTION REQUIREMENTS..................................................................................................................................................................... 1.0-13FEB 2015D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICTHIS PAGE INTENTIONALLY LEFT BLANKBLANK787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5REVISIONSREVISION AND REVISION DESCRIPTIONFAA APPROVALAUGUST 2011Original Release (internal - never published)SEPTEMBER 2011Added Supplemental Inspection for Line Number 8.Approved by: Ken Schroer(Seattle FAA ACO)SIGNATURE ON FILE9/19/2011DECEMBER 2011Section A: Revised front matter text supplementing discussionson D011Z009-03-01 and repeat intervals, reporting of results ofstructuralinspections and removal of excess sealant when inspecting. Also updated Table Notes.Section B: Added acronym listing.Section C: Added Flight Length Sensitive Chart and DTR forms for new Side Fitting inspections.Added Supplemental Inspections for Line Numbers 4 though 64 due to NC EPD 1368125.Added Supplemental Inspections for Line Number 43 due to NC-EPD 976616.Added Supplemental Inspections for Line Number 46 due to NC-EPD 996685.Approved by: Patrice Adjibly(Seattle FAA ACO)SIGNATURE ON FILE12/7/2011DECEMBER 2011 R1Internal - never publishedDECEMBER 2011 R2Internal - never publishedDECEMBER 2011 R3Section A: Added Operational Limitation for Line Number 41 due to NC-EPD 1419558.Section B: Amended acronym listing to include BCL, S-n, and TCL.Approved by: Ivan Li(Seattle FAA BASOO)SIGNATURE ON FILE12/22/2011FEB 2015D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICJANUARY 2012Section A:Added Operational Limitation for Line Number 40 and 42 due toNC-EPDs 1510108 and 1512138. (The Operational Limitation is thesame asthat previously applied to LN 41 due to NC-EPD 1419558.)Corrected listing of affected airplanes for 53-58-xx_MRB2 due toNC-EPD 1368125. The defined limitation is applicable to all 787-8 airplanesL/N 4 through 64, however the listing of airplane variable effectivities and serial numbers inadvertently omitted ZA501, ZA502,ZA504, ZA505,and ZA175 (S/N 34505, 34492, 34491, 34487, and 34831, respectively). This information is added to the LINE NUMBER/SERIAL NUMBERlisting for the limitation associated with 53-58-xx_MRB2.Approved by: Ivan Li(Seattle FAA BASOO)SIGNATURE ON FILE2/13/2012MAY 2012Section A:Removed Operational Limitation for PSE 53-81-04_MRB5 on Line Numbers 40,41, and 42 originally imposed due toNC-EPDs 1510108,1419558, and 1512138, respectively. The removal of this limitation was facilitated via further structural evaluation of the MRB condition.Removed Note 5 from the Table Notes list.Approved by: Ivan Li(Seattle FAA BASOO)SIGNATURE ON FILE7/5/2012OCTOBER 2013Added reference to Service BulletinB787-81205-SB530007-00 to PSE 53-18-08_MRB1.Removed supplemental inspections for PSEs 53-58-0xx_MRB2 on Line Numbers 4 through 64 originally imposed due to NC-EPD 1368125.The removal of these inspections was facilitated viafurther structural evaluation of the MRB condition.Deleted Note 4 from the Table Notes list and deleted Figure 1 as they are both no longer applicable. Renumbered remaining figuresaccordingly.SIGNATURE ON FILEFAA BASOO12/11/2013JUNE 2014Section A, Section C:Added Supplemental Structural Fatigue Inspections for PSE Nos.53 58 03_MRB5 and 53-41-04_MRB5 applicable to Line Number 186 due toNC EPD 2958886. DTR Check Forms are provided in Section C, Figures 5, 6, and 7.Added FSOWL, LHS, L/N, NoE, RHS, RSOWL,and S/N to the Acronym list in Section B.SIGNATURE ON FILEFAA BASOO6/18/2014AUGUST 2014Deleted the Boeing submittal signature column from the RevisionLog to improve the layout and provide consistency across all Section9/AWL/CMR/SCI documents. A submittal signature will no longer be included in the revision log; only the FAA BASOO approval date will beshown.Added Supplemental Structural Fatigue Inspections for PSE Nos.57-10-06a_MRB7 and _MRB8 applicableto Line Number 214 due toNC EPD 3128665. The DTR Check Forms for these items are provided in Section C, Figures 8 and 9.Added “NDT – Nondestructive Testing” tothe list of acronyms in Section B.Added Figures 8 and 9 to Section C to provide the DTR Check Formsfor the new Supplemental Structural Fatigue Inspection itemsabove.SIGNATURE ON FILEFAA BASOO9/12/2014REVISION AND REVISION DESCRIPTIONFAA APPROVALFEB 2015787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-7FEBRUARY 2015Revised the table of Supplemental Structural Fatigue Inspection Requirements in Section A by adding PSE No. 57-10-06a_MRB9 for L/N 78and 57-10-06a_MRB10 for Line Number 82 due to NC-EPD 2296786.Added two DTR Check Forms supporting the additions above to Section C, as Figures 10 and 11.SIGNATURE ON FILEFAA BASOO3/2/2015REVISION AND REVISION DESCRIPTIONFAA APPROVALFEB 2015Section Page Date Section Page Date Section Page Date Section Page Date Section Page DateD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-8LIST OF EFFECTIVE PAGES787 AIRWORTHINESS LIMITATIONS - LINE NUMBER SPECIFIC1.0 1 FEB 20151.0 2 BLANK1.0 3 FEB 20151.0 4 BLANK1.0 5 FEB 20151.0 6 FEB 20151.0 7 FEB 20151.0 8 FEB 20151.0 9 OCT 20131.0 10 FEB 20151.0 11 FEB 20151.0 12 AUG 20141.0 13 OCT 20131.0 14 OCT 20131.0 15 OCT 20131.0 16 OCT 20131.0 17 JUN 20141.0 18 JUN 20141.0 19 JUN 20141.0 20 AUG 20141.0 21 AUG 20141.0 22 FEB 20151.0 23 FEB 20151.0 24 BLANKFEB 2015787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-9A. INDIVIDUAL AIRPLANE (LINE NUMBERSPECIFIC) AIRWORTHINESS LIMITATIONSPURPOSEThe purpose of this section is to identify additional or revised Airworthiness Limitation (AWL) Supplemental Structural FatigueInspection requirementsunique to specific airplanes. Only those individual airplaneslisted in this section have these additional or revised AWLs. These additional or revised AWLsare due to differences in configuration asa result of Material Review Board actions.NOTE: The Airworthiness Limitations defined in this document are in addition to the limitations defined in D011Z009-03-01. See Section C of D011Z009-03-01for requirements regarding Repeat Inspection Interval, Reporting Results of Structural Inspections,and Removal of Excess Sealant When Inspecting.The following table lists the additional Supplemental Structural Fatigue Inspection requirements for certain individual serialnumber airplanes. Each item islisted by Production Line/Serial Number, Principal StructuralElement (PSE) Number, PSE Title and Description, Location, Inspection Requirements andThreshold.LINE NUMBER/SERIAL NUMBER PSE NUMBER PSE TITLEAND DESCRIPTION LOCATION INSPECTION REQUIREMENTS THRESHOLD1, 2L/N 8 (ZA101)S/N 3448853-18-08_MRB1NWW - Aft Bulkhead ChordSection 41; Material Review BoardDisposition for Nonconformance EPD(Emergent Process Document):1269598;Fastener Hole DamageBS 277,RBL 78,WL 1381. Remove fasteners common to 418Z8210-2 at JointDefinition JD76 17.3, 412Z0500-2 JD1.005 and412Z0000-7 JD 03.178, 03.181, 03.279, 08.154,08.157, 08.159, 17.230, 20.CU008(10 locations).2. Accomplish a special detailed visual (borescoperequired) inspection of each fastener hole (10total) for damage.3. Rework/repair discrepant holes in accordance withFAA approved service document (Service BulletinB787-81205-SB530007-00).4. Restore to engineering requirements. No repeatinspections required.33,000L/N 43 (ZA382)S/N 3492553-58-03_MRB3Wheel Well Bulkhead Side Fitting - LHS,at Upper Flap Support Fitting Interface(fillet radius)MRB Disposition for NC-EPD 976616;Mislocated HolesBS 1209,LBL 95,WL 180See Figures 1 through 3.FLS (Group 2)3OCT 2013D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-10787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICL/N 46 (ZA237)S/N 3627753-58-03_MRB4Wheel Well Bulkhead Side Fitting -RHS, Outer Chord between Stringers18 and 19MRB Disposition for NC-EPD 996685;Mislocated HoleBS 1209,RBL 112,WL 223See Figure 4.33,0003L/N 186 (ZA295)S/N 3482853-58-03_MRB5Aft Wheel Well Bulkhead – BS1209 SideFitting, Right-hand Side (RHS), InnerChord, S-17R SpliceMRB Disposition for NC-EPD 2958886;Shifted Hole PatternBS 1209,RBL 106,WL 243See Figures 5 and 6.Note: Two DTR forms are provided for this detail.One form (Figure 6) is labeled "< 2.5 Hours", and oneform (Figure 7) is without an hour label. While thisdetail is not FLS, follow theinstructions provided inD011Z009-03-01 Section C, "Repeat InspectionInterval" to determinewhich form to use.44,0003L/N 186 (ZA295)S/N 3482853-41-04_MRB5Aft Wheel Well Bulkhead – BS 1209 –RHS Bulkhead Frame Splice InnerChord, S-17RMRB Disposition for NC-EPD 2958886;Shifted Hole PatternBS 1209,RBL 106,WL 243See Figure 7.44,0003L/N 214 (ZA566)S/N 3531957-10-06a_MRB7Overwing Flex-T – Web Fastener HolesHidden by RSOWL – RHS STA 1042,1055, 1064, 1088, 1090, 1101 and 1110MRB Disposition for NC-EPD 3128665;Extra Plugged HolesBS 1042-1110,RBL112,WL 192-194See Figure 8.33,0003L/N 214 (ZA566)S/N 3531957-10-06a_MRB8Overwing Flex-T – Web Fastener HolesHidden by RSOWL – RHS STA 1025MRB Disposition for NC-EPD 3128665;Extra Plugged HolesBS 1025,RBL112,WL 187-194See Figure 9.33,0003L/N 78 (ZA271)S/N 3789457-10-06a_MRB9Overwing Flex-Tee – Web FastenerHolesMRB Disposition for NoE NC-EPD2296786; Lack of Deburr onFlex-Tee No. 5BS 883 - 933,RBL 113,WL 200See Figure 10.Note: The 57-10-06a_MRB9 inspection is notrequired if airplane retrofit has been accomplished inaccordance with the terminating action defined inBoeing Service Bulletin B787 81205-SB 570016-00-001 prior to 16,000flight cycles.26,0003LINE NUMBER/SERIAL NUMBER PSE NUMBER PSE TITLEAND DESCRIPTION LOCATION INSPECTION REQUIREMENTS THRESHOLD1, 2FEB 2015787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-11TABLE NOTES:1. Thresholds designated as "FLS" are sensitive to flight length; unless otherwise noted, see D011Z009-03-01, Figure 1. All other values shown are inflight cycles.2. In addition to the stated flight cycle threshold, a calendar threshold of 22 years from date of aircraft delivery applies toall Supplemental StructuralFatigue Inspections.3. The 787-8 airplane identified may not be operated beyond 75%of the stated threshold (or operational limit) until the applicable inspection proceduresare published in the appropriate manual, validated, and accepted bythe FAA. If the applicable published inspection procedurecan not beaccomplished, an alternative FAAaccepted procedure must be used.L/N 82 (ZA464)S/N 3832157-10-06a_MRB10Overwing Flex-Tee – Web FastenerHolesMRB Disposition for NoE NC-EPD2296786; Lack of Deburr onFlex-Tee Nos. 1 and 2BS 1030 - 1091,LBL 113,WL 191See Figure 11.Note: The 57-10-06a_MRB10 inspection is notrequired if airplane retrofit has been accomplished inaccordance with the terminating action defined inBoeing Service Bulletin B787 81205-SB 570016-00-001 prior to 7,000 flight cycles.12,0003LINE NUMBER/SERIAL NUMBER PSE NUMBER PSE TITLEAND DESCRIPTION LOCATION INSPECTION REQUIREMENTS THRESHOLD1, 2FEB 2015D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-12787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICB. ACRONYMSBCLBottom CenterlineDTRDamage Tolerance RatingFLSFlight Length SensitiveFSOWLFront Spar Overwing LongeronLHSLeft-hand SideL/NLine NumberMRBMaterial Review BoardNC-EPDNonconformance - Emergent Process DocumentNDTNondestructive TestingNoENotice of EscapementPSEPrincipal Structural ElementRHSRight-hand SideRSOWLRear Spar Overwing LongeronS/NSerial NumberS-nStringer number “n”, where“n” is the integer numberdefining the fuselage stringerTCLTop CenterlineAUG 2014787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-13C. ADDITIONAL INSPECTION REQUIREMENTSFigure 1. NC-EPD976616 - PSE 53-58-03_MRB3 Wheel Well Bulkhead Side Fitting (ShortMission), L/N 43



# Inspect the LHS side fitting in fillets with freeze plug-filled holes. Inspect around the freeze plug. 53-58-03_MRB3

Wheel Well Bulkhead Side Fitti ng L/N 43 

# 787-8OCT 2013D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-14787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICFigure 2. NC-EPD 976616 - PSE 53-58-03_MRB3Wheel Well Bulkhead Side Fitting (Medium Mission), L/N 43



# Inspect the LHS side fitting in fillets with freeze plug-filled holes. Inspect around the freeze plug. 53-58-03_MRB3

Wheel Well Bulkhead Side Fitti ng L/N 43 

# 787-8OCT 2013787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-15Figure 3. NC-EPD 976616- PSE 53-58-03_MRB3Wheel Well Bulkhead Side Fitting (Long Mission), L/N 43



# Inspect the LHS side fitting in fillets with freeze plug-filled holes. Inspect around the freeze plug. 53-58-03_MRB3

Wheel Well Bulkhead Side Fitti ng L/N 43 

# 787-8OCT 2013D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-16787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICFigure 4. NC-EPD 996685 - PSE 53-58-03_MRB4Wheel Well Bulkhead Side Fitting, L/N 46



# Direction 1: Conduct internal high frequency eddy current (HFEC) inspection of the side fitting

outer chord around the radius block just above the integrally machined rib.

Inspect right side of airplane only at RBL 112, WL 223, between stringers 18 and 19. Side fitting outer chord between Stringers 18 and 19,

BS 1209, RBL 112, WL 223.

1

AFT 

# 53-58-03_MRB4

Wheel Well Bulkhead Side Fitti ng L/N 46

RHS, View Looking AftOCT 2013787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-17Figure 5. NC-EPD 2958886 - PSE 53-58-03_MRB5 Aft Wheel WellBulkhead – BS 1209 SideFitting, RHS, InnerChord, S-17R Splice(L/N 186) – < 2.5 HoursJUN 2014D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-18787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICFigure 6. NC-EPD 2958886 - PSE 53-58-03_MRB5 Aft Wheel WellBulkhead – BS 1209 SideFitting, RHS, InnerChord, S-17R Splice(L/N 186) – No hour labelJUN 2014787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-19Figure 7. NC-EPD 2958886- PSE 53-41-04_MRB5 Aft Wheel Well Bulkhead – BS 1209, RHS Bulkhead Frame Splice Inner Chord,S-17R, L/N 186JUN 2014D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-20787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICFigure 8. NC-EPD3128665 - PSE 57-10-06a_MRB7 Overwing Flex-T Web Fastener Holes Hidden by RSOWLRHS STA 1042, 1055,1064, 1088, 1090, 1101and 1110 (L/N 214)AUG 2014787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-21Figure 9. NC-EPD3128665 - PSE 57-10-06a_MRB8 Overwing Flex-T Web Fastener Holes Hidden by RSOWLRHS STA 1025 (L/N 214)AUG 2014D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-22787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICFigure 10. NC-EPD 2296786 –PSE 57-10-06a_MRB9 Overwing Flex-Tee No. 5 (L/N 78)FEB 2015787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICD011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-23Figure 11. NC-EPD 2296786 – PSE 57-10-06a_MRB10 Overwing Flex-Tee Nos. 1 and 2 (L/N 82)FEB 2015D011Z009-03-02BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-24787 AIRWORTHINESS LIMITATIONS – LINE NUMBER SPECIFICTHIS PAGE INTENTIONALLY LEFT BLANKBLANK