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COMPILED AND PUBLISHED BY:

MAINTENANCE PROGRAMS ENGINEERING

COMMERCIAL AVIATION SERVICES

BOEING COMMERCIAL AIRPLANE GROUP

SEATTLE, WASHINGTON

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TABLE OF CONTENTS

REVISIONS .......................................................................................................................................................................................LIST OF EFFECTIVE PAGES ...........................................................................................................................................................A. INDIVIDUAL AIRPLANE (LINE NUMBER SPECIFIC) AIRWORTHINESS LIMITATIONS............................................................B. ACRONYMS..................................................................................................................................................................................C. ADDITIONAL INSPECTION REQUIREMENTS............................................................................................................................

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REVISIONS

REVISION AND REVISION DESCRIPTION 

AUGUST 2011Original Release (internal - never published)SEPTEMBER 2011Added Supplemental Inspection for Line Number 8.

A 

DECEMBER 2011Section A: Revised front matter text supplementing discussions on D011Z009-03-01 and repeat intervals, reporting of results of structural 

inspections 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.

A 

DECEMBER 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.

A 

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JANUARY 2012Section A:Added Operational Limitation for Line Number 40 and 42 due to NC-EPDs 1510108 and 1512138. (The Operational Limitation is the same as 

that previously applied to LN 41 due to NC-EPD 1419558.)Corrected listing of affected airplanes for 53-58-xx_MRB2 due to NC-EPD 1368125. The defined limitation is applicable to all 787-8 airplanes 

L/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 NUMBER listing for the limitation associated with 53-58-xx_MRB2.

A 

MAY 2012Section A:Removed Operational Limitation for PSE 53-81-04_MRB5 on Line Numbers 40, 41, and 42 originally imposed due to NC-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.

A 

OCTOBER 2013Added reference to Service Bulletin B787-81205-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 via further 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 figures accordingly.JUNE 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 to 

NC 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.

AUGUST 2014Deleted 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.Added Supplemental Structural Fatigue Inspections for PSE Nos. 57-10-06a_MRB7 and _MRB8 applicable to Line Number 214 due to NC EPD 3128665. The DTR Check Forms for these items are provided in Section C, Figures 8 and 9.Added “NDT – Nondestructive Testing” to the list of acronyms in Section B.Added Figures 8 and 9 to Section C to provide the DTR Check Forms for the new Supplemental Structural Fatigue Inspection items above.

REVISION AND REVISION DESCRIPTION 

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FEBRUARY 2015Revised the table of Supplemental Structural Fatigue Inspection Requirements in Section A by adding PSE No. 57-10-06a_MRB9 for L/N 78 and 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.

REVISION AND REVISION DESCRIPTION 

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Section Page Date Section Page Date Section Page Date Section Page Date 

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LIST OF EFFECTIVE PAGES

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1.0 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 BLANK

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A. INDIVIDUAL AIRPLANE (LINE NUMBER SPECIFIC) AIRWORTHINESS LIMITATIONS

PURPOSEThe purpose of this section is to identify additional or revised Airworthiness Limitation (AWL) Supplemental Structural Fatigue Inunique to specific airplanes. Only those individual airplanes listed in this section have these additional or revised AWLs. These 

are due to differences in configuration as a 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. Se

for requirements regarding Repeat Inspection Interval, Reporting Results of Structural Inspections, and Removal of Ex

The following table lists the additional Supplemental Structural Fatigue Inspection requirements for certain individual serial num

listed by Production Line/Serial Number, Principal Structural Element (PSE) Number, PSE Title and Description, Location, Inspe

Threshold.

LINE NUMBER/

SERIAL NUMBER PSE NUMBER PSE TITLE AND DESCRIPTION LOCATION INSPECTION REQUIREM

L/N 8 (ZA101)

S/N 34488

53-18-08_MRB1 NWW - Aft Bulkhead Chord

Section 41; Material Review BoardDisposition for Nonconformance EPD (Emergent Process Document): 1269598;Fastener Hole Damage

BS 277,

RBL 78,

WL 138

1. Remove fasteners common to 418Z

Definition JD76 17.3, 412Z0500-2 J412Z0000-7 JD 03.178, 03.181, 03.08.157, 08.159, 17.230, 20.CU008 (10 locations).

2. Accomplish a special detailed visua

required) inspection of each fastenetotal) for damage.

3. Rework/repair discrepant holes in ac

FAA approved service document (SB787-81205-SB530007-00).

4. Restore to engineering requirement

inspections required.

L/N 43 (ZA382)

S/N 34925

53-58-03_MRB3 Wheel Well Bulkhead Side Fitting - LHS, 

at Upper Flap Support Fitting Interface (fillet radius)MRB Disposition for NC-EPD 976616; Mislocated Holes

BS 1209,

LBL 95,WL 180

See Figures 1 through 3. 

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L/N 46 (ZA237)

S/N 36277

53-58-03_MRB4 Wheel Well Bulkhead Side Fitting - 

RHS, Outer Chord between Stringers 18 and 19MRB Disposition for NC-EPD 996685; Mislocated Hole

BS 1209,

RBL 112,

WL 223

See Figure 4. 

L/N 186 (ZA295)

S/N 34828

53-58-03_MRB5 Aft Wheel Well Bulkhead – BS1209 Side 

Fitting, Right-hand Side (RHS), Inner Chord, S-17R SpliceMRB Disposition for NC-EPD 2958886; Shifted Hole Pattern

BS 1209,

RBL 106,

WL 243

See Figures 5 and 6.Note: Two DTR forms are provided foOne form (Figure 6) is labeled "< 2.5 Hform (Figure 7) is without an hour labedetail is not FLS, follow the instructionD011Z009-03-01 Section C, "Repeat IInterval" to determine which form to us

L/N 186 (ZA295) 

S/N 34828

53-41-04_MRB5 Aft Wheel Well Bulkhead – BS 1209 – 

RHS Bulkhead Frame Splice Inner Chord, S-17RMRB Disposition for NC-EPD 2958886; Shifted Hole Pattern

BS 1209,

RBL 106,

WL 243

See Figure 7. 

L/N 214 (ZA566)

S/N 35319

57-10-06a_MRB7 Overwing Flex-T – Web Fastener Holes 

Hidden by RSOWL – RHS STA 1042, 1055, 1064, 1088, 1090, 1101 and 1110MRB Disposition for NC-EPD 3128665; Extra Plugged Holes

BS 1042-1110,

RBL112,

WL 192-194

See Figure 8. 

L/N 214 (ZA566)

S/N 35319

57-10-06a_MRB8 Overwing Flex-T – Web Fastener Holes 

Hidden by RSOWL – RHS STA 1025MRB Disposition for NC-EPD 3128665; Extra Plugged Holes

BS 1025,

RBL112,

WL 187-194

See Figure 9. 

L/N 78 (ZA271)

S/N 37894

57-10-06a_MRB9 Overwing Flex-Tee – Web Fastener 

HolesMRB Disposition for NoE NC-EPD 2296786; Lack of Deburr on Flex-Tee No. 5

BS 883 - 933,

RBL 113,

WL 200

See Figure 10.Note: The 57-10-06a_MRB9 inspectiorequired if airplane retrofit has been acaccordance with the terminating action Boeing Service Bulletin B787 81205-S001 prior to 16,000 flight cycles.

LINE NUMBER/

SERIAL NUMBER PSE NUMBER PSE TITLE AND DESCRIPTION LOCATION INSPECTION REQUIREM

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TABLE NOTES:1. Thresholds designated as "FLS" are sensitive to flight length; unless otherwise noted, see D011Z009-03-01, Figure 1. All o

flight cycles.

2. In addition to the stated flight cycle threshold, a calendar threshold of 22 years from date of aircraft delivery applies to all S

Fatigue Inspections.

3. The 787-8 airplane identified may not be operated beyond 75% of the stated threshold (or operational limit) until the applica

are published in the appropriate manual, validated, and accepted by the FAA. If the applicable published inspection proced

accomplished, an alternative FAA accepted procedure must be used.

L/N 82 (ZA464)

S/N 38321

57-10-06a_MRB10 Overwing Flex-Tee – Web Fastener 

HolesMRB Disposition for NoE NC-EPD 2296786; Lack of Deburr on Flex-Tee Nos. 1 and 2

BS 1030 - 1091,

LBL 113,

WL 191

See Figure 11.Note: The 57-10-06a_MRB10 inspectrequired if airplane retrofit has been acaccordance with the terminating action Boeing Service Bulletin B787 81205-S001 prior to 7,000 flight cycles.

LINE NUMBER/

SERIAL NUMBER PSE NUMBER PSE TITLE AND DESCRIPTION LOCATION INSPECTION REQUIREM

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B. ACRONYMS

BCL Bottom CenterlineDTR Damage Tolerance RatingFLS Flight Length SensitiveFSOWL Front Spar Overwing LongeronLHS Left-hand SideL/N Line NumberMRB Material Review BoardNC-EPD Nonconformance - Emergent Process DocumentNDT Nondestructive TestingNoE Notice of EscapementPSE Principal Structural ElementRHS Right-hand SideRSOWL Rear Spar Overwing LongeronS/N Serial NumberS-n Stringer number “n”, where “n” is the integer number 

defining the fuselage stringer

TCL Top Centerline

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C. ADDITIONAL INSPECTION REQUIREMENTS

Figure 1. NC-EPD 976616 - PSE 53-58-03_MRB3 Wheel Well Bulkhead Side Fitting (Short Mis

Inspect the LHS side fitting in fillets with freeze plug-filled holes. Inspect around the freeze plug.

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Figure 2. NC-EPD 976616 - PSE 53-58-03_MRB3 Wheel Well Bulkhead Side Fitting (Medium M

Inspect the LHS side fitting in fillets with freeze plug-filled holes. Inspect around the freeze plug.

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Figure 3. NC-EPD 976616 - PSE 53-58-03_MRB3 Wheel Well Bulkhead Side Fitting (Long Mis

Inspect the LHS side fitting in fillets with freeze plug-filled holes. Inspect around the freeze plug.

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Figure 4. NC-EPD 996685 - PSE 53-58-03_MRB4 Wheel Well Bulkhead Side Fitting, L

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

Inspect right side of airplane only at RBL 112, WL 223, between stringers 18 and 19.

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

BS 1209, RBL 112, WL 223.

1

AFT

RHS, View Looking Aft

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Figure 5. NC-EPD 2958886 - PSE 53-58-03_MRB5 Aft Wheel Well Bulkhead – BS 1209 Side Fitting, RHS, 

(L/N 186) – < 2.5 Hours

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Figure 6. NC-EPD 2958886 - PSE 53-58-03_MRB5 Aft Wheel Well Bulkhead – BS 1209 Side Fitting, RHS, 

(L/N 186) – No hour label

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Figure 7. NC-EPD 2958886 - PSE 53-41-04_MRB5 Aft Wheel Well Bulkhead – BS 1209, RHS Bulkhead F

S-17R, L/N 186

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Figure 8. NC-EPD 3128665 - PSE 57-10-06a_MRB7 Overwing Flex-T Web Fastener Holes Hidd

RHS STA 1042, 1055, 1064, 1088, 1090, 1101 and 1110 (L/N 214)

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Figure 9. NC-EPD 3128665 - PSE 57-10-06a_MRB8 Overwing Flex-T Web Fastener Holes Hidd

RHS STA 1025 (L/N 214)

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Figure 10. NC-EPD 2296786 – PSE 57-10-06a_MRB9 Overwing Flex-Tee No. 5 (L/N 

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Figure 11. NC-EPD 2296786 – PSE 57-10-06a_MRB10 Overwing Flex-Tee Nos. 1 and 2 

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