787 AIRWORTHINESS LIMITATIONS

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787

AIRWORTHINESS LIMITATIONS (AWLs)

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APRIL 2013

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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 ...........................................................................................................................................................REFERENCES ..................................................................................................................................................................................A. SCOPE..........................................................................................................................................................................................B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITS.....................................................................................

C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS..............................................

D. AIRWORTHINESS LIMITATIONS – LIFE LIMITS.........................................................................................................................

E. OTHER AIRWORTHINESS LIMITATIONS – SYSTEMS AND STRUCTURES ............................................................................

APPENDIX A. POST-THRESHOLD INTERVALS FOR STRUCTURES AND ZONAL TASKS .........................................................

APPENDIX B. DISCREPANT STRUCTURE REPORT FORM..........................................................................................................

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REVISIONS

REVISION AND REVISION DESCRIPTION APPROVAL

AUGUST 2011Original Release

Submitted by: Ray Smith (Boeing) Approve

 

SEPTEMBER 16, 2011Revised 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.

Submitted by: Ray Smith (Boeing) Approve

 

OCTOBER 2011For 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.

Submitted by: Ray Smith (Boeing) Approve

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787 AIRWORTHINESS LIMITATIONS

NOVEMBER 2011Revised 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.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.

Submitted by: Ray Smith (Boeing) Approve

 

REVISION AND REVISION DESCRIPTION APPROVAL

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DECEMBER 2011Revised 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.

Submitted by: Ray Smith (Boeing) Approve

 

DECEMBER 2011 R1Revised 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.

Submitted by: Ray Smith (Boeing) Approve

 

JUNE 2012Revised 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.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)".

(Continued on next page)

Submitted by: Ray Smith (Boeing) Approve

 

REVISION AND REVISION DESCRIPTION APPROVAL

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JUNE 2012, ContinuedRevised 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.

Continued from previous page Co

JULY 2012Revised 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.

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REVISION AND REVISION DESCRIPTION APPROVAL

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SEPTEMBER 2012Revised 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. 

Submitted by: Ray Smith (Boeing)

FEBRUARY 2013Revised 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.

(Continued on next page)

Submitted by: Rod von Rotz (Boeing)

REVISION AND REVISION DESCRIPTION APPROVAL

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FEBRUARY 2013, ContinuedRevised 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.

Continued from previous page Co

APRIL 2013Revised 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.

Submitted by: Ray Smith (Boeing)

REVISION AND REVISION DESCRIPTION APPROVAL

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

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REFERENCES

APPLICABLE FEDERAL AVIATION REGULATIONSSections 25.1309 (ARSENAL), 25.571, 25.1529 of 14 CFR Part 25 of the Federal Aviation RegulationsRELATED DOCUMENTS:Advisory Material Joint (AMJ) 25.1309, System Design and AnalysisFAA Advisory Circular 25-19, Certification Maintenance RequirementsFAA Advisory Circular 121-22A, Maintenance Review Board (MRB) ProceduresFAA Advisory Circular 120-17A, Maintenance Program Management through Reliability MethodsFAA Advisory Circular 20-114, Manufacturers Service DocumentsAir Transport Association of America (ATA) Maintenance Steering Group (MSG-3), Operator/Manufacturer Scheduled Maintenadocument, MSG-3 Revision 2005.1, January 2005Air Transport Association of America (ATA) Specification for Manufacturers Technical Data, A.T.A. Specification No. 100, Octob

"Airline Requirements for Aircraft Zoning"Boeing Document D011Z009-03, 787 Maintenance Planning DataBoeing Document D011Z009-03-02, 787 Airworthiness Limitations (AWLs) - Line No. SpecificBoeing Document D011Z009-03-04, 787 Special Compliance Items (SCIs)/Airworthiness Limitations (AWLs)Boeing Document D634Z301, Non Destructive Testing (NDT) ManualBoeing Document D011Z009-02, 787 Maintenance Review Board Report Document, 22 March 2010Boeing Document B787-81205-A0101-00, Aircraft Maintenance Manual (AMM)

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A. SCOPE

The scheduled maintenance requirements described in this document result from Model 787-8 airplane certification activities w

Administration (FAA). Accordingly, this FAA approved Airworthiness Limitations document is cross-referenced in the Model 787Sheet. These maintenance actions are mandatory.This Airworthiness Limitations document is FAA approved and specifies maintenance required under Sec. 43.16 and 91.403 of Regulations, unless an alternative program has been FAA approved.

B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITS

This section summarizes the airplane operational limits imposed on the 787-8. The operational limitation imposed on each 787

individual limitations as defined in the Temporary Operational Limit and Freedom From Widespread Fatigue Damage subsectio

TEMPORARY OPERATIONAL LIMITThe FAA has agreed to the following three-stage approach for Boeing to compile and publish the information necessary to accostructural fatigue inspections.• Stage 1 results in publishing the baseline inspection program which consists of the 787 Maintenance Planning Data (MPD) 

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 imposed on every 787 airplane equal to 75% of the lowest threshold defined in Table 1 for which the inspection procedurnot published.

• Stage 3 results in publishing the DTR Check Forms and the procedures necessary to accomplish the Supplemental Structu

Stage 3 is complete, the Stage 2 temporary operational limit will be removed.

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This approach is illustrated in the table below:

Stage Description Publication Date Details of Publication Threshold Te

1 Baseline Inspection 

Program Data published.

Prior to issuance of the 

787-8 TC.

MPD Structures and Zonal Programs at time of certification.

Not Applicable. Not 

2 Supplemental structural 

fatigue inspection thresholds published.

3,000 total flight cycles, 10,000 total flight hours, or 18 months from issuance of the 787-8 TC, whichever comes first.

Thresholds for all PSEs identified.

Published in Table 1 for each PSE requiring supplemental inspection

75% definspChe

3 DTR Check Forms and 

NDT Manual Procedures published.

Prior to Stage 2 operational limit.

NDT Manual: Inspection procedure details (including 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.

Same as Stage 2. Non

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FREEDOM FROM WIDESPREAD FATIGUE DAMAGETitle 14 Code of Federal Regulations Section 25.571(b) (Amendment 96) states that

"Special consideration for widespread fatigue damage must be included where the design is such that this type of damage 

demonstrated with sufficient full-scale fatigue test evidence that widespread fatigue damage will not occur within the design airplane. The type certificate may be issued prior to completion of full-scale fatigue testing, provided the Administrator has 

completing the required tests, and the airworthiness limitations section of the instructions for continued airworthiness requir

this part specifies that no airplane may be operated beyond a number of cycles equal to 1⁄2 the number of cycles accumulat

article, until such testing is completed."

In compliance with 14 CFR 25.571(b), Boeing is conducting a full-scale fatigue test of the 787 airframe. Until this testing is com

operational limitation is imposed on the 787 fleet:The operational limitation noted above will be revised periodically as the full-scale test progresses.

LIMIT OF VALIDITYTitle 14 Code of Federal Regulations Section 26.21 (Amendment 5) requires establishment of a limit of validity of the engineerin

structural maintenance program that corresponds to the period of time, stated as a number of total accumulated flight cycles or 

which it is demonstrated that widespread fatigue damage will not occur in the airplane.

The limit of validity for the 787 will be established based on results of the 787 airframe full-scale fatigue test and other data. Wh

of validity will be included in this document.

Applicability

Accumulated Cycles – 

Full-Scale Fatigue Test Fleet Operational Limitation

787-8 Aircraft 61,059 Fatigue Test Cycles 30,529 Flight Cycles

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C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONS

INTRODUCTIONThe Structural Maintenance Program and the Zonal Inspection Program approved in the 787-8 Maintenance Review Board Rep

D011Z009-02, and contained in the 787 MPD, Document D011Z009-03, describe an initial baseline Structural Maintenance Pro

Significant Items (SSIs). These programs were developed in accordance with the guidelines of MSG-3, Revision 2005.1, and a

requirements of 14 CFR 25.571 by providing accidental damage and environmental deterioration detection opportunity, and in s

detection opportunity, for all Principal Structural Elements (PSEs).NOTE: Escalation of MPD Sections 2 and 3 Structures and Zonal tasks beyond the initial repeat interval considered at certifica

as compliance to 14 CFR 25.571 requirements for accidental damage to composite structure was based on the initial 

certification. Escalation of the Structures and Zonal MPD tasks may be possible in the future subsequent to Boeing/FAparameters under which 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 fatigu

opportunity from the initial baseline Structural Maintenance and Zonal Inspection Programs. (Such 787 MPD Section 2 inspect

corresponding Supplemental Structural Fatigue Inspections will be identified by the letter "F" (for fatigue) in the Program (PGM) c

Structural Fatigue Inspections defined herein shall be accomplished in addition to the baseline Structural Maintenance Program

damage tolerance requirements are satisfied by the MPD Section 2 Structural Maintenance Program or Section 3 Zonal Inspec

Appendix A.The Supplemental Structural Fatigue Inspection Program has been developed using the Boeing Damage Tolerance Rating (DTDTR System, the inspections and repeat intervals necessary to provide adequate fatigue damage detection are determined. Trequired DTR (a numerical value) that must be achieved for each PSE. DTR Check Forms defining the inspection intervals, insrequired DTR will be provided in a future Boeing document. The Supplemental Structural Fatigue Inspections must be accompl

defined threshold for each PSE.See Section D for PSEs certified per 14 CFR 25.571(c) as safe-life structure.

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There is no separate 787 Corrosion Prevention and Control Program (CPCP) as each MPD Section 2 inspection requires that t

inspected are also evaluated for corrosion. All tasks defined therein are necessary to maintain the aircraft to Corrosion Level 1 

NOTE: Supplemental Structural Fatigue Inspections necessitated by major non-conformances occurring during airplane produ

D011Z009-03-02, 787 Airworthiness Limitations (AWLs) – Line Number Specific. Revised inspection requirements an

listed in Document D011Z009-03-02 as applicable to individual production line number airplanes. These line number-

included in the applicable operator's maintenance program.

The Airworthiness Limitations - Supplemental Structural Fatigue Inspections may only be revised with the approval of the Seatt

Office (ACO). If the inspections cannot be accomplished due to repairs and/or modifications, an alternate inspection approved must be used. An exception to this is allowed if the alternative inspections are for a condition where:

1. An existing repair prevents proper accomplishment of the required Supplemental Structural Fatigue Inspections,2. The required damage tolerance inspections for the repair have been FAA-approved as meeting the damage tolerance requ

25.571(b) and 14 CFR 26.43(c) or 14 CFR 26.43(d), and

3. The part which is repaired contains the lead crack as identified on the associated DTR Check Form for the applicable Supp

Inspection.

For this condition, the inspection requirements approved for the repair plus the inspection requirements of this section for any a

acceptable alternative inspections.THRESHOLD (787-8 AIRPLANES)The Supplemental Structural Fatigue Inspections must be accomplished prior to accumulation of a certain number of flights (threach PSE requiring Supplemental Structural Fatigue Inspections is defined in Table 1, "Airworthiness Limitations – SupplementInspections". The threshold for PSEs for which the damage tolerance requirements are satisfied by MPD Section 2, Structural 

Section 3, Zonal Inspection Program, is 44,000 flight cycles or 22 years, whichever occurs first (see Appendix A).

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787 AIRWORTHINESS LIMITATIONS

NOTE: Supplemental inspection thresholds and repeat intervals are measured in flight cycles or flight hours that a particular P

regardless of what the airframe as a whole has accumulated. Most PSE details will never be replaced and therefore ha

cycles and flight hours as the airframe. Some PSE details will be replaced, such as when installing removable structu

rotable/expendables) or installing used structural parts as part of a repair. In these cases, the accumulated flight cycle

replacement PSE details may be different from that of the airframe they have now been installed on. The operator mus

when inspections must be done.

Each PSE requiring a Supplemental Structural Fatigue Inspection is categorized as either Group 1 or Group 2. For the 787-8, 

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 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 

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 maintena

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 T

thresholds described in Table 1, a calendar threshold of 22 years applies to all Supplemental Structural Fatigue Inspections.Some PSE details are sensitive to flight length; such details are identified by "FLS" (Flight Length Sensitive) in the Threshold co

threshold for FLS Items must be determined from the FLS Threshold Curves of Figure 1, based upon the actual airplane utiliza

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 f

JUN 2012
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

NOTE: For reference, the PSEs listed below, as also indicated in Table 1, have a threshold less than 33,000 Flight Cycles.

PSE DTR Check Form Title DTR Location 

53-41-05B MLG Hanger Link Aft Lug - BS 1209

(L/N 4 - 70)

Forward and Aft Flanges common to Wheel Well Longeron Extens

57-13-02A Overwing Beams Web Pocket at BL 11 BS 1021-1104, 1071-1104 BL 39 BS 1011-1

1071-1104, BL 66 BS 948-979, 1011-1041, 1081-1104

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

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 I

point falls outside the curve for the specified group, the threshold has been exceeded. Operators must accomplish the inspe

threshold. Find the appropriate DTR Check Form (to be published in a future Boeing document) for the FLS PSE detail baseflight for the detail.

0

5,000

10,00015,00020,00025,00030,00035,00040,00045,00050,000

0 20,000 40,000 60,000 80,000 100,000 120,000 140,00

Flight Hours

Flight Cycles

Group 2Group 1

GROUP 1

GROUP 2

33,000 FC,

49,500 FH

 7,500 FC,101,300 FH

44,000 FC,66,000 FH

 10,0135,0

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

REPEAT INSPECTION INTERVALThe repeat interval for the Supplemental Structural Fatigue Inspection of each PSE detail is established from its respective DTR 

published in a future Boeing document). The DTR Check Forms are the result of the damage tolerance assessment/evaluation certification of the airplane. Revision to the required DTR Check Form or the DTR Curve is not allowed without the prior approvaSome DTR Check Forms provide options for the type of inspection to be carried out (Detailed Visual, High Frequency Eddy Cu

direction of inspection (Internal, External, etc.), and the corresponding interval of the repeat inspection. However, for a given DTDTR from more than one inspection method (instrumented or visual) is not allowed in the same zone, at the same interval. AlsDetailed Visual Inspections are considered a single inspection unless accomplished at different check intervals. They cannot stowards an achieved DTR if accomplished at the same check. Combination of delta DTR from the corresponding MPD Section 

supplemental inspection method is allowed if the MPD Section 2 task inspection occurs more frequently, or at intervals which wsupplemental inspections. Where a high total DTR is obtained operators can consider a phased inspection within their fleet for 

Optional inspection methods, where offered, provide operators flexibility in accommodating the supplemental inspections to besplan and maintenance check intervals.If the threshold for the PSE detail designates "FLS", the average hours per flight (cumulative flight hours divided by cumulative calculated for the detail. The repeat inspection interval and inspection requirements are then based on the DTR Check Form w

average flight hours label. • If the average hours per flight is less than 2.5, use the form labeled "< 2.5 Hours".• If the average hours per flight is greater than 9.0, use the form labeled "> 9.0 Hours".• If the average hours per flight is between 2.5 and 9.0, use the form without an hour label.NOTE: 1. For some FLS PSE details, all three check forms are not required. If, for example, a form labeled "< 2.5 Hours" an

 are provided, use the form without an hour label for average hours per flight of 2.5 or more. 2. As the average hours per flight may vary over an airplane’s life, if the current average hours per flight is longer than 

 calculated for a prior inspection interval, the current average hours per flight shall be used for determining the appro

SEP 2011
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BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

REPORTING RESULTS OF STRUCTURAL INSPECTIONSAll cracks or other fatigue damage found during these inspections shall be reported within ten (10) days directly to the Manage

Transport Airplane Directorate, the FAA, and to Boeing Commercial Airplane Group using the Discrepant Structure Report Formthe required report form (any suitable alternative which contains the same information may be used).REMOVAL OF EXCESS SEALANT WHEN INSPECTING1. In areas where the inspection is prevented due to sealant, remove any fastener cap, fillet or brush sealant that extends bey

fastener at locations that are to be inspected. Remove any additional sealant which impairs visibility of the structure adjaceor brush sealant. This requirement applies to post-threshold inspection of PSEs for which the MPD Section 2 or 3 tasks sa

2. For PSEs requiring Supplemental Structural Fatigue Inspections, requirements to remove fastener cap, fillet or brush seala

Check Forms (to be published in a future Boeing Document).

3. Sealant and corrosion protection finishes should be removed only when specified in the inspection task. Upon completion o

sealant in accordance with the AMM section or other reference noted below. Sealant restoration common to the fuel tanks 

limitations identified in Document D011Z009-03-04, Special Compliance Items/Airworthiness Limitations. Adherence to the 

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 for general sealant removal and application.Refer to AMM 28-11-00 (Task B787-A-28-11-00-14A-663A-A) for sealant (BMS 5-45) inside the fuel tank removal and applrequirements in the AMM are subject to airworthiness limitations identified in Document D011Z009-03-04. Adherence to thlimitation requirements is required to prevent the development of an ignition source within the fuel tanks.Refer to AMM 28-11-00 (Task B787-A-28-11-00-15A-663A-A) for removal and application of secondary fuel barrier sealant Coating - Heat Resistant Secondary Fuel Barrier) outside the fuel tank.If sealant inside the fuel tank is removed for inspection, care must be taken to remove any sealant debris in the fuel tank.

SEP 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

Locations where sealant is removed for inspections must have the sealant restored to drawing or AMM requirements (and 

Bulletins or repair instructions) after completion of the inspections.

SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTION REQUIREMENTSTable 1 lists the threshold for each Airworthiness Limitation Supplemental Structural Fatigue Inspection. The table identifies ea

or more DTR Check Forms will be provided (to be published in a future Boeing document). Each item is listed by PSE Number, 

Location, and Airplane Applicability/Threshold. Where there is more than one listing for a given PSE Number, the DTR Check Funique identifier. Appendix A identifies PSE details for which the required DTR is satisfied by the inspection tasks of the Struct

(refer to the 787 MPD, Section 2). No DTR Check Forms are required for these details.Airplane applicability is listed as shown below (no entry implies all 787 airplanes):ALL = All 787 Airplanes-8 = B787-8-9 = B787-9RR = Rolls Royce Trent 1000 Series EngineGE = General Electric GEnx-1B Series EngineNOTE: C/L or L/N = Airplane Cumulative Line Number, where mentioned with DTR Check Form Title, identifies certain DTR C

line numbers.

SEP 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

27-41-16A 787-8 HSTA (Horizontal Stabilizer Trim Actuator) 

C99145 Ballscrew Assy (CA39590)

Ballscrew Flange and Threads 1 33,000(5

27-41-16B 787-8 HSTA (Horizontal Stabilizer Trim Actuator) 

C99145 Ballscrew Assy (CA39590)

Ballnut Trunnion 1 33,000(5

27-41-16C 787-8 HSTA (Horizontal Stabilizer Trim Actuator) 

C99145-001 Upper Gimbal Pin Assy (CA29233)

Section 48 1 33,000(5

52-34-01C3 Forward Large Cargo Door Shear Fitting Shear Roller Main Lug 1 33,000(552-34-01C4 Forward Large Cargo Door Shear Fitting Shear Roller Auxiliary Lug 1 FLS(5)

52-36-01A Bulk Cargo Door Stops Corner of the critical section under the Stop Head 2 44,000(5

52-37-01C3 Aft Large Cargo Door Shear Fitting Shear Roller Main Lug 1 FLS(5)52-37-01C4 Aft Large Cargo Door Shear Fitting Shear Roller Auxiliary Lug 1 FLS(5)

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 Inner Splice Strap at Mid AB Post / Upr AB Post 

Joint (BS 182.0, BL 0.0, WL 277)

2 44,000(5

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 Outer Splice Strap at Upr CD Post / CD Post 

Extension Joint (BS 192, LBL 29, WL 280)

1 33,000(5

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 Outer Splice Strap at QF Sill / FH1 Sill Extension 

Joint (BS 193, LBL 67, WL 233)

1 33,000(5

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 Outer Splice Angle at CD Post Extension Joint 

(BS 217, LBL 25, WL 293)

2 44,000(5

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 Frame / Post Inner Chord at J1-E1 Frame 

(BS 192.0, LBL 15.0, WL 280)

2 44,000(5

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 Cab EF Post Outer Chord at Cab QH1 Sill OC 

Splice hardpoint (BS 195, BL 66, WL 235)

1 33,000(5

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 J1-E1 Frame Web at Outboard Door Stop Ftg 

attachment (BS 193, RBL 32, WL 275)

2 44,000(5

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 Frame / Post Web at EF Center Frame / Mid AB 

Post Joint (BS 183, BL 0, WL 280)

1 33,000(5

53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 AB Post Inner Chord at BS 142, WL 249 2 44,000(553-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 AB Post Web at BS 142, WL 249 1 33,000(553-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5 AB Post Outer Chord at BS 108, WL 226 2 44,000(553-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Forward Extension Chord BS 138, BL 27.5, WL 125

2 44,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Forward Extension Chord Splice BS 143, BL 27.5, WL 125

2 44,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Forward Extension Chord Hidden at Splice BS 143, BL 27.5, WL 125

2 44,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R (L/N 4-6)

BS 148 Frame Shear Tie WL 217 2 44,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Integration Strap at S-37 BS 276 1 33,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Aft Extension Fitting at S-37L BS 284

2 44,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Aft Extension Chord at S-37L BS 294

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Aft Extension Chord Hidden at Extension Fitting S-37L BS 287

2 44,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Nose Wheel Well Bulkhead Frame Splice BS 276 WL 178

2 44,000(5

53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5 

between S-22L and S-22R

Intercostal Webs at BS 276, BL 6, WL 107 2 44,000(5

53-11-03 Lower Lobe Skin/Stringer/Frame Lower Stanchion 

Fittings Assembly Forward of BS 338.5

Passenger Floor Lower Stanchion Fitting BS 302, WL 137

2 44,000(5

53-11-07 Passenger Entry Door 1 - Lower Main Sill (L/N 4-6) Lead Crack at Inner Chord Web Flange Hidden 

Detail at Splice - BS 267.71

2 44,000(5

53-11-07 Passenger Entry Door 1 - Lower Main Sill (L/N 4-6) Lead Crack at Inner Chord Web Flange NonHidden Detail - BS 317.4 2 44,000(553-11-07 Passenger Entry Door 1 - Lower Main Sill (L/N 4-6) Lead Crack at Inner Chord Free Flange BS 267.71 2 44,000(553-11-07 Passenger Entry Door 1 - Lower Main Sill (L/N 4-6) Lead Crack at Splice Angle Free Flange 

BS 267.71

2 44,000(5

53-11-07 Passenger Entry Door 1 - Lower Main Sill Lead Crack at Outer Chord at Split Frame BS 302 2 44,000(553-11-07 Passenger Entry Door 1 - Lower Main Sill Lead Crack at Outer Chord at Girt Bar BS 284 & 

BS 322

2 44,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Forward Edge Frame at Lower Splice Joint, 

BS 276.5, WL180

2 44,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Forward Edge Frame at Upper Splice BS 276.5, 

BL 57.58, WL 291.12

2 44,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame at Lower Splice BS 327.5, 

BL 98.88, WL 175.1

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 Inner Chord Free 

Flange near Doorstop No. 1

2 44,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 Web Nutplates 2 44,000(553-11-07 Passenger Entry Door 1 - Edge Frame

(L/N 55 and on)

Aft Edge Frame BS 327.5 - Web at Nutplate Retainer, S-20 to S-21

1 33,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 - Web at Door Stop 

Fitting #1 Tension Bolt WL 207.5

2 44,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Forward Edge Frame Web at Passenger Floor 

Fitting Fastener BS 276.5, BL 93.4, WL 190

2 44,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 near Doorstop #4 Outer 

Chord Fastener common to skin

2 44,000(5

53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 near Doorstop #4 Outer 

Chord at Nutplate Retainer

2 44,000(5

53-11-08 Passenger Entry Door 1 - Stop Fittings & 

Intercostals (L/N 4-32)

Aft Stop Fitting #1, BS 327.5, WL 207.5 where hidden by radius fillers

2 44,000(5

53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame Inner Chord Edge of 

Flange at S-31R

2 44,000(5

53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame at Nutplates between 

S-32R and Lower Main Sill (WL 122)

2 44,000(5

53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame Web at Lower Main Sill 

(WL 122) where Hidden by Sill Clips

1 33,000(5

53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame Web at Edge of Mouse 

Hole at S-21R

2 44,000(5

53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame Outer Chord at Fasteners 

between S-21R and S-22R

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

JUN 2012
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame Outer Chord at Nutplate 

Retainer; S-31R and S-32R

2 44,000(5

53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Inner Chord edge BS 448 2 44,000(553-11-11 Forward Large Cargo Door Cutout - Upper Main Sill 

(L/N 4-26)

Inner Chord Web flange BS 437 1 33,000(5

53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill 

(L/N 4-26)

Inner Chord strap BS 436 1 33,000(5

53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Web at attachment to Outer Chord, BS 441 1 33,000(553-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Outer Chord skin flange BS 433 and BS 477 1 33,000(553-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Outer Chord with nut plate, BS 540 2 44,000(553-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

BS 537, Inner Chord Inboard Flange - lead crack at latch backup fitting fastener

2 44,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

BS 537, Inner Chord Web leg - lead crack at latch backup fitting fastener

1 33,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

BS 545, Inner Chord fastener hole at edge frame 1 33,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

Inner Chord at BS 537 1 33,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

Sill Web hidden by Shear Backup Fitting BS 496 2 44,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

Outer Chord skin fastener BS 521 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

Edge Frame Hidden Chord detail at BS 545 1 33,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure (L/N 4-6)

Auxiliary Sill Inner Chord at BS 537, WL 112.5 2 44,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

Lower Split Frame at Inner Chord Splice Strap, BS 537

2 44,000(5

53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill 

& Latch Backup Structure

Latch Backup Fitting at Split Frame attachment, BS 441

2 44,000(5

53-11-15 Forward Equipment Access Door - Cutout/Backup 

Structure

Intercostal Inner Chords at BS 142, RBL 13 and LBL 13

2 44,000(5

53-11-15 Forward Equipment Access Door - Cutout/Backup 

Structure

Intercostal Webs at BS 148, RBL 13 and LBL 13 2 44,000(5

53-11-17 Crew Window Cutout #1 - Window Frame Window Frame along AB Post 2 44,000(553-11-17 Crew Window Cutout #1 - Window Frame Window Frame along CD post 1 33,000(553-11-18 Crew Window Cutout #1 - Window Sills BD Sill Inner Chord at LBL 29.0 Intercostal Splice 2 44,000(553-11-18 Crew Window Cutout #1 - Window Sills BD Sill Web at LBL 29.0 Intercostal Splice 2 44,000(553-11-18 Crew Window Cutout #1 - Window Sills Window Sill Web at BS 160, LBL 26, WL 258 1 33,000(553-11-18 Crew Window Cutout #1 - Window Sills Window Sill Web at BS 163, LBL 29, WL 258 2 44,000(553-11-19 Crew Window Cutout #2 - Window Frame Window Frame along the QF Sill 2 44,000(553-11-19 Crew Window Cutout #2 - Window Frame Window Frame Outer Flange at Upper CD Post 

Joint (BS 169, LBL 36, WL 260)

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-11-20 Crew Window Cutout #2 - Window Sills Cab EF Post Web at BS 193.0, LBL 59.0, 

WL 242.0

2 44,000(5

53-13-01 Forward Pressure Bulkhead - Bulkhead Web Web circumferential direction - BS 106 2 44,000(553-13-02 Forward Pressure Bulkhead - Bulkhead Chord & 

Splices

Outboard joint common to bulkhead web, doubler, & angle chord - BS 107, BL 0, WL 132

2 44,000(5

53-13-02 Forward Pressure Bulkhead - Bulkhead Chord & 

Splices

Outboard joint common to Bulkhead Web, Doubler, Angle Chord - BS 106, LBL 28, WL 143

1 33,000(5

53-13-02 Forward Pressure Bulkhead - Bulkhead Chord & 

Splices

Joint common to Angle Chord, Y-Chord, and Skin. Forward fastener, BS 110.5, S-40L/R

2 44,000(5

53-13-02 Forward Pressure Bulkhead - Bulkhead Chord & 

Splices

Joint common to Angle Chord, Y-Chord, BL14 Header Intercostal and Skin BS 110.5

1 33,000(5

53-17-01 Nose Wheel Well - Trunnion Support Fitting Frame Joint at WL 121.9, BS 265.5 1 FLS(5)53-17-01 Nose Wheel Well - Trunnion Support Fitting Frame Joint at WL 121.9, BS 265.5, Free Flange 2 FLS(5)53-17-01 Nose Wheel Well - Trunnion Support Fitting Beam Joint at WL 165, BS 265.5 2 44,000(553-17-02 Nose Wheel Well - Drag Brace Fitting Drag Brace Fitting Side Panel Attachment 

BS 202.7 and BS 217.2

2 FLS(5)

53-17-02 Nose Wheel Well - Drag Brace Fitting Grease fitting hole, BS 202.7 and BS 217.2 1 FLS(5)53-17-03 Nose Wheel Well - Retract Actuator Fitting Actuator Fitting Lug BS 276.5, WL 161.0, 

RBL 19.6

1 33,000(5

53-18-01 Nose Wheel Well - Forward Bulkhead Panel Web at BS 148.0, between BL 28.25 and BL 52.5 2 44,000(553-18-01 Nose Wheel Well - Forward Bulkhead Panel Web at BS 148.0, BL 24.0, WL 121.7 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-18-01 Nose Wheel Well - Forward Bulkhead Panel Web - Inner Chord at BS 148.0, BL 49.0, 

WL 150.0

2 44,000(5

53-18-01 Nose Wheel Well - Forward Bulkhead Panel Web at BS 148.0, BL 27.5, WL 132.0 under Lower 

Beam

2 44,000(5

53-18-01 Nose Wheel Well - Forward Bulkhead Panel Web at BS 148.0, BL 5.9, WL 118.0 under 

Doorstop Fittings

2 44,000(5

53-18-01 Nose Wheel Well - Forward Bulkhead Panel Vertical Beams at free flange edges at BS 143.2, 

BL 11.0, WL 165.7

2 44,000(5

53-18-0153-18-05

Nose Wheel Well - Forward Bulkhead Panel Vertical Beam to Top Panel Stiffener joint at 

BS 148.0, BL 11.0, WL 165.7

2 44,000(5

53-18-04 Nose Wheel Well - Side Panels Side Panel Beam #4 at free flange edges at 

BS 193.8, BL 33.2, WL 124.5

2 44,000(5

53-18-04 Nose Wheel Well - Side Panels Side Panel Beam #4 to Stub Frame Joint at 

BS 193.8, BL 32.7, WL 122.9

2 44,000(5

53-18-04 Nose Wheel Well - Side Panels NWW Side Panel Web at Beam 4 BS 193.8, 

BL 28.25 from WL 115.8 to WL 133

2 44,000(5

53-18-04 Nose Wheel Well - Side Panels Along Beam No. 5 BS 202.75, WL 112.94 at 

Lower Chord Joint

1 33,000(5

53-18-05 Nose Wheel Well - Top Panel Top Panel Beam #7 at free flange edges at 

BS 232.5, BL 29.0, WL 168.5

2 44,000(5

53-18-06 Nose Wheel Well - Aft Bulkhead Beams Aft Bulkhead Beam #2 flange at Aft Bulkhead Web 

(BS 276.5, RBL 42.4, WL141)

2 44,000(5

53-18-06 Nose Wheel Well - Aft Bulkhead Beams Aft Bulkhead Beam #4 attachment to Web and 

Vertical Beam (BS 276.5, LBL 6.0, WL 115)

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-18-07 Nose Wheel Well - Aft Bulkhead Web Nose Wheel Well Aft Bulkhead Web at BS 276, 

BL 86.5 & WL 170

2 44,000(5

53-18-07 Nose Wheel Well - Aft Bulkhead Web Web at BS 276.5, between BL 28.25 and BL 76.0 2 44,000(553-18-07 Nose Wheel Well - Aft Bulkhead Web Web at BS 276.5, BL 0.0, WL 115.0, under Beam 

No. 4

2 44,000(5

53-18-07 Nose Wheel Well - Aft Bulkhead Web Web inner chord at BS 276.5, BL 75.0, WL 150.5 2 44,000(553-18-07 Nose Wheel Well - Aft Bulkhead Web Web at BS 276.5, BL 27.4, WL 115.0, under Beam 

No. 4 

2 44,000(5

53-18-07 Nose Wheel Well - Aft Bulkhead Web Web at BS 276.5, BL 15.0, WL 115.0, under Beam 

No. 4 

2 44,000(5

53-31-27 Underwing Longeron Back-up Fitting Underwing Longeron Back-up Fitting BS 849, 

BL 92.8, WL148.1

2 44,000(5

53-31-27 Skin/Stringer/Shear Tie Panel Assy (Section 43) BS 657 Titanium Shear Tie Web Frame Joint 2 44,000(553-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame Inner Chord at Edge Frame Splice 

BS 682 S-10 to S-11

2 44,000(5

53-31-34 Passenger Entry Door 2 - Edge Frame (L/N 4-6) Edge Frame Inner Chord at BS 682 S17-18 2 44,000(553-31-34 Passenger Entry Door 2 - Edge Frame (L/N 7 and 

on)

Edge Frame Inner Chord at BS 632 S11-12 2 44,000(5

53-31-34 Passenger Entry Door 2 - Edge Frame (L/N 4-6) Edge Frame Web at BS 682 S-17 to S-18 2 44,000(553-31-34 Passenger Entry Door 2 - Edge Frame (L/N 7 and 

on)

Edge Frame Web at BS 682 S-17 to S-18 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-31-34 Passenger Entry Door 2 - Edge Frame (L/N 4-6) Edge Frame Web at BS 682 S-19 (stop fitting 

3A Interface)

2 44,000(5

53-31-34 Passenger Entry Door 2 - Edge Frame (L/N 7 and 

on)

Edge Frame Web at BS 682 S-19 (stop fitting 3A Interface)

2 44,000(5

53-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame Web at latch fitting BS 682, S-18 

to S-19

2 44,000(5

53-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame Outer Chord at Stow Bin Ftg 

attached BS 632, S11-12

1 33,000(5

53-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame outer chord BS 682, S-21 to S-22 2 44,000(553-31-34 Passenger Entry Door 2 - Upper Sill Upper Sill Inner Chord Splice at BS 632, S-13 2 44,000(553-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Inner Chord at Stringer 2.5 

Splice

2 44,000(5

53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Inner Chord BS 873, S-17 Splice 2 44,000(553-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Inner Chord at TCL 2 44,000(553-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Inner Chord at Stringer 3L-4L 2 44,000(553-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Web at Stringer 2.5 Splice 2 44,000(553-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Web Mouse Hole at TCL - 

Stringer 1

2 44,000(5

53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Outer Chord and Web BS 873, 

S-17 Splice

1 33,000(5

53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Outer Chord at Stringer 2 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Outer Chord at Stringer 2-3 2 44,000(553-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 BS 1209 - S-2.5 Bulkhead Inner Chord 2 44,000(553-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Inner Chord BS 1209, S-17 splice 2 44,000(553-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame Inner Chord at TCL LH and 

RH sides

2 44,000(5

53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame to Bracket interface at TCL/S-1 

LHS side.

2 44,000(5

53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Stringer 2.5 Web Splice location 2 44,000(553-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Web BS 1209, S-17 Splice 2 44,000(553-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 TCL-Stringer 1 2 44,000(553-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Crown Bulkhead Fitting Outer Chord at 

Stringer 17 Splice Region

1 33,000(5

53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame Outer Chord at Stringer 1 2 44,000(553-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame Outer Chord at Stringer 2-3 2 44,000(5

53-41-05A Forward Hanger Link Lug Section 44 - BS 1185 Flange at Bulkhead Frame joint 2 44,000(553-41-05A Forward Hanger Link Lug Section 44 - BS 1185 Lug Hole 1 33,000(553-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 4-70) Lug Base Corner Fillet Radius 2 44,000(553-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 71 and on) Lug Base Corner Fillet Radius 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

JUN 2012
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 4-70) Forward and Aft Flanges common to Wheel Well 

Longeron Extension

1 21,860(5

53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 71 and on) Forward and Aft Flanges common to Wheel Well 

Longeron Extension

1 33,000(5

53-41-07 Wheel Well Longeron Rear Spar Overwing Longeron BS 1024-1128 

(LHS/RHS) at Fasteners

2 44,000(5

53-41-07 Wheel Well Longeron Rear Spar Overwing Longeron BS 1111-1117 

(LHS/RHS) at Fairing Strut Bracket

1 33,000(5

53-41-07 Wheel Well Longeron RS OWL BS 1024-1128 (LHS/RHS) at Edges 2 44,000(553-41-07 Wheel Well Longeron BS 1194-1221 WWLE Vertical and Horizontal 

Flanges Hidden Details

1 33,000(5

53-41-07 Wheel Well Longeron Wheel Well Longeron Horizontal Flange, 

BS 1121-1135

1 FLS(5)

53-41-07 Wheel Well Longeron Wheel Well Longeron Horizontal Flange, 

BS 1139-1141

1 FLS(5)

53-41-07-A Wheel Well Longeron Vertical Flange at attachment to splice plate and 

uplock fitting

1 33,000(5

53-41-07B Wheel Well Longeron BS 1190-1257 Visible Fastener Holes Vertical and 

Horizontal Flanges

2 44,000(5

53-41-07-B Wheel Well Longeron Vertical & Horizontal Flanges, BS 1120-1190 

Open Areas

2 44,000(5

53-41-07-C Wheel Well Longeron Vertical Flange, BS 1137-1141 2 44,000(553-41-07-D Wheel Well Longeron Vertical and Horizontal Flanges, BS 1120-1201 

Hidden Areas

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

JUN 2012
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-41-08 Bulkhead Frame / Transverse Beam Splice Bulkhead Upper Chord, BS 1113 & 1137 2 FLS(5)53-41-08 Bulkhead Frame / Transverse Beam Splice Bulkhead Upper Chord at Outboard Pedestal 

Fitting Fastener, (BL ±103.4)

2 44,000(5

53-41-08 BS 1113 to BS 1185 Bulkhead Frame BS 1161 Inner Chord at Stringer 22-23 2 44,000(553-41-11 Front Spar Underwing Longeron Fuselage and Wing Lower Panel Attachment 1 33,000(553-41-12 Front Spar Pickle Fork Fitting Pickle Fork outer chord and web BS 873, 

S-17 splice

1 33,000(5

53-41-12 Front Spar Pickle Fork Fitting Fail-Safe Strap, S-18 to S-21 1 33,000(553-41-12 Front Spar Pickle Fork Fitting Outer Chord Attachment to Fail-Safe Strap and 

Skin - Hidden Details - Stringer 19 to Stringer 21

1 33,000(5

53-41-12 Front Spar Pickle Fork Fitting Outer Chord Attachment to Fail-Safe Strap and 

Skin - Stringer 22 to Stringer 19

2 44,000(5

53-41-12 Front Spar Pickle Fork Fitting Pickle Fork inner chord BS 873, S-17 splice 2 44,000(553-41-12 Front Spar Pickle Fork Fitting Inner Chord from WL 184 to Top of Pickle Fork 2 44,000(553-41-12 Front Spar Pickle Fork Fitting Stringer 19 and 20 Mouse Holes 2 44,000(553-41-12 Front Spar Pickle Fork Fitting Front Spar and Skin Attachments WL 165 to 

WL 189.5

1 33,000(5

53-41-13 Trapezoidal Panel/Vertical Flex Tee Fastener Holes at Trapezoidal Panel/Vertical 

Shear Tie Interface

2 44,000(5

53-41-13 Trapezoidal Panel/Vertical Flex Tee Trapezoidal Panel Aft Horizontal Flange Fastener 

Holes, BS 1120 to 1140.4

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-41-13 Trapezoidal Panel/Vertical Flex Tee Lower Penetration, inspection applies to both 

penetrations

2 44,000(5

53-41-13 Trapezoidal Panel/Vertical Flex Tee Stiffeners Horizontal, Vertical, and Diagonal Stiffeners 

Inboard and Outboard Surfaces

2 44,000(5

53-41-13 Trapezoidal Panel / Vertical Flex Tee Fastener Holes at Vertical Shear Tie/Trapezoidal 

Panel Interface, (8) Fasteners Common to Splice Plate

1 33,000(5

53-41-13 Trapezoidal Panel / Vertical Flex Tee Vertical Shear Ties, rebate and radius area 2 44,000(553-41-13 Trapezoidal Panel / Vertical Flex Tee Trapezoidal Panel fastener holes at Flex-T, 

Horizontal and Vertical flanges / Trap Stiffener Bracket

2 44,000(5

53-41-13 Trapezoidal Panel / Vertical Flex Tee Trapezoidal Panel fastener holes at Flex-T at 

BS 1089 and 1113 Frames

2 44,000(5

53-41-13 Trapezoidal Panel / Vertical Flex Tee Flex T-Chord Fastener Hole and Trap Panel 

Stiffener Brackets (Hidden Locations)

1 33,000(5

53-41-13 Trapezoidal Panel / Vertical Flex Tee Visible Fastener Holes in Vertical Shear Tie (both 

upper and lower)

2 44,000(5

53-55-01 Pressure Deck-Stiffened Web 

Gutter - Hidden Fastener details

LBL 94.6 to RBL 94.6 BS 1077 to BS 1081 1 33,000(5

53-55-01 Pressure Deck-Stiffened Web Drainage Gutter, BL 66 to BL 90 Approximately at 

WL 180 and BS 1083

2 44,000(5

53-55-01 Pressure Deck-Stiffened Web Outboard Pressure Pan framing member 1 33,000(553-55-01 Pressure Deck-Stiffened Web Inboard Pressure Pan framing member 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-55-01 Pressure Deck Stiffened Web Fastener Hole on Splice Fitting (BS 1080) 1 33,000(553-55-01 Pressure Deck Stiffener Splice Fittings BS 1113 Section 45 BL 11, 19, 25.75, 32.5, 46, 

52.75, 59.5, 74, 82

2 44,000(5

53-55-01 Pressure Deck Splice Fittings Section 45 BS 1113, BL 39.5 & 66 1 33,000(5

53-55-01B Horizontal Pressure Deck to Wheel Well Longeron 

Splice Plate #3

BS 1137-1161, BL +/-108.2 1 33,000(5

53-55-01B Horizontal Pressure Deck to Wheel Well Longeron 

Splice Fitting #3 (L/N 7 and on)

BS 1137-1161, BL +/-108.2 2 44,000(5

53-55-02 Bulkhead Frame/Transverse Beam Splice Fitting Upper Chord 2 44,000(553-55-02 Bulkhead Frame/Transverse Beam Splice Fitting Web 2 44,000(553-55-02 Transverse Beams - Attachment to Keel Beam at 

H-Frames

Upper Fittings BS 1113-1185, LBL 9, BL 0, RBL 9 1 33,000(5

53-58-01B Wheel Well Bulkhead - Upper Chord Angle - BS 1209, LBL 92 to RBL 92 2 44,000(553-58-01B Wheel Well Bulkhead - Upper Chord Gusset - BL 19, 39.5 & 66 LH and RH sides 2 44,000(5

53-58-01C AWWB Stiffener Splice BS 1209, WL 130 to WL 151, LBL 16 to RBL 16 1 33,000(553-58-01C AWWB Stiffener Splice BS 1209, WL 116 to WL 158, LBL 16 to RBL 16, 

Typical Flange

2 44,000(5

53-58-01C AWWB BL 0 Vertical Chord - Lower Section, 

Section A-A, Splice Straps

BS 1209, BL0, WL 106-120 2 44,000(5

53-58-01D AWWB BL 0 Vertical Chord - Lower Section, 

Section B-B, Chord Fitting

BS 1209, BL0, WL 106-113 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-58-01E AWWB BL 0 Vertical Chord - Lower Section, 

Section C-C, Chord Fitting

BS 1209, BL0, WL 98-106 2 44,000(5

53-58-02 Pressure Deck Vertical Beam Extension Splice - 

Extension Location

Extension Beam Web 2 44,000(5

53-58-02 Pressure Deck Vertical Beam Extension Splice Doubler & Tripler, BS 1205 to BS 1216 WL 179.7 - 

188, BL19, 39.5 & 66

1 33,000(5

53-58-02 Pressure Deck Vertical Beam Extension Extension Beam Upper Chord, BS1185-1209, 

BL19, 39.5 & 66

2 44,000(5

53-58-02-4 Pressure Deck Splice Beam Extension Angle BL 19, 

39.5 & 66 LH and RH Sides

Wheel Well Bulkhead - Vertical Beams Scenario #1 Hole Crack

2 44,000(5

53-58-02-4 Pressure Deck Splice Beam Extension Angle BL 19, 

39.5 & 66 LH and RH Sides

Wheel Well Bulkhead - Vertical Beams Scenario #2 Edge Crack

2 44,000(5

53-58-02A Vertical Beam Lower Clip - Base Flange Vertical Beam Lower Joint BL 19.0 Clip 2 44,000(553-58-02B Vertical Beam Lower Clip - Base Flange Vertical Beam Lower Joint BL 39.5 Clip 2 44,000(5

53-58-02C Vertical Beam Lower Clip - Base Flange Vertical Beam Lower Joint BL 66.0 Clip 2 44,000(5

53-58-03 Wheel Well Bulkhead Side Fitting BS 1209 Side Fitting Outer Chord Splice Region 

at WL 238

1 33,000(5

53-58-03 Wheel Well Bulkhead Side Fitting Side Fitting Inner Chord BS 1209, S-17 splice 2 44,000(553-58-03 Wheel Well Bulkhead Side Fitting Side Fitting Web BS 1209, S-17 splice 2 44,000(553-58-0353-58-04

Aft Wheel Well Bulkhead Lower Chord and Wheel Well Bulkhead Side Fitting

Lower Chord and Side Fitting at splice details (Stringer 28 and 37)

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-58-03A Wheel Well Bulkhead Side Fitting Outer Chord between WL 223 and the Lower 

Splice at WL 150

1 33,000(5

53-58-03B Wheel Well Bulkhead Side Fitting Outer Chord between WL 210 and WL 180 

(Stringer 21 to Stringer 24)

2 44,000(5

53-58-03B Wheel Well Bulkhead Side Fitting Outer Chord, Bifurcation Area - Hoop Loading - 

Hidden Fasteners from WL 210 to WL 180 (Stringer 21 to Stringer 24)

1 33,000(5

53-58-03C Wheel Well Bulkhead Side Fitting Outer Chord, Bifurcation Area - Longitudinal 

Loading - Fastener Holes between WL 210 to WL 180

2 FLS(5)

53-58-03C Wheel Well Bulkhead Side Fitting Outer Chord, Bifurcation Area - Longitudinal 

Loading - Hidden Fasteners between WL 210 to WL 180 (Stringer 21 to Stringer 24)

1 FLS(5)

53-58-03D Wheel Well Bulkhead Side Fitting Pressure Deck Flange, Details Hidden Under 

Stiffeners at WL 186, BL 97 and BL 90

1 33,000(5

53-58-03E Wheel Well Bulkhead Side Fitting BS 1209 Web at Stringer 19 and 20, Lower Mouse 

Holes

2 44,000(5

53-58-03F Wheel Well Bulkhead Side Fitting Fillet radii along Side Fitting Ribs at WLs 158, 165, 

171, and 179

2 44,000(5

53-58-03G Wheel Well Bulkhead Side Fitting Upper Flap Fitting Interface Fastener Hole 

Bending

1 FLS(5)

53-58-03H Wheel Well Bulkhead Side Fitting Inner Chord above the Pressure Deck at WL 185 

to WL 210

2 44,000(5

53-58-03K Wheel Well Bulkhead Side Fitting Fail-Safe Strap, Stringer 19 and 20 1 33,000(5

53-58-03L Wheel Well Bulkhead Side Fitting Fail-Safe Strap between Stringer 21 and 

Stringer 25

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-58-03M Wheel Well Bulkhead Side Fitting Outer Chord - Hidden by Stringer Splice, BS 1209 1 33,000(553-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Visible Stringer 19 and 20, 

BS 1209

2 44,000(5

53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Outer Chord, between 

Stringer 18 - 18.5, BS 1209

1 33,000(5

53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Outer Chord, between 

Stringer 18.5 - 21, BS 1209

1 33,000(5

53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Stringer Fitting, BS 1209 1 33,000(5

53-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Edge Crack, BS 1209 2 44,000(553-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Fillet Radius, BS 1209 2 44,000(553-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Stiffener Radius, BS 1209 2 44,000(5

53-58-04A Aft Wheel Well Bulkhead Lower Chord Lower Chord at BL 39.5 Vertical Beam 

Attachment

1 33,000(5

53-58-04B Aft Wheel Well Bulkhead Lower Chord Lower Chord at BS 1209, LBL 91 to RBL 91 

Typical Lower Chord Section

1 33,000(5

53-58-04C Aft Wheel Well Bulkhead Lower Chord Lower Chord Splices at Stringer 28 and 

Stringer 37

2 44,000(5

53-58-04D Aft Wheel Well Bulkhead Lower Chord Lower Chord at BL 66.0 Vertical Beam 

Attachment - Critical Hidden Detail

1 33,000(5

53-58-04E Aft Wheel Well Bulkhead Lower Chord Circumferential Cracking in the Chord Radius 2 44,000(5

53-58-05 Upper Flap Support Fitting Outer Fitting Clevis Lugs 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-58-05 Upper Flap Support Fitting Base Flange Outer Fillets and Fasteners 2 FLS(5)53-58-05 Upper Flap Support Fitting Base Flange Inner Fillets 1 FLS(5)53-58-05 Lower Flap Support Fitting Aft Wheel Well Bulkhead BS 1208 2 44,000(5

53-58-05A Upper Flap Support Fitting Inner Fitting Clevis Lugs 1 33,000(5

53-59-01 Keel Beam Upper BL0 Web Attachment BS 1089-1209 Upper Web Fastener Holes Hidden 

Details

1 33,000(5

53-59-01 Keel Beam BL 0 Web Attachment to Upper Chord 

Bay 35

BS 1161-1185 2 44,000(5

53-59-01 Keel Beam BL 0 Web Attachment to Upper Chord 

and Rear Spar Beam

BS 1089-1161 2 44,000(5

53-59-01 BL 0 Web Penetrations (L/N 4-6) All Penetrations from BS 1088 to BS 1209, WL 97 

to WL 185

1 33,000(5

53-59-01 BL 0 Web Penetrations (L/N 7 and on) All Penetrations from BS 1088 to BS 1209, WL 97 

to WL 185

2 44,000(5

53-59-01A Keel Beam BL 0 Web Attachment to Upper Chord & 

Aft Wheel Well Bulkhead Vertical Chord

BS 1185 - 1209 2 44,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 4-19)

A/H-Frames at BS 1089, LH and RH, Lower Fastener Row

1 33,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 20 and on)

A/H-Frames at BS 1089, LH and RH, Lower Fastener Row

1 33,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 4-6)

A/H-Frames at BS 1113, 1137, 1161 and 1185, LH and RH, Lower Fastener Row

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 7 and on)

A/H-Frames at BS 1113, 1137, 1161 and 1185, LH and RH, Lower Fastener Row

1 33,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 4-19)

A/H-Frames at BS 1089 WL 100 through WL 105 2 44,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 20 and on)

A/H-Frames at BS 1089 LH and RH, Upper Fastener Row

1 33,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 4-6)

A/H-Frames at BS 1113, 1137, 1161 and 1185, LH and RH, Upper Fastener Row

2 44,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 7-19)

A/H-Frames at BS 1113, 1137, 1161 and 1185, WL 100 through WL 105

2 44,000(5

53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel Chord 

Attachments (L/N 20 and on)

A/H-Frames at BS 1113, 1137, 1161 and 1185, LH and RH, Upper Fastener Row

2 44,000(5

53-59-02 Keel Beam - A/H-Frame Inner Chord (L/N 4-19) BS 1089, BL0, WL 117 & 124 1 33,000(553-59-02 Keel Beam - A/H-Frame Inner Chord (L/N 20 and 

on)

BS 1089, BL0, WL 117 & 124 1 33,000(5

53-59-02 BL0 Web at Keel Beam H-Frame Inner Chord 

(L/N 4-19)

BS 1089 1 33,000(5

53-59-02 BL0 Web to Keel Beam A/H Frame Inner Chord 

(L/N 20 and on)

BS 1089, WL 137 to WL 160 1 33,000(5

53-59-02 BL0 Web at Keel Beam H-Frame Inner Chord 

(L/N 4-19)

BS 1113, 1137, 1161, and 1185 1 33,000(5

53-59-02 Keel Beam H-Frame Inner Chord (L/N 4-19) BS 1089 1 33,000(553-59-02 Keel Beam H-Frame Inner Chord (L/N 4-19) BS 1113, 1137, 1161, and 1185 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-59-02 Keel Beam - H-Frames - Attachment to Transverse 

Beams

Lower Fittings and H-Frame Upper Chords BS 1113-1185, LBL 9, BL 0, RBL 9

1 33,000(5

53-59-03 Keel Beam - Rear Spar Fittings BL 0 Pressure Deck 

Splice Ftg

BL 0, BS 1050-1100, WL 181 Base Flange 1 33,000(5

53-59-03 Keel Beam - Rear Spar Fittings BL 0 Pressure Deck 

Splice Ftg

BL 0, BS 1050-1100, WL 181 Vertical Flange 1 33,000(5

53-59-03 Keel Beam - Rear Spar Fitting At Rear Spar Web (WL 131 to WL 180) and BL 0 

Web (WL 154 to WL 182)

1 33,000(5

53-59-04 Main Landing Gear Torque Box Torque Box Forward and Aft Upper Chord and 

Side Web Hand Hole

1 33,000(5

53-59-04 Main Landing Gear Torque Box Tension Fitting and Hinge Fitting 1 33,000(553-59-04 Main Landing Gear Torque Box (L/N 4-19) Lower Tension Fitting 1 33,000(553-59-04 Main Landing Gear Torque Box (L/N 20 and on) Lower Tension Fitting 1 33,000(5

53-59-04a S45 MLG Door Hinge Fittings Forward, Mid, and Aft Hinges Lower Lug on 

both sides

1 33,000(5

53-59-04b MLG Door Hinges Fittings Fillet Radius Details Mid, Forward and Aft Hinge Fillets @ BS 1145, 

BS 1195, and BS 1089

2 44,000(5

53-59-05A Underwing Vertical Webs Detail A Shear Web Boundaries BS 868-1075 Critical 

Location Bay 4 Lower

2 44,000(5

53-59-05B Underwing Vertical Webs - Keel Beam Flange 

Detail B

Keel flange under clip in Bay 1 2 44,000(5

53-59-05C Underwing Vertical Webs - Stiffeners, Keel Side 

of Attachment

Critical Location is #18 at BS 879 Analysis covers all similar details

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-59-07-2 Keel Chord Splice BS 867.7 and 1209, LBL 14 and RBL 14 1 33,000(553-59-07-3 Keel Ladder Vertical Supports Keel to Vertical Support at Front Spar BS 868 & 

AWW Bulkhead BS 1209 LH & RH Side

2 44,000(5

53-59-07-7 Rear Spar Lattice Fitting BS 1073.33 LBL 11.5 to 

RBL 11.5

Lattice Fitting Lower Chord common to Vapor Barrier Web

1 FLS(5)

53-59-07-7 Rear Spar Lattice Fitting 12 End Pad at Keel Chord Attachment 1 FLS(5)

53-61-01A Wheel Well Longeron Extension Backup Fitting BS 1233 Backup Fitting Fillet 2 44,000(553-61-01A Section 46 Aft EE Bay Door Surround Door Support 

Flange

BS 1233 Stringer 39L - 39R 2 44,000(5

53-61-02 Circumferential Skin-Stringer Splice - BS 1605 Upper Sill, BS 1593 - Str 22 RHS Inner Chord 2 44,000(553-61-03 Circumferential Skin-Stringer Splice - BS 1209 BS 1209 Doubler, hidden by longeron 1 33,000(553-61-07 Passenger Entry Door 3 - Edge Frame Edge Frame Web at Door Stop BS 1304, S-19 

to S-20

2 FLS(5)

53-61-07 Passenger Entry Door 3 - Edge Frame BS 1304, Stringer 22-23, LHS 2 44,000(553-61-07 Passenger Entry Door 3 - Edge Frame BS 1354, Stringer 14-15, RHS 2 44,000(553-61-07 Passenger Entry Door 3 - Edge Frame BS 1304, Stringer 20-21, RHS 2 44,000(553-61-07 Passenger Entry Door 3 - Edge Frame Edge Frame at Splice BS 1354, S-10 to S-11 2 44,000(553-61-09 Aft Large Cargo Door - Lower Main Sill BS 1465 Inner Chord 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-61-09 Aft Large Cargo Door - Lower Main Sill Inner Chord at BS 1465 fastener hole at 

Edge Frame

1 33,000(5

53-61-09 Aft Large Cargo Door - Lower Main Sill Inner Chord at BS 1569 Latch Back-Up Ftg 1 33,000(553-61-09 Aft Large Cargo Door - Lower Main Sill BS 1569 Inner Chord 1 33,000(553-61-09 Aft Large Cargo Door - Lower Main Sill BS 1569 Web where hidden by latch and 

backup structure

1 33,000(5

53-61-09 Aft Large Cargo Door - Lower Main Sill BS 1510 Web 1 33,000(553-61-09 Aft Large Cargo Door - Lower Main Sill Outer Chord at Edge Frame at BS 1465 1 33,000(553-61-09 Aft Large Cargo Door - Lower Main Sill BS 1545 Outer Chord at Latch Back-Up Fitting 1 33,000(553-61-09 Aft Large Cargo Door - Lower Main Sill BS 1562 Stringer 33 RHS Outer Chord 2 44,000(553-61-09 Aft Large Cargo Door - Upper Main Sill Inner Chord at BS 1556 at Hinge Back-up Fitting 

Fastener Hole

2 44,000(5

53-61-09 Aft Large Cargo Door - Upper Main Sill Inner Chord, BS 1577 2 44,000(553-61-09 Aft Large Cargo Door - Upper Main Sill Inner Chord at Edge Frame BS 1577 2 44,000(553-61-09 Aft Large Cargo Door - Upper Main Sill BS 1577 Outer Chord at Edge Frame 1 33,000(553-61-09 Aft Large Cargo Door - Upper Main Sill BS 1574, Upper Sill RHS, Outer Chord 2 44,000(553-61-09 Aft Large Cargo Door - Upper Main Sill Outer Chord at BS 1569 where not hidden 2 44,000(553-61-09 Aft Large Cargo Door - Upper Main Sill Sill Outer Chord at BS 1569 split frame 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-61-09 Aft Large Cargo Door - Edge Frame BS 1577 Stringer 26, RHS, Inner Chord 2 44,000(553-61-09 Aft Large Cargo Door - Edge Frame Pull-in Pin attachment at S-30R 2 44,000(553-61-09 Aft Large Cargo Door - Edge Frame BS 1577 Stringer 33 Edge Frame Web Sill 

Attachment

2 44,000(5

53-61-09 Aft Large Cargo Door - Edge Frame BS 1577 between S-23R and Upper Sill Outer 

Chord

2 44,000(5

53-61-09 Aft Large Cargo Door - Edge Frame BS 1577 at Upper Sill Outer Chord 2 44,000(553-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame Inner Chord and Web BS 1744 

S-12R to S-13R

2 44,000(5

53-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame at Door Stop BS 1794, S-21L 2 44,000(553-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame Web BS 1794 at Upper Sill 1 33,000(553-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame Outer Chord BS 1744, S-19L to 

S-20L

2 44,000(5

53-71-08 Bulk Cargo Door - Lower Sill Lower Sill Inner Chord, BS 1644 to 1670 2 44,000(553-71-08 Bulk Cargo Door - Lower Sill Lower Sill Inner Chord, BS 1644 to 1670 Hidden 

at Forward Edge Frame

1 33,000(5

53-71-08 Bulk Cargo Door - Edge Frame Edge Frame Inner Chord and Web BS 1670, 

S-29L at Door Stop 2 & BS 1719 at Latch Back-up Fitting

2 44,000(5

53-71-08 Bulk Cargo Door - Edge Frame Forward Edge Frame Inner Chord and Web 

BS 1670, S-30L at latch fitting

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-71-08 Bulk Cargo Door - Edge Frame Edge Frame at Door Stop BS 1719, S-29 1 33,000(553-71-08 Bulk Cargo Door - Edge Frame Edge Frame Web BS 1670 at Lower Sill 1 33,000(553-71-08 Bulk Cargo Door - Edge Frame Edge Frame Outer Chord BS 1719, S-26L 2 44,000(553-81-04 Aft Pressure Bulkhead Assembly Y-Chord at Web attachment BS 1878, outboard 

fastener row

2 44,000(5

53-81-04 Aft Pressure Bulkhead Assembly Y-Chord aft most fastener row common to skin 

and splice strap, BS 1878

2 44,000(5

53-81-06 Circumferential Splice at Pivot Bulkhead Forward Chord Splice at S-13 Left 1 33,000(553-81-06 Circumferential Splice at Pivot Bulkhead Forward Crown Chord at S-9L 1 33,000(553-81-06 Circumferential Splice at Pivot Bulkhead Forward and Aft Keel Chords at S-35L 2 44,000(553-81-06 Circumferential Splice at Pivot Bulkhead Side Chord at fasteners common to pivot backup 

fitting, WL 248.5

2 44,000(5

53-81-06 Circumferential Splice at Pivot Bulkhead Forward Side Chord at Skin Attachment to 

Longeron Fitting, WL 259

1 33,000(5

53-81-06 Circumferential Splice at Pivot Bulkhead Forward Chord at Splice - S-13L, BS 2064.5 at 

Upper Stringer End Fitting

2 44,000(5

53-81-06 Circumferential Splice at Pivot Bulkhead Side Chord Splice to Jack Fitting 2 44,000(553-81-08 Sec. 48 Horizontal Stabilizer Pivot Fitting Pivot Fitting Flange Common to Bulkhead Web at 

BS 2064.5

2 44,000(5

53-81-08 Sec. 48 Horizontal Stabilizer Pivot Fittings Pivot Fitting Lug (BS 2064.5) 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-81-10 Horizontal Stabilizer Trim Actuator Fitting Assembly Primary Pins at BS 1942 1 33,000(553-81-10 Horizontal Stabilizer Trim Actuator Fitting Assembly Primary / Secondary Lug at BS 1942 1 33,000(553-81-11 Section 48 Horizontal Stabilizer Cutout - Longeron 

Fittings

Upper Longeron & Failsafe Fittings Bolts BS 2064.5

1 33,000(5

54-51-01-B Pylon To Wing Fittings Rolls Royce Engine Pylon 2 44,000(554-51-01-B Pylon To Wing Fittings General Electric Engine 

Pylon

2 FLS(5)

54-51-02-A Upper Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface - Bays 1 - 3 2 FLS(5)

54-51-02-C Upper Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 0 - 3, Inboard 

Side Only

2 FLS(5)

54-51-02-D Upper Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface at Frames 1 & 2, 

Inboard Side Only

1 FLS(5)

54-51-02-D Upper Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface at Frames 1 & 2 1 FLS(5)

54-51-02-F Upper Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 4 & 5, Inboard 

Side Only

2 FLS(5)

54-51-02-F Upper Spar Assembly General Electric Engine 

Pylon

R3/R4 Chord - Bay 5 1 FLS(5)

54-51-02-G Upper Spar Assembly Rolls Royce Engine Pylon R1 Upper Spar Fitting 1 33,000(554-51-02-G Upper Spar Assembly General Electric Engine 

Pylon

R1 Upper Spar Fitting 1 FLS(5)

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

54-51-03-B Side Skins Rolls Royce Engine Pylon Side Skin Cutouts 2 FLS(5)54-51-03-B Side Skins General Electric Engine Pylon Side Skin Cutouts 2 FLS(5)

54-51-04-A1 Lower Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 1 - 3 2 FLS(5)54-51-04-A1 Lower Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface - Bays 1 - 3 2 FLS(5)

54-51-04-A2 Lower Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 1 - 3 at Brackets 1 FLS(5)54-51-04-A2 Lower Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface - Bays 1 - 3 at Brackets 1 FLS(5)

54-51-04-A3 Lower Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface - Bays 1 - 3 at Partial Bracket Locations

1 FLS(5)

54-51-04-B1 Lower Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 4 and 5 2 FLS(5)54-51-04-B1 Lower Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface - Bays 4 and 5 2 FLS(5)

54-51-04-B2 Lower Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 4 and 5 at 

Brackets

1 FLS(5)

54-51-04-B2 Lower Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface - at Shear Fittings 1 FLS(5)

54-51-04-B3 Lower Spar Assembly General Electric Engine 

Pylon

Chord/Skin/Web Interface - at Heat Shield 1 FLS(5)

54-51-05-A Forward Engine Mount Bulkhead Rolls Royce 

Engine Pylon

Tension Bolt Attachments 2 FLS(5)

54-51-06-B Frame 3 General Electric Engine Pylon Tension Bolt Attachments 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

54-51-09-A Aft Engine Mount Tension Fittings Rolls Royce 

Engine Pylon

2 FLS(5)

54-51-09-A Aft Engine Mount Tension Fittings General Electric 

Engine Pylon

2 FLS(5)

54-51-10-A Aft Strut Bulkhead Rolls Royce Engine Pylon Upper Mid Stiffener 2 44,000(554-51-10-A Aft Strut Bulkhead General Electric Engine Pylon Upper Mid Stiffener 2 44,000(5

54-51-11 Rolls Royce Forward Engine Mount Installation Mount Fitting, Mount Links, Engine Lugs, 

Attach Bolts

2 FLS(5)

54-51-12 General Electric Forward Engine Mount Installation Mount Fitting, Mount Links, Engine Lugs, 

Attach Bolts

2 FLS(5)

54-51-13 Rolls Royce Aft Engine Mount Installation Engine 

Serial Numbers: 10025 -10047

Thrust Links, Fitting, Mount Links, Evener Bar, Engine Lugs, Attach Bolts

2 FLS(5)

54-51-13 Rolls Royce Aft Engine Mount Installation Thrust Links, Fitting, Mount Links, Evener Bar, 

Engine Lugs, Attach Bolts

2 FLS(5)

54-51-14 General Electric Aft Engine Mount Installation Thrust Links, Fitting, Mount Links, Evener Bar, 

Engine Lugs, Attach Bolts

2 FLS(5)

55-10-01 T-Chord Upper Center Box Side Rear Spar - Pivot Strap 1 33,000(555-10-01 Upper T-Chord, Multispar Box Side (L/N 4-6) Front Spar 1 33,000(555-10-01 T-Chord Upper Multispar Box Side (L/N 4-6) Rear Spar - Pivot Strap 1 33,000(555-10-01 T-Chord Upper Center Box (L/N 4-6) Front Spar - Jackscrew Plate 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

55-10-01 T-Chord Upper Front Spar Zone Multispar Box Side 

(L/N 7 and on)

Front Spar 2 44,000(5

55-10-01 T-Chord Upper Front Spar Center Box Side 

Jackscrew Plate (L/N 7 and on)

Front Spar 2 FLS(5)

55-10-01 T-Chord Upper Front Spar Center Box Side 

(L/N 7 and on)

Front Spar 2 44,000(5

55-10-02 T-Chord Lower Center Box Side Rear Spar - Pivot Strap 1 33,000(555-10-02 Lower T-Chord, Multispar Box side (L/N 4-6) Front Spar 1 33,000(555-10-02 T-Chord Lower Multispar Box Side (L/N 4-6) Rear Spar 1 33,000(555-10-02 T-Chord Lower Center Box (L/N 4-6) Front Spar - Jackscrew Plate 1 33,000(555-10-02 T-Chord Lower Front Spar Zone Multispar Box Side 

(L/N 7 and on)

Front Spar 2 44,000(5

55-10-10 Pivot Fitting Upper Flange (L/N 4-6) Upper Flange 1 33,000(555-10-10 Lower Flange Pivot Fitting Lower Flange (L/N 4-6) Lower Flange 1 33,000(555-10-10 Pivot Fitting Web (L/N 4-6) Web 1 33,000(555-10-10 Pivot Fitting Lug (L/N 4-6) Lug 1 33,000(555-10-10 Pivot Fitting Upper Flange (L/N 7 and on) Pivot Fitting Upper Flange Center Box Horizontal 

Stabilizer

2 44,000(5

55-10-10 Pivot Fitting Lower Flange (L/N 7 and on) Pivot Fitting Lower Flange Center Box Horizontal 

Stabilizer

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

55-10-10 Pivot Fitting Angle - Web Bolt (L/N 7 and on) Pivot Fitting Web bolt Center Box Horizontal 

Stabilizer

2 44,000(5

55-10-10 Pivot Fitting Lug Analysis (L/N 7 and on) Pivot Fitting Lug Center Box Horizontal Stabilizer 2 44,000(555-10-12 Upper Strap Pivot Side (L/N 4 - 6) Pivot Side 2 44,000(555-10-12 Lower Strap Pivot Side (L/N 4 - 6) Pivot Side 2 FLS(5)55-10-12 Upper Strap Pivot side - Transversal Stress 

(L/N 7 and on)

Upper Strap - Pivot Side - Horizontal Stabilizer Center Box

2 44,000(5

55-10-12 Upper Strap Pivot Side Long Stress (L/N 7 and on) Pivot Side 2 44,000(555-10-12 Upper Strap (L/N 7 and on) T-Chord 2 44,000(555-10-12 Pivot Lower Strap Crack Growth-FX (L/N 7 and on) Pivot Strap Lower LHS - Horizontal Stabilizer 

Center Box

2 44,000(5

55-10-12 Lower Strap Pivot Side Longitudinal Stress 

(L/N 7 and on)

Pivot Side 2 44,000(5

55-10-12 Lower Strap T-Chord Side (L/N 7 and on) T-Chord zone 2 44,000(555-10-13 Pivot Outboard Angle (L/N 4 - 6) Pivot Side 2 44,000(555-10-13 Rear Spar Splice Pivot Side Vertical Stress 

(L/N 7 and on)

Pivot Web Side 2 44,000(5

55-10-13 Rear Spar Splice Pivot Side Horizontal Stress 

(L/N 7 and on)

Pivot Web Side 2 44,000(5

55-10-13 Rear Spar Splice Multispar Box Side Vertical Stress 

(L/N 7 and on)

Multispar Box Side 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

55-10-13 Rear Spar Splice Multispar Box Side Horizontal 

Stress (L/N 7 and on)

Multispar Box Side 2 44,000(5

55-10-14 Pivot Pin Outer Pivot 1 33,000(555-15-01 Jackscrew Fitting Upper Plate Front Side Front Side 2 FLS(5)55-15-01 Jackscrew Fitting Upper Plate Multispar Box Side 

(L/N 4 - 6)

Jackscrew Fitting Upper Plate Multispar Box Side 2 44,000(5

55-15-01 Jackscrew Upper Plate (L/N 7 and on) Jackscrew Upper Plate Middle Side 2 44,000(555-15-01 Jackscrew Upper Plate (L/N 7 and on) Jackscrew Upper Plate Multispar Box Side 2 44,000(555-15-02 Jackscrew Fitting Lower Plate Front Spar Side 

(L/N 4 - 6)

Jackscrew Fitting Lower Plate Front Spar Side 2 44,000(5

55-15-03A Jackscrew Front Spar Web Splice (L/N 4-6) Center Box Side Flange 2 44,000(555-15-03A Jackscrew Web Splice (L/N 7 and on) Center Box Side (y direction), Center Box 

Horizontal Stabilizer

2 44,000(5

55-15-03A Jackscrew Web Splice (L/N 7 and on) Web Splice Multispar Box Side (y direction), 

Center Box Horizontal Stabilizer

2 44,000(5

55-15-03B Jackscrew Front Spar Upr/Lwr Angle (L/N 4 - 6) 1 33,000(555-15-03B Jackscrew Upper Angle (L/N 7 and on) Upper Angle (Bolt UH1) Center Box Horizontal 

Stabilizer

2 44,000(5

55-15-03C Jackscrew Lower Angle (L/N 7 and on) Upper Angle (Bolt LH1) Center Box Horizontal 

Stabilizer

2 44,000(5

55-15-04 Jackscrew Terminal Fitting (L/N 7 and on) Web Splice Side y-direction Center Box Horizontal 

Stabilizer

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

55-15-04 Jackscrew Terminal Fitting (L/N 7 and on) Web Splice Side x-direction Center Box Horizontal 

Stabilizer

2 44,000(5

55-15-04 Horizontal Stabilizer Center Box (L/N 7 and on) Jackscrew Terminal Fitting Rib Side (fy) 2 44,000(555-18-01 Jackscrew Inboard/Outboard Fittings L/R (L/N 4 - 6) Upper Horizontal Flange 2 44,000(555-18-01 Jackscrew Inboard/Outboard Fittings L/R (L/N 4 - 6) Lower Horizontal Flange 2 44,000(555-18-01 Jackscrew Inboard/Outboard Fittings L/R (L/N 4 - 6) Lug 2 44,000(555-18-01 Jackscrew Inboard/Outboard Fittings Upr Horizontal 

Flange (L/N 7 and on)

Upper Flange 2 44,000(5

55-18-01 Jackscrew Inboard/Outboard Fittings Lwr Horizontal 

Flange (L/N 7 and on)

Lower Flange 2 44,000(5

55-18-01 Jackscrew Inboard/Outboard Fittings (L/N 7 and on) Lug 2 FLS(5)55-18-02 Jackscrew Outer Gimbal Nut Outer Pin 2 FLS(5)55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1, -2, -4

1st Forward 0.25" dia. fastener common to the main box skin panel

2 FLS(5)

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1, -2, -4 (L/N 7 and on)

Forward .25" Dia Chord Fasteners common to the Main Box Skin Panel

2 FLS(5)

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1, -2, -4

Aft 0.25" dia. chord fastener common to the main box skin panel

2 FLS(5)

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1, -2, -4

Aft 0.3125" dia. chord fastener common to the main box skin panel

2 FLS(5)

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1, -2, -4 (L/N 7 and on)

Forward .19" Dia Chord Field Fastener common to Main Box Skin Panel

2 FLS(5)

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1, -2, -4 (L/N 7 and on)

Aft .19" Dia Chord Field Fastener Common to Main Box Skin Panel

2 FLS(5)

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1 (L/N 4-6)

Forward .25" Dia Chord Fasteners common to the Main Box Skin Panel

2 FLS(5)

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1 (L/N 4-6)

Forward .19" Dia Chord Field Fastener common to Main Box Skin Panel

2 FLS(5)

55-33-10 Main Torque Box - Closeout Rib 15 

P/N 212Z5115-1 (L/N 4-6)

Aft .19" Dia Chord Field Fastener common to Main Box Skin Panel

2 FLS(5)

55-37-01 Root Attach Fittings, Rear Spar, Left & Right 

P/N 212Z7101-1, -2, -3, -4

Forward & Aft Tension Bolt Lugs 2 FLS(5)

55-37-01 Root Attach Fittings, Rear Spar, Left & Right 

P/N 212Z7101-1, -2, -3, -4

Fitting web and stiffeners below Rib 1 WL 325 to WL 327

2 FLS(5)

55-37-01 Root Attach Fittings, Rear Spar, Left & Right 

P/N 212Z7101-1, -2, -3, -4

Fitting web and stiffeners below Rib 1 WL 317 to WL 325

2 FLS(5)

55-37-01 Root Attach Fittings, Rear Spar, Left & Right 

P/N 212Z7101-1, -2, -3, -4

Flange common to Fin Deck Fasteners 2 FLS(5)

55-37-02 Root Attach Fittings, Stringer 3 Left & Right 

P/N 212Z7111-1, -2, -3, -4

Aft Tension Bolt Lug 2 FLS(5)

55-37-02 Root Attach Fittings, Stringer 3 Left & Right 

P/N 212Z7111-1, -2, -3, -4

Stringer 3 Root Splice between WL 325 and W 331 (cut 4)

2 FLS(5)

55-37-02 Root Attach Fittings, Stringer 3, Left and Right 

P/N 212Z7111-1, -2, -3, -4

10.41 inches below Rib 1 centerline along center 

stiffener centerline (cut 3)

2 FLS(5)

55-37-02 Root Attach Fittings, Stringer 3, Left and Right 

P/N 212Z7111-1, -2, -3, -4

Flange common to Fin Deck Fasteners 2 FLS(5)

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

55-37-03 Root Attach Fittings, Stringer 6, Left & Right 

Empennage Vertical Stabilizer

Forward Tension Bolt Lug 2 FLS(5)

55-37-03 Root Attach Fittings, Stringer 6, Left & Right 

Empennage Vertical Stabilizer

Stringer 6 Root Splice Between WL 328 and WL 333

2 FLS(5)

55-37-03 Root Attach Fittings, Stringer 6, Left & Right 

Empennage Vertical Stabilizer

8.27" below Rib #1 centerline along center stiffener centerline (Cut 3)

2 FLS(5)

55-37-03 Root Attach Fittings, Stringer 6,Left & Right 

Empennage Vertical Stabilizer

Flange Common to Fin Deck Fasteners 2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

PN 212Z7131-1,-2, -3, -4

Forward Tension Bolt Lug 2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

PN 212Z7131-1,-2, -3, -4

Fitting 1 Web and Flange adjacent to the Front Spar Root Strap, WL 329 to WL 333

2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

PN 212Z7131-1,-2, -3, -4

Flange common to Fin Deck Fasteners 2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

PN 212Z7131-1,-2 (L/N 4-6)

Fitting 1 Web and Stiffener below Forward Torque Box Rib 1 attachment (cut 3)

2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

PN 212Z7131-1,-2 (L/N 4-6)

Fitting 1 Web and Spar Flange Aft of the Front Spar (cut 1)

2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

P/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)

Fitting 1 Web and Spar Flange Aft of the Front Spar, WL 321 to WL 333

2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

P/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)

Fitting 1 Web and Stiffener below Forward Torque Box Rib 1 attachment (cut 3) WL 323 to WL 325

2 FLS(5)

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

P/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)

Fitting 1 Web and Spar Flange Aft of the Front Spar, WL 317 to WL 321

2 FLS(5)

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

55-37-04 Root Attach Fittings, Front Spar, Left & Right 

P/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)

Fitting 1 Web & Stiffener below Forward Torque Box Rib 1 Forward of the Front Spar, WL 320 to WL 323

2 FLS(5)

55-37-05 Root Attach Tension Bolt Frame 4 - Forward Tension Bolt - Vertical Fin 2 FLS(5)

57-10-01A Side of Body Splice - Upper Surface Critical Surface 

Inspection Areas

Upper Splice Plate - BS 1026.5 - 1076.5 Rear Spar to Stringer 4

2 FLS(5)

57-10-01B Side of Body Splice - Upper Surface General 

Surface Inspection Areas

Upper Splice Plate - BS 873.0 - 1026.5 Front Spar to Stringer 5

2 44,000(5

57-10-01C Side of Body Splice - Upper Surface Upper Splice Plate - BS 873.0 - 1076.5 Areas 

Hidden by Pi Fittings - Section 11

1 FLS(5)

57-10-01D

57-10-01E

Side of Body Splice - Upper Surface Tee Chord and Splice Plate

Upper Splice Plate - BS 873.0-1076.5 areas hidden by Flex Tee at Pi Fittings

1 FLS(5)

57-10-01D

57-10-01E

Side of Body Splice - Upper Surface Tee Chord and Splice Plate

Upper Splice Plate - BS 873.0-1076.5 areas hidden by Flex Tee

1 FLS(5)

57-10-02 Side of Body Splice - Lower Surface Jack Pad Fitting bolt holes 2 44,000(557-10-02 Side of Body Splice - Lower Surface Side of Body Rib Lower Chord visible fasteners at 

Web attachment

1 33,000(5

57-10-02 Side of Body Splice - Lower Surface 

LHS (L/N 4-21), RHS (L/N 4-20)

Outboard Wing, Lower Chord and Splice Plate from Front Spar to Rear Spar

1 33,000(5

57-10-02 Side of Body Splice - Lower Surface 

LHS (L/N 22 and on), RHS (L/N 21 and on)

Outboard Wing, Lower Chord and Splice Plate from Front Spar to Rear Spar

1 33,000(5

57-10-03-1 Side of Body Splice - Front Spar Terminal Fitting, Lower Cap Horizontal Flange 1 FLS(5)57-10-03-2 Side of Body Splice - Front Spar Terminal Fitting Vertical Flanges 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

JUN 2012
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-10-03-5 Side of Body Splice - Front Spar Terminal Fitting, Upper Cap Flange Common to 

Side of Body Rib

1 33,000(5

57-10-03-9 Side of Body Splice - Front Spar Terminal Fitting, Upper Cap Flange Common to 

Front Spar Web

1 33,000(5

57-10-04 Side of Body Splice - Rear Spar Rear Spar Terminal Fitting at attachment Side of 

Body Rib Web - Hidden Areas

1 FLS(5)

57-10-04 Side of Body Splice - Rear Spar Rear Spar Terminal Fitting at attachment Side of 

Body Rib Web - Non-Hidden Areas

1 33,000(5

57-10-04 Side of Body Splice - Rear Spar Rear Spar Terminal Fitting lower horizontal & 

vertical flanges

1 FLS(5)

57-10-04 Side of Body Splice - Rear Spar Lower Splice Plate holes common to rear spar 

lower chord

2 44,000(5

57-10-05 Side of Body Splice - Rear Spar Side of Body Rib Web at Front & Rear Spar 

Terminal Ftg & Upper and Lower Chords

1 FLS(5)

57-10-05 Side of Body Rib Web penetration holes with satellite holes 2 44,000(557-10-05 Side of Body Rib Web penetrations without satellite holes 2 44,000(557-10-05 Side of Body Rib (L/N 4-6) Web to Access Door Detail (LHS/RHS) 1 33,000(557-10-05 Side of Body Rib (L/N 7 and on) Web to Access Door Detail (LHS/RHS) 2 44,000(557-10-05 Side of Body Rib (L/N 4-6) Vertical stiffeners No.1-12 to web joints 

(LHS/RHS)

2 44,000(5

57-10-05 Side of Body Rib (L/N 34 and on) Web at Base of Integral Horizontal Stiffeners - 

Group 1

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-10-05 Side of Body Rib (L/N 34 and on) Web at Base of Integral Horizontal Stiffeners - 

Group 2

2 44,000(5

57-10-05 Side of Body Rib (L/N 34 and on) Web at Base of Integral Horizontal Stiffeners - 

Group 3

2 44,000(5

57-10-06A Overwing Flex-T Flex-T Fastener Holes at Trapezoidal Panel 

Visible Locations

2 44,000(5

57-10-06A Overwing Flex-T Flex-T Fastener Holes at Trapezoidal Panel - 

Hidden Locations

1 33,000(5

57-10-06A Overwing Flex-T Flex-T web fastener holes hidden by FSOWL & 

RSOWL and locations in Note 2

1 33,000(5

57-10-06A Overwing Flex-T Flex-T rebate edge at BS 933 Forward edge of #4 

and Aft edge of #5 Flex-T

2 44,000(5

57-10-06A Overwing Flex-T Flex-T rebate edges at BS 882, 981, 1031, 1071, 

1085, and 1120

2 44,000(5

57-10-06A Overwing Flex-T Flex-T rebate, from BS 883 to BS 1120 except 

Flex-T rebate edges

2 44,000(5

57-10-06A Overwing Flex-T No. 1 Flex Tee Clevis Bore - BL 113.13, BS 1076 1 33,000(557-10-06A Overwing Flex-T No. 1 Flex Tee Clevis Neck - BL 113.13, BS 1076 2 44,000(557-10-06A Overwing Flex-T No. 2 Flex Tee Lug Bore - BL 113.4, BS 1076 1 33,000(557-10-06B Pi-Fitting - Frame BS 897-1089 Upper Flange Joint, Pi-Fittings #1-9 (LHS/RHS) 2 44,000(557-10-06B Pi-Fitting - Frame BS 897-1089 Upper flange radius, Pi-Fittings #1-9 (LHS/RHS) 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-10-06B Pi-Fitting - Frame BS 897-1089 Wall Flange Joint

L/N 4-6: BS 897, 945, 1017, 1041, 1065L/N 7 and on: BS 945, 1017, 1041, 1065

2 FLS(5)

57-10-06B Pi-Fitting - Frame BS 897-1089 Wall Flange, Fitting Base Radius Pi Fittings #1-9 

(LHS/RHS)

2 44,000(5

57-10-06B Pi-Fitting - Frame BS 897-1089 All Base Joint Fasteners, Pi Fittings #1-9 1 33,000(5

57-10-06C Shear Fitting - Frame BS 897-1089 Vertical & Base Flange Radius 2 44,000(5

57-12-01A Rear Spar, Stiffener, Edge of Flange BL 11 (LHS/RHS) at WL 130 to 147 2 44,000(557-12-01A Rear Spar Stiffener, Free Flange Fasteners BL 11 

(LHS/RHS) at WL 140 to WL 157

1 33,000(5

57-12-01a Rear Spar Stiffener, Hole Section BL 11 (LHS/RHS) at 

WL 94.5 - 98

2 44,000(5

57-12-01A Rear Spar Manufacturing Door Horizontal Stiffener 1 33,000(557-12-01B Rear Spar Access Doors Manufacturing Door Fastener Hole 

(Hidden Locations)

1 33,000(5

57-12-01C Rear Spar - Miscellaneous Fittings Bracket, BL 74 and BL 59.5 (LHS/RHS) RBL 32.5, 

RBL 19 at WL 181.7

2 44,000(5

57-12-01C Rear Spar - Miscellaneous Fittings T Clip @ BL 82, 52.8 46, 25.8 (LHS/RHS) 

LBL 32.5, LBL 19 at WL 181.7

2 44,000(5

57-12-01C Rear Spar - Miscellaneous Fittings Inboard/Outboard OWB Fittings, BL 66 

(LHS/RHS) at WL 181.7

1 33,000(5

57-12-01C Rear Spar - Miscellaneous Fittings (L/N 4-19) T-Clip at MLG Door Support Intercostal, LBL 90 

and RBL 90, WL 135

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-12-01C Rear Spar - Miscellaneous Fittings (L/N 4-19) Lug - R/S MLGD Support Ftg, LBL 90, RBL 90, 

LBL 102, RBL 102 Lug Area

1 33,000(5

57-12-01C Rear Spar - Miscellaneous Fittings (L/N 20 and on) Lug - R/S MLG Door Support Upper Fittings, 

LBL 90, RBL 90, LBL 102, RBL 102 Lug Area

1 33,000(5

57-12-01C Rear Spar - Miscellaneous Fittings (L/N 4-19) Upper Flange Detail - R/S MLG Door Support Ftg, 

LBL 90 and RBL 90

2 44,000(5

57-12-01C Rear Spar - Miscellaneous Fittings (L/N 4-19) R/S MLG Door Support Fitting Joint LBL 90, 

RBL 90, LBL 102, RBL 102 Joint Area

1 FLS(5)

57-12-01C Rear Spar - Miscellaneous Fittings Rear Spar Back-up Angles, LBL and RBL 46 and 

82, WL 146

2 44,000(5

57-12-01C Rear Spar - Miscellaneous Fittings Lower Beam Lug and Clevis Fitting, LBL and 

RBL 46 and 82, WL 144

1 33,000(5

57-12-02A Front Spar - Stiffener BL 82, BL 90 (LHS/RHS) WL 136 to WL 192 2 44,000(557-12-02A Front Spar - Stiffener, Gage Steps BL 82, BL 90 (LHS/RHS) WL 196 to WL 192 2 44,000(557-12-02A Front Spar - Horizontal Stiffener Between BL 90 to BL 114, left and right 2 44,000(557-12-02B Front Spar - Miscellaneous Fittings Overwing Beam Fitting @ BL 11, 39.5, 66, 90, 

(LHS/RHS) at Front Spar Attachment

2 44,000(5

57-12-02B Front Spar - Miscellaneous Fittings (L/N 7-45) Overwing Beam Fitting @ BL 11, 39.5, 66, 90, 

(LHS/RHS) where hidden by doubler

1 33,000(5

57-12-02B Front Spar - Miscellaneous Fittings Overwing Beam Fitting, Upper Flange @ BL 11, 

39.5, 66, 90, (LHS/RHS) at WL 194

2 44,000(5

57-12-02B Front Spar - Miscellaneous Fittings Stiffener End Fitting @ BL 3, 11, 25, 39.5, 52, 59, 

65, and 74 (LHS/RHS) WL 98 to WL 133

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-12-02B Front Spar - Miscellaneous Fittings Stiffener End Ftg, Radius Section @ BL 3, 11, 25, 

39.5, 52, 59, 65, 74 (LHS/RHS), WL 98 to WL 133

2 44,000(5

57-12-02B Front Spar - Miscellaneous Fittings Lower Beam Lugs and Clevis Fittings LBL and 

RBL 46 and 82, WL 144

1 33,000(5

57-12-03a Front Spar Body Chord Skin Flange BL 30 - BL 104 1 FLS(5)57-12-03a Front Spar Body Chord Skin Flange, Hidden Flange at BL 95 - 98 1 33,000(557-12-03a Front Spar Body Chord Web Side Flange BL 30 - BL 104 1 33,000(557-12-03a Front Spar Body Chord Web Side Flange, Hidden Fastener Details 

BL 30 - BL 104

1 33,000(5

57-12-03a Front Spar Body Chord Web Flange @ BL 0 - BL 30 Hidden Details 1 33,000(557-12-03a Front Spar Body Chord Radius 2 44,000(557-12-03a57-12-03b

Front Spar Body Chord Skin Flange at BL 0 - BL 30 1 33,000(5

57-12-03a57-12-03b

Front Spar Body Chord Web Flange at BL 0 - BL 30 1 33,000(5

57-12-03b Front Spar Body Chord Splice Details Body Chord at BL 0 Splice - Web Flange at 

Stiffener End Fittings

1 33,000(5

57-12-03b Front Spar Body Chord Splice Details Pickle Fork and Front Body Chord at Outboard 

Splice - Skin Flange

1 33,000(5

57-12-03b Front Spar Body Chord Splice Details Pickle Fork and Front Body Chord at Outboard 

Splice - Web Flange

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-12-03b Front Spar Body Chord Splice Details BL 0 Body Chord Splice - Skin Flange (LBL 5.3 to 

RBL 5.3)

2 44,000(5

57-12-03b Front Spar Body Chord Splice Details BL 0 Body Chord Splice - Web Flange (LBL 5.3 to 

RBL 5.3)

2 44,000(5

57-12-03b Front Spar Body Splice Chord Details Body Chord at BL 0 Splice - Skin Flange at 

Stiffener End Fittings

1 33,000(5

57-12-03b Front Spar Body Chord Splice Details Pickle Fork to Body Chord Splice Fitting 2 44,000(557-13-01a Spanwise Beams - Stiffener Spanwise Beam #1, #2, #3 at BL 46, BL 82 

(LHS/RHS)

2 44,000(5

57-13-01a Spanwise Beams - Stiffener Base Flange Radius Spanwise Beam #1, #2, #3 at 

BL 46, BL 82 (LHS/RHS) at Top End

2 44,000(5

57-13-01b Spanwise Beam Corner Fittings Forward and Aft Corner Fittings at Lower Chord of 

Spanwise Beams 1, 2, & 3

2 FLS(5)

57-13-02A Overwing Beams Seat Track (Upper Chord) - Web Attachment at 

BL11, 39.5, 66, and 90

2 FLS(5)

57-13-02A Overwing Beams Web at Seat Track (Upper Chord) Attachment at 

BL 11, 39.5, 66 and 90

2 44,000(5

57-13-02A Overwing Beams Lower Chord - Upper Skin Attachment at BL 11, 

39.5, 66, and 90

1 33,000(5

57-13-02A Overwing Beams Lower Chord - Upper Skin Attachment @ BL 66, 

Overwing Beam hidden details @ BL 11, 39.5, 66, and 90

1 33,000(5

57-13-02A Overwing Beams Aft Lower Chord, BL 90, (LHS and RHS) Fastener 

holes common to Aft Lower Chord and Splice Fitting BS 1113

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

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

1 11,790(5

57-13-02A Overwing Beams Lwr Chord - Hidden Detail, RS Splice Fittings at 

BL 11, 39.5, 66, and 90. Fastener Holes Common to RS Splice Fitting and Lwr Chord

1 33,000(5

57-13-02A Overwing Beams Seat Track at BS 1113 Splice Fitting, BL 11, 

BL 39.5, BL 66 (LHS/RHS)

1 33,000(5

57-13-02B Overwing Beams - Miscellaneous Fittings Rear Spar Splice Fittings - Horizontal Flange, 

BS 1072 to 1087 (LHS and RHS)

1 33,000(5

57-13-02B Overwing Beams - Miscellaneous Fittings Splice Fitting, BS 1113 - BL 11, 39.5, 66, and 90 

(LHS and RHS)

2 44,000(5

57-13-02B Overwing Beams - Miscellaneous Fittings Drain Hole - BS 1113 Splice Ftg at BL66, 

Outboard BS 1113 splice fitting at RBL 66 and LBL 66

1 33,000(5

57-13-02B Overwing Beams - Miscellaneous Fittings Overwing Beam Web, BS 1113 Splice Fittings - 

BL 11, 39.5, 66 (LHS and RHS)

1 33,000(5

57-13-02C Overwing Beam - Tie Rods Aluminum Clevis Fittings - BS 1017, 1041, 1065, 

1077, 1089, and 1113, at BL 66 and 90 (LHS and RHS)

1 33,000(5

57-13-02C Overwing Beam - Tie Rods Rod end shaft - BS 1017, 1041, 1065, 1077, 1089, 

and 1113 at inboard and outboard rod ends (LHS/RHS)

1 33,000(5

57-13-02C Overwing Beam - Tie Rods Inboard Rod End Lugs - BS 1017, 1041, 1065, 

1077, 1089 1113 at BL 66 and 90 (LHS and RHS)

1 FLS(5)

57-13-02C Overwing Beam - Tie Rods Outboard Rod End Clevis at Frames - Clevis 

Base, BS 1017, 1041, 1065, 1089 (LHS and RHS)

2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-13-02C Overwing Beam - Tie Rods Outboard Rod End Clevis at Frames - Lug Hole, 

BS 1017, 1041, 1065, 1089 (LHS and RHS)

1 33,000(5

57-15-01 Lower Panel - Keel Attach Chord Bays 1, 2, 3 (BS 1039 to 1075), and 19 (BS 870 

to 882) (LHS/RHS)

2 44,000(5

57-15-01 Lower Panel - Metallic Fittings (L/N 4-6) Section 11 Lower Panel Stringer 1 Forward/Aft 

LHS/RHS fittings, all 5 fasteners per fitting

1 33,000(5

57-15-01 Lower Panel - Metallic Fittings (L/N 4-6) Section 11 Lower Panel Stringer 1, End Fitting 2 44,000(557-21-02 Front Spar Splice (L/N 4-6) Wing Front Spar at Rib 14 1 FLS(5)57-21-02 Front Spar Splice (L/N 4-6) Wing Front Spar at Rib 30 1 FLS(5)57-21-02 Front Spar Splice Wing Front Spar at Rib 39.5 (wing tip) 1 FLS(5)57-21-04 Rear Spar Splice (L/N 4-6) Wing Rear Spar at Rib 19 1 FLS(5)57-21-04 Rear Spar Splice (L/N 4-6) Wing Rear Spar at Rib 30 1 FLS(5)57-21-04 Rear Spar Splice Wing Rear Spar at Rib 39.5 (wing tip) 1 FLS(5)

57-22-01A Wing Tip Inspar Rib 40 Bay #3 Upper Chord 1 33,000(557-22-01B Wing Tip Inspar Rib 40 Bay #1 Front Spar Attachment 1 33,000(5

57-22-01C Wing Tip Inspar Ribs 41, 42, and 43 Bay #2 Upper Chord 1 33,000(557-22-01D Wing Tip Inspar Ribs 41, 42, and 43 Bay #2 Lower Chord 1 33,000(5

57-22-01E Wing Tip Inspar Ribs 41, 42, and 43 Bay #1 Front Spar Attachment 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-24-01 R4 Inboard Side Load Fitting Strut Joint Lug 1 FLS(5)57-24-02 R3 Outboard Side Load Fitting Strut Joint Lug 1 FLS(5)57-24-03 R2 Aft Pitch Load Fitting Diagonal Brace Joint Lug 1 FLS(5)57-24-04 R1 Inboard/Outboard Forward Pitch Load Fittings Upper Link Joint Lug 1 FLS(5)57-24-05 R7/R8 Side Load Fitting Side Link Joint Lug 1 FLS(5)

57-24-06C R3 Forward Backup Fitting at Rib 12 Fitting attachment to Rib 12 Web 1 FLS(5)

57-25-02J Lower Stringer Splice at Rib 35 Stringer L-13 and L-15 Fastener LBF-7 and LBF-8 1 FLS(5)

57-25-02L Lower Stringer-8 @ Rib 17 (L/N 4-6) Fastener Rows 7 and 8 (hidden details) Both 

fittings are used in the analysis

1 FLS(5)

57-27-01 MLG Forward Trunnion Side Load Backup Fitting Lower flange attachments to lower skin panel 2 44,000(557-27-02 MLG Drag Brace Lower Backup Fitting Upper flange of cross section H-H 2 FLS(5)57-27-03 MLG Drag Brace Upper Backup Fitting Lower flange of cross section F-F 2 FLS(5)57-27-05 MLG Drag Brace Upr/Lwr Rib 2 Attach Clips Drag Brace Lower Backup Fitting to Rib 2 

Attachment Clip

2 FLS(5)

57-30-01A Wing Tip Inboard Closure Rib Front and Rear Spar Lower Splice Joints 1 33,000(557-30-01B Wing Tip - Inboard Closure Rib Barrel Nut Housing 1 FLS(5)

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-51-01A Fixed Trailing Edge Flap Support #3 (Inboard+Outboard)-Lower Flange-wing 

attachment Hinge Lugs (Inboard & Outboard) Ribs

2 FLS(5)

57-51-01B Fixed Trailing Edge Auxiliary-C Fixed Trailing Edge Auxiliary-C Support 2 44,000(5

57-51-01C1A Auxiliary-D Mini-Cantilever Lower Joint Auxiliary-D Mini-Cantilever Lower Joint (Lug) 1 33,000(557-51-01C1B Auxiliary-D Mini-Cantilever Lower Joint Auxiliary-D Mini-Cantilever Lower Joint (Pin) 1 33,000(5

57-51-01C1C Auxiliary-D Mini-Cantilever Lower Joint Auxiliary-D Mini-Cantilever Lower Joint (Link Lug) 1 33,000(5

57-51-01C2 Auxiliary-D Backup Rib Lower Chord Auxiliary-D Backup Rib Lower Chord 2 44,000(557-51-01C3 Auxiliary-D Roller Rib Auxiliary-D Roller Rib (Aft of Backup Rib) 2 44,000(5

57-51-01D Spoiler 5 Main Support Fitting Lower Wing Skin Attachment 2 44,000(5

57-51-02 Fixed Trailing Edge Flaperon Support Structure Hinge Ribs, Cam Track Ribs, and Cam Track 2 44,000(5

57-51-03A Fixed Trailing Edge Flap Support #1 Ribs Flap Support #1 lower flange / wing skin 

attachments (Inboard + Outboard) Ribs

2 44,000(5

57-51-03B Fixed Trailing Edge Flap Support #2 Ribs Flap Support #2 lower flange / wing skin 

attachments (Inboard + Outboard Ribs)

2 44,000(5

57-51-04A Fixed Trailing Edge Aileron Hinge Rib #1 Hinge Rib #1 with failed Rib #2 2 44,000(5

57-51-04C Fixed Trailing Edge Aileron Hinge Rib #2 Hinge Rib #2 with failed Rib #3 2 44,000(557-51-04D Fixed Trailing Edge Aileron Hinge Rib #3 Hinge Rib #3 with failed Rib #4 2 44,000(5

57-51-04E Fixed Trailing Edge Aileron Hinge Rib #4 Hinge Rib #4 with failed Rib #3 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-51-04F Fixed Trailing Edge Aileron Hinge Rib #5 Hinge Rib #5 with failed Rib #4 2 44,000(5

57-53-02 Inboard Flap Support 3 Carrier Fitting and Internal Fitting Bathtub Bolt 

Holes, Qty. 6 total

1 33,000(5

57-53-02 Inboard Flap Support #3 Carrier Fitting Attachment 

Bolts

All BACB30LE9K Bolts (Qty 6) per notes on DTR Check Form

1 33,000(5

57-53-02 Support 3 Carrier Fitting Lower Flange Edge Cracks 2 44,000(5

57-53-03A Inboard Flap Torque Tube Carrier Beam Attachment Lug 1 33,000(557-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Outer Torque Tube, Fitting 5 Attachment Lugs 1 33,000(557-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Inner Torque Tube, Pad-Up at Fitting 5 1 33,000(557-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Inner Torque Tube, Collar Fitting Attachment Lugs 1 33,000(557-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Outer Torque Tube, Drain Holes 1 33,000(557-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Outer Torque Tube, Flange at Fitting 5 1 33,000(557-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Outer Torque Tube, Pad-Up at Attachment to 

Fitting 5

1 33,000(5

57-53-03B Support 4 Torque Tube Shear Rib 4 (Fitting 4) Fitting 4 Fastener Holes at Collar Attachment 1 33,000(557-53-03B Support 4 Torque Tube Shear Rib 4 (Fitting 4) Torque Tube Cut Out 1 33,000(557-53-03B Support 4 Torque Tube Shear Rib 4 (Fitting 4) Upper Skin Flange Fastener Hole 1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-53-03C Inboard Flap Fitting 5 Fitting 5 Lower Flange to Lower Skin fastener 

holes, Quantity 8 total

1 33,000(5

57-53-03C Inboard Flap Fitting 5 Outer torque tube bolt hole 1 33,000(557-53-03D Wing Trailing Edge - Inboard Flap - Torque Tube Inner Torque Tube Collar Flange 1 33,000(557-53-03D Wing Trailing Edge - Inboard Flap - Torque Tube Torque Tube Collar, Inner Torque Tube 

Attachment Lugs

1 33,000(5

57-53-03E Wing Trailing Edge - Inboard Flap - Torque Tube Torque Tube Support Pin 1 33,000(557-53-04A Support 3 Carrier Fitting and Internal Fitting Bathtub Fillets 1 33,000(557-53-04B Inboard Flap Support 4 Support 4 Carrier Beam Hinge Lug (B joint lugs) 1 33,000(557-53-04B Inboard Flap Support 4 Support 4 Carrier Torque Tube Attachment Aft 

Joint Lugs (138Z4041 & 138Z4044)

1 33,000(5

57-53-04B Inboard Flap Support 4 Support 4 Carrier Beam Lower Flange 1 33,000(557-53-04B Inboard Flap Support 4 Support 4 Carrier Beam Aft Lug Field Fastener 

Holes

1 33,000(5

57-53-04B Inboard Flap Support 4 Support 4 Carrier Beam Drain Holes 1 33,000(5

57-53-04C Inboard Flap Support 4 Support 4 Forward Flange Crack (Stress 

concentration)

2 44,000(5

57-53-04C Inboard Flap Support 4 Support 4 Vertical Bulk Head Lug (K Lug) 1 33,000(557-53-04C Inboard Flap Support 4 Support 4 Hinge Joint (B - Joint) 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-53-04C Inboard Flap Support 4 Support 4 Pyramid Section 1 33,000(557-53-04C Inboard Flap Support 4 Lower Fastener Hole on Panel 138Z4058 2 44,000(5

57-53-04E Inboard Trailing Edge Flap Support #4 Inner Pin 

(Failed Outer Pin)

Hinge "B" Pin 1 33,000(5

57-53-04F Inboard Trailing Edge Flap Support #4 Inner Pin 

(Failed Outer Pin)

Upper Bulkhead Pin 1 33,000(5

57-53-04G Inboard Trailing Edge Flap Support #4 Inner Pin 

(Failed Outer Pin)

Torque Tube to Carrier Beam Attachments 1 33,000(5

57-53-06A Auxiliary Supports Inboard Flap Auxiliary Supports 2 44,000(557-53-09A Outboard Flap Support #1 Carrier Fitting 

Attachment Bolts

All BACB30LE8K Bolts (Qty 6) per notes on DTR Check Form

1 33,000(5

57-53-09A Support 1 Carrier Fitting Lower Flange Edge Cracks 2 44,000(557-53-09A Support 1 Carrier Fitting C-Joint Clevis (Actuator Joint) 2 44,000(557-53-09B Outboard Flap Support #2 Carrier Fitting 

Attachment Bolts

All BACB30US8K Bolts (Qty 6) per notes on DTR Check Form

1 33,000(5

57-53-09B Support 2 Carrier Fitting Lower Flange Edge Cracks 2 44,000(557-53-09B Support 2 Carrier Fitting C-Joint Clevis (Actuator Joint) 2 44,000(557-53-09B Outboard Flap Support 2 Carrier Fitting and Internal Fitting Bathtub Bolt 

Holes, Qty. 6 total

1 33,000(5

57-53-10A Outboard Flap Support 1 Carrier Fitting and Internal Fitting Tension Bolt 

Holes, Qty. 6 total

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-53-10A Support 1 Carrier Fitting and Internal Fitting Bathtub Fillets 1 33,000(557-53-10B Support 2 Carrier Fitting and Internal Fitting Bathtub Fillets 1 33,000(557-53-12A Outboard Flap Auxiliary Supports and Deflection Control 2 44,000(557-53-13A Wing Trailing Edge - Aileron Hinge 1 Radius 2 44,000(557-53-13A Wing Trailing Edge - Aileron Hinge 1 Lug 1 33,000(557-53-13A Wing Trailing Edge - Aileron Hinge 1 Joint 2 44,000(557-53-13B Wing Trailing Edge - Aileron Hinge 2 Joint 2 44,000(557-53-13B Wing Trailing Edge - Aileron Hinge 2 Radius 2 44,000(557-53-13B Wing Trailing Edge - Aileron Hinge 2 Lug 1 33,000(5

57-53-13C Wing Trailing Edge - Aileron Hinge 3 Lug 1 33,000(557-53-13C Wing Trailing Edge - Aileron Hinge 3 Radius 2 44,000(557-53-13C Wing Trailing Edge - Aileron Hinge 3 Joint 2 44,000(557-53-13D Wing Trailing Edge - Aileron Hinge 4 Lug 1 33,000(557-53-13D Wing Trailing Edge - Aileron Hinge 4 Radius 2 44,000(557-53-13D Wing Trailing Edge - Aileron Hinge 4 Joint 2 44,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-53-13E Wing Trailing Edge - Aileron Hinge 5 Lug 1 33,000(557-53-13E Wing Trailing Edge - Aileron Hinge 5 Radius 2 44,000(557-53-13E Wing Trailing Edge - Aileron Hinge 5 Joint 2 44,000(557-53-14A Wing Trailing Edge - Aileron Actuator 1 Actuator Lug 1 33,000(557-53-14A Wing Trailing Edge - Aileron Actuator 1 Link Lug 1 33,000(557-53-14A Wing Trailing Edge - Aileron Actuator 1 Radius 2 44,000(557-53-14A Wing Trailing Edge - Aileron Actuator 1 Joint 2 44,000(557-53-14B Wing Trailing Edge - Aileron Actuator 2 Actuator Lug 1 33,000(557-53-14B Wing Trailing Edge - Aileron Actuator 2 Link Lug 1 33,000(557-53-14B Wing Trailing Edge - Aileron Actuator 2 Radius 2 44,000(557-53-14B Wing Trailing Edge - Aileron Actuator 2 Joint 2 44,000(557-54-07A MLG Mini-Cantilever Fitting Auxiliary-D Lower Lug 1 FLS(5)57-54-07B MLG Mini-Cantilever Fitting Lower Skin Attachment 2 FLS(5)

57-54-08 MLG Beam Bridge Fitting Mini-Cantilever Fitting Attachment 1 FLS(5)57-54-14 MLG Forward Trunnion Outboard Vertical Fitting Rear Spar Web attachment between Ribs 7 and 8 2 FLS(5)

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

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 Check Form Title, Location, and Model-Series information. All inspections 

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 pub

manual, validated, and accepted by the FAA. If the applicable published inspection procedure cannot be accomplished, an alternative FA

be used.

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

57-54-20 MLG Drag Brace Down Lock Support Fitting Outboard Main Lug 2 FLS(5)

57-54-21A MLG Drag Brace Shackle Support Fitting Critical Cross Section B-B 2 FLS(5)57-54-21B MLG Drag Brace Shackle Support Fitting Critical Cross Section G-G 2 FLS(5)

57-54-21C MLG Drag Brace Shackle Support Fitting Tension fastener attaching to lower backup fitting 1 FLS(5)

57-70-01A Monolithic Inboard Spoiler Beam Inboard Spoiler Beam Upper Chord 1 33,000(557-70-01B Inboard Spoiler Beam Inboard joint 2 44,000(5

57-70-01C Inboard Spoiler Beam Outboard joint 2 FLS(5)57-70-01D Inboard Spoiler Beam Auxiliary-D Attachment Inboard Spoiler Beam / Auxiliary-D attachment 1 33,000(5

57-70-02A Mid Spoiler Beam Mid-Spoiler Beam Upper Chord 1 33,000(557-70-02B Mid Spoiler Beam Mid-Spoiler Beam Auxiliary-D/Flap Support 3 

Attachments

1 33,000(5

TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECT

PSE(2) DTR CHECK FORM TITLE (3) DTR LOCATION GROUP

APPLI

787-8

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

D. AIRWORTHINESS LIMITATIONS – LIFE LIMITS

STRUCTURAL SAFE-LIFE PARTSThe 787 landing gear and some of its support structure is certified per 14 CFR 25.571(c) as safe-life structure. The data prese

defines the safe life limits, as a function of accumulated flight cycles and flight hours, for the main and nose landing gear and suNomenclature for applicability of landing gear parts is given in Table 2.

TABLE 2. AIRPLANE APPLICABILITY NOMENCLATURE

Note: “k” in the MTGW (Ref) column denotes (x 1000 pounds).

The nose landing gear safe life test has been completed. The main landing gear and support structure safe life test is currently 

limits presented here are based on test results to date.The carbon fiber reinforced plastic portion of the main landing gear drag brace (513Z3101, 513Z3102) and side brace (514Z31as damage tolerant per 14 CFR 25.571(b) and hence safe life limits are not defined for these parts.

Airplane Applicability Airplane Effectivity MTGW (Ref)

Table 3 an

Column H

787-8 ZA004 - ZA006, ZA100 - ZA102

ZA151 - ZA152, ZA500 - ZA505ZA534 - ZA535

486k 787

787-8MI (Mission Improvement) ZA103 - ZA150, ZA153 - ZA499

ZA506 - ZA533, ZA536 - ZA999

503.5k 787-

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

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 

of the Safe Life Limit Curve, then the safe life limit has been exceeded. Operators must replace parts prior to exceeding th

LANDING GEAR AND SUPPORT STRUCTURE

SAFE-LIFE LIMIT

FAA EASA

787-8 Nose Landing Gear Figure 2 (FAA and EASA)

787-8 Main Landing Gear Figures 3, 4, 5 (FAA and EASA)

787-8 Main Landing Gear Support Fittings Figures 6 and 7 (FAA and EASA)

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

Figure 2. 787-8 NOSE LANDING GEAR SAFE-LIFE LIMITS

See Table 3 for a listing of Life-Limited Nose Landing Gear Parts.

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

Figure 3. 787-8 MAIN LANDING GEAR TRUCK ASSEMBLY SAFE-LIFE LIMITS (TESTING IN 

See Table 4 for a listing of Life-Limited Main Landing Gear Truck Assembly Parts.

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

Figure 4. 787-8 MAIN LANDING GEAR SHOCK STRUT ASSEMBLY SAFE-LIFE LIMITS (TESTING 

See Table 4 for a listing of Life-Limited Main Landing Shock Strut Assembly Parts.

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 associa

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

Figure 5. 787-8 MAIN LANDING GEAR SIDE AND DRAG BRACE ASSEMBLIES SAFE-LIFE LIMITS (TE

See Table 4 for a listing of Life-Limited Main Landing Gear Side and Drag Brace Assembly Parts.

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

Figure 6. 787-8 MAIN LANDING GEAR SUPPORT FITTINGS SAFE-LIFE LIMITS (TESTING IN 

1 MLG Beam Outboard Support, MLG Forward Trunnion Support, MLG Drag Brace Support 

55411, 4105

22000, 14667 19800

0

2000400060008000

100001200014000160001800020000

0 20000 40000 60000 80000 100000 120000 140000 160000 180000 

FLIGHT HOURS

FLIGHT CYCLES

All Other Parts All Parts Actuator Sup't Ftg Lug

All Parts ExceptRetract Actuator Support Fitting, 126Z2503

All Parts

Retract Actuator SupportFitting, 126Z2503

1

 See Table 4 for a listing of Life-Limited Main Landing Gear Support Fitting Parts.

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

Figure 7. 787-8 MAIN LANDING GEAR BEAM ASSEMBLY SAFE-LIFE LIMITS (TESTING IN P

44

0, 14667 22000, 14667

0

2000400060008000

100001200014000160001800020000

0 5000 10000 15000 20000 25000 30000 35000 40000 45000 

FLIGHT HOURS

FLIGHT CYCLES

See Table 4 for a listing of Life-Limited Main Landing Gear Beam Assembly Parts.

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 NOSE LANDING GEAR (NLG) PART LISTThe general arrangement of the Boeing 787-8 NLG is shown in Figure 8 and Figure 9.The NLG arrangement consists of dual wheels on a single axle spaced with a centerline separation of 28.5 inches. The axle ha

shock strut centerline to the axle centerline. The NLG steering is hydraulically-actuated with the ability to disengage for full casto

strut consists of a gas-oil design using a tapered metering pin and orifice plate for absorption of landing energy. The shock struof 20.0 inches.The NLG is attached to the fuselage at five points that transfer primary structural loads to the aircraft:• Left and right trunnions of the Outer Cylinder;• Left and right trunnions of the Upper Drag Brace;• Aft Lock Link attachment lug.The NLG is locked into the down position using a folding drag brace in conjunction with a lock link mechanism. The Lock Link a

gear in the extended position, as well as in the retracted position, where it acts as the gear uplock.A linear hydraulic actuator is used to retract the gear forward, pivoting about the Outer Cylinder trunnion axis. The retraction ac

Outer Cylinder trunnion by way of an integral crank arm, while the head end is connected to the fuselage structure.See Table 3 for a list of 787-8 NLG components and assemblies.

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

Figure 8. NOSE LANDING GEAR OVERVIEW

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

Figure 9. NOSE LANDING GEAR GEOMETRY

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

TABLE 3. NOSE LANDING GEAR – LIST OF SAFE-LIFE PARTS AND ASSEMBLIES

Part Description Part Name Part Number

Airplane Applicability

(Maximum Taxi Gross Weight – Reference O

787-8

(486k)

787-8MI

(503.5k)

Inner Cylinder Assembly Inner Cylinder 522Z3001-2  

Outer Cylinder Assembly Outer Cylinder 521Z3001-2  

Pin, Trunnion 521Z3013-1, -2*  Pin, RetractionActuator, Rod End

521Z3017-1  

Pin, RetractionActuator, Head End

521Z3018-1  

Torque Link Assembly Upper Torque Link 521Z3003-1  

Lower Torque Link 521Z3005-1  Pin, Upper Torque Link 521Z3007-1  Pin, Lower Torque Link 521Z3009-1  

Steering System Assembly

Steer Collar 524Z3003-1  Steer Support Tube 524Z3001-1  Steer Plate 524Z3005-1  Nut, Steering 524Z3007-1  Pin, Steer Tube 521Z3019-2  Pin, Steer Actuator 524Z3009-1  

Drag Brace Assembly Upper Drag Brace 523Z3001-1  

Lower Drag Brace 523Z3002-1  Pin, Upper Drag Brace Trunnion 523Z3011-2  Pin, Drag Brace Apex 523Z3009-1, -2*  Pin, Lower Drag Brace 521Z3015-1, -2*  

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

TABLE NOTES:* = Preferred Spare in Group = Part may be used.Part numbers listed together in pairs denote opposite side parts, e.g., 52xZxxxx-1/-2, where 52xZxxxx-1 is left side and 52xZxx

Where non-paired part numbers are listed, the same part is used for both left hand and right hand.

1. Part Number 523Z3004-1 has effectivity for L/N 1 through 87; Part Number 523Z3004-2 has effectivity for L/N 88 throu

Lock Link Assembly Aft Lock Link 523Z3004-1, -2*   

Forward Lock Link 523Z3003-1  

Pin, Lock Link Aircraft 523Z3015-1  Pin, Lock Link Apex 523Z3013-1  

Shock Strut Internal Components

Orifice Support Tube 522Z3025-3*, -4  Orifice Plate 522Z3029-1  Gland Nut 522Z3011-1  Metering Pin 522Z3022-1*, -2  

TABLE 3. NOSE LANDING GEAR – LIST OF SAFE-LIFE PARTS AND ASSEMBLIES

Part Description Part Name Part Number

Airplane Applicability

(Maximum Taxi Gross Weight – Reference O

787-8

(486k)

787-8MI

(503.5k)

SEP 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

787 MAIN LANDING GEAR (MLG) PART LISTThe 787-8 model MLG arrangement consists of a dual wheel nose gear and a two post, four wheel bi-tandem axle main gear. 

assembly measures 51 inches wide, wheel centerline to wheel centerline, by 57.5 inches long, axle centerline to axle centerlineairplane with an initial rake angle of 7 degrees aft and a camber angle of 0.75 degree inboard. The shock strut is an air/oil type 

tapered metering pin and an orifice to absorb landing energy.The shock strut has a total available stroke of 22.0 inches. The general arrangement of the MLG is shown in Figure 10. The MFigure 11.The MLG is attached to the airplane at six (6) points. Five (5) of the points are the primary structural load paths when the gear 

• Forward trunnion,• Aft trunnion,• Drag brace upper attachment,• Drag brace lock link attachment,• Side brace upper attachment.The sixth attach point is the retraction actuator at the outer cylinder.The forward trunnion, drag brace and drag brace lock link are attached to fittings connected to the rear spar of the wing. A singbeam supports the aft trunnion and side brace.Gear loads are transferred to the body at the forward trunnion, drag brace, drag brace lock links, and gear beam. The inboard e

attached to the fuselage by a hanger link and a mini cantilever beam at the outboard end.The MLG utilizes a dual folding strut arrangement which locks the gear in the down position by means of an 'over center' lock linThe MLG retracts inboard about the trunnion centerline using a linear actuator connected between a retract fitting that resides n

an integral lug on the inboard side of the outer cylinder barrel. The forward trunnion is connected to the rear spar at the forward 

rigidly mounted to the rear spar and allows the landing gear to rotate into the retracted position.

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

The MLG support fittings consisted of three major assemblies as shown in Figure 12: MLG Beam Outboard Support, Forward T

Brace Support Fittings.The general arrangement of the main landing gear beam assembly is shown in Figure 13. The MLG beam assembly consists o

an upper stabilizer brace, and a lower stabilizer brace. The MLG beam is approximately 160 inches long and 25 inches tall.

The inboard end of the MLG beam attaches to the hanger link. The other end of the hanger link attaches to the body of the airc

of the MLG beam also attaches to the side brace. The outboard end of the MLG beam attaches to load distribution plates that cantilevered fitting, which is located on the rear spar of the wing box.The middle of the MLG beam contains a large aft trunnion bearing, which attaches to the aft trunnion. The upper, middle area othe upper stabilizer brace, while the lower middle area of the MLG beam attaches to the lower stabilizer brace. Fuse pins are ubraces to fittings on the rear spar.The MLG beam reacts loads at the aft trunnion and the side brace and transfers these loads into the body of the aircraft (througthe wing rear spar.

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

Figure 10. MAIN LANDING GEAR OVERVIEW

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

Figure 11. MAIN LANDING GEAR GEOMETRY

FEB 2013
D011Z009-03-01

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787 AIRWORTHINESS LIMITATIONS

Figure 12. 787-8 MAIN LANDING GEAR SUPPORT FITTINGS

MLG Fwd Trunnion Support Assembly 

MLG Beam O/B Support Assembly

MLG Drag Brace Downlock Support Fitting

MLG Drag Brace Support Fitting

O/B Wing Rear Spar

Up 

O/B Fwd

(LH Wing Shown, RH Wing Opposite)

FEB 2013
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BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

Figure 13. GENERAL ARRANGEMENT OF MAIN LANDING GEAR ASSEMBLY

Upper Aft Hanger

Link Pin

151Z2300 Hanger Link 

Upper Forward Hanger Link Pin 

Upper Forwa

151Z1321 Upper Stabilizer Brace Aft Fitting

151Z3301

Upper Stabilizer Brace 151Z1300 Main Landing Gear Beam

Lower Hanger 

MLG Side Link Pin

Brace Interface 

MLG Aft Trunnion 

Interface

151Z3300 

Lower Stabilizer

Brace Aft Fitting 

151Z1320 Lower

Stabilizer Brace

Lower Forwa

Up

Outboard 

Forward 

FEB 2013
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787 AIRWORTHINESS LIMITATIONS

TABLE 4. MAIN LANDING GEAR – LIST OF SAFE-LIFE PARTS AND ASSEMBLIES

Part Description Part Name Part Number

Airplane Applicability

(Maximum Taxi Gross Weight – Refe

787-8

(486k)

787-8MI

(503.5k)

MLG Truck Assembly (See Figure 3 forSafe-life limits)

Pivot Pin, Truck Beam 515Z3003-1  

Nut, Pivot Pin 515Z3018-1  Truck Beam 515Z3001-1,-2*   

MLG Shock Strut Assembly(See Figure 4 for Safe-life limits)

Cross Pin, Fwd Trunnion Monoball 511Z3010-1  

Pin, Aft Trunnion 511Z3007-1  Outer Cylinder, Shock Strut 511Z3001-1/-2 

511Z3001-3/-4,-5*/-6*   

Torsion Link 511Z3002-2  

511Z3002-3  511Z3002-4  

Pin, Torsion Link Base 511Z3004-1  Nut, Torsion Link Base 511Z3023-1  Pin, Torsion Link Apex 511Z3003-1  Nut, Torsion Link Apex 511Z3014-1  Inner Cylinder, Shock Strut 512Z3001-1, -2*   

Gland Nut (Threaded) 512Z3011-1  

Orifice Support Tube 512Z3042-1  Orifice Plate 512Z3024-1  Metering Pin 512Z3027-1  Pin, Retract Rod Attach 511Z3021-1  Pin, Fuse, Retract Head Attach 511Z3022-1  

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MLG Side and Drag Brace Assemblies (See Figure 5 for Safe-life limits)

Spindle, Drag Brace 513Z3004-1  Pin, Shackle, Drag Brace 513Z3005-2,-3*   

Nut, Spindle, Drag Brace 513Z3029-1  

Lock Link, Lower, Drag Brace 513Z3010-1  Lock Link, Upper, Drag Brace 513Z3009-2  Shackle, Lock Link, Drag Brace 513Z3019-1/-2  Pin, DB8, Lock Link, Shackle, Drag Brace 513Z3020-1  Pin, Fuse, DB9, Lock Link, Drag Brace 513Z3012-2  Pin, Apex Joint, DB10, Lock Link, Drag Brace 513Z3013-1  Pin, DL3, DL4, Toggle, Drag Brace 513Z3011-1  Spindle, Upr, Side Brace 514Z3003-1/-2,-3*/-4*   

Spindle, Lwr, Side Brace 514Z3004-1  

Nut, Upr Spindle, Side Brace 514Z3021-1  Nut, Lwr Spindle, Side Brace 514Z3026-1  Lock Link, Outboard, Side Brace 514Z3008-1  Spindle, Lock Link, Side Brace 514Z3010-1  Pin, Spindle, Lock Link, Side Brace 514Z3011-1  Pin, Apex Joint, Lock Link, Side Brace 514Z3012-1  Nut, Lock Link Spindle, Side Brace 514Z3025-1  Shackle, Drag Brace Composite 513Z3003-3/-4  Pin – Fuse, 3.5 in, HVOF 513Z3139-4  Pin Apex Drag Brace 513Z3104-1  Pin Lwr Joint DB7 Drag Brace 513Z3105-1, -2*  Pin Upr and Lwr Joint Side Brace 514Z3103-1, -2*  Pin Apex Side Brace 514Z3104-2  Lock Brace – Inbd, Side Brace 514Z3209-2,-11  

TABLE 4. MAIN LANDING GEAR – LIST OF SAFE-LIFE PARTS AND ASSEMBLIES

Part Description Part Name Part Number

Airplane Applicability

(Maximum Taxi Gross Weight – Refe

787-8

(486k)

787-8MI

(503.5k)

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787 AIRWORTHINESS LIMITATIONS

MLG Beam Outboard Support(See Figure 6 for Safe-life limits)

Mini-Cantilever Fitting (Lugs only) 126Z2501-1,-2,-3,-4  Actuator Support Fitting (Lug only) 126Z2503-1,-2,-3,-4  Load Distribution Plate, Aft 126Z2504-1,-2  Load Distribution Plate Fwd 126Z2505-1,-2  Fuse Pin A 126Z2511-1  Fuse Pin B 126Z2512-1 

126Z2512-2*  

MLG Beam Pin O 126Z2525-1  

MLG Forward Trunnion Support (See Figure 6 for Safe-life limits)

Forward Trunnion Outboard Vertical Fitting (Lug only)

126Z2602-1,-2,-3,-4  

Forward Trunnion Inboard Vertical Fitting (Lug only)

126Z2603-1,-2,-3,-4  

Forward Trunnion Lower Housing 126Z2604-1,-2,-3,-4  Forward Trunnion Upper Housing 126Z2605-1,-3  Forward Trunnion Lower Fuse Pin 1 126Z2611-1  Forward Trunnion Lower Fuse Pin 2 126Z2611-1  Forward Trunnion Lower Fuse Pin 3 126Z2611-1  Forward Trunnion Lower Fuse Pin 4 126Z2611-1  Forward Trunnion Upper Fuse Pin 1 126Z2612-1  Forward Trunnion Upper Fuse Pin 2 126Z2612-1  

MLG Drag Brace Support(See Figure 6 forSafe-life limits)

Drag Brace Shackle Support Fitting(Lugs only)

126Z2702-1,-2,-3,-4,-5,

-6,-7,-8

 

TABLE 4. MAIN LANDING GEAR – LIST OF SAFE-LIFE PARTS AND ASSEMBLIES

Part Description Part Name Part Number

Airplane Applicability

(Maximum Taxi Gross Weight – Refe

787-8

(486k)

787-8MI

(503.5k)

FEB 2013
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TABLE NOTES:* = Preferred Spare in Group = Part may be used.Part numbers listed together in pairs denote opposite side parts, e.g., 51xZxxxx-1/-2, where 51xZxxxx-1 is left side and 51xZxxxxx-2 is right s

Where non-paired part numbers are listed, the same part is used for both left hand and right hand.1. Part Number 515Z3001-1 has effectivity for L/N 1 through 54; Part Number 515Z3001-2 has effectivity for L/N 55 through 9900.

2. Part Number 511Z3001-3/-4 has effectivity for L/N 20 through 54; Part Number 511Z3001-5/-6 has effectivity for L/N 55 through 9900, and  all 787-8 L/Ns.3. Part Number 513Z3005-2 has effectivity for L/N 4 through 68; Part Number 513Z3005-3 has effectivity for L/N 69 through 9900.

4. Part Number 514Z3003-1, -2 has effectivity for L/N 4 through 39; Part Number 514Z3003-3, -4 has effectivity for L/N 40 through 9900.5. Part Number 512Z3001-1 has effectivity for L/N 4 through 64; Part Number 512Z3001-2 has effectivity for L/N 65 through 9900.

MLG Beam Assembly (See Figure 7 for Safe-life limits)

Main Landing Gear Beam 151Z1300-1/-2,-3*/-4*  

Lower Stabilizer Aft Ftg 151Z1320-1/-2  Upper Stabilizer Aft Ftg 151Z1321-1/-2  Hanger Link 151Z2300-1/-2  Lower Stabilizer Brace 151Z3300-1/-2,-3/-4,-5/-6  Upper Stabilizer Brace 151Z3301-1/-2,-3/-4,-5/-6  Hinge Pin Lower Stabilizer Aft 151Z3320-1,-3*  Lower Hanger Link Pin 151Z4302-1  Upper Fwd Hanger Link Pin 151Z4303-1  Upper Aft Hanger Link Pin 151Z4304-1  Lower Stabilizer Fuse Pin 151Z4305-1,-3*  Upper Stabilizer Fuse Pin 151Z4306-1,-3  Hollow Pin Upper Stabilizer 151Z4308-1  

TABLE 4. MAIN LANDING GEAR – LIST OF SAFE-LIFE PARTS AND ASSEMBLIES

Part Description Part Name Part Number

Airplane Applicability

(Maximum Taxi Gross Weight – Refe

787-8

(486k)

787-8MI

(503.5k)

FEB 2013
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787 AIRWORTHINESS LIMITATIONS

STRUCTURES LIFE-LIMITED PARTSThe replacement times established for the life-limited parts listed below result from Model 787-8 airplane certification activities w

the Airworthiness Limitations section of the Instructions for Continued Airworthiness. These maintenance actions are mandator

be revised with the approval of the Seattle FAA ACO.NOTE: Life-limited parts are installed on 787-8 Line Numbers 7 through 55. Prior to exceeding the specified life limit, the parts 

P/Ns 311Z6401-5 (Inner Pivot Pin) and 311Z6402-5 (Outer Pivot Pin). The P/N 311Z6401-5 and 311Z6402-5 pivot pins

Installation Requirements Model P/N IR044Z0001-5 are not life-limited. Instructions for replacement of the pivot pins aService Bulletin 787-55-0001 provides warranty information and replacement instructions. The calendar life limit applie

COMPONENT LIFE LIMIT

Horizontal Stabilizer Pivot Pins (LH & RH) as configured per Boeing Installation Requirements Model (IR044Z0001-3):Inner Pivot Pin (311Z6401-3)Outer Pivot Pin (311Z6402-3)

12,000 landings or 2,200 days, whiche

SEP 2012
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

SYSTEMS LIFE-LIMITED PARTSThe replacement times established for the life-limited parts listed below result from Model 787-8 airplane certification activities w

the Airworthiness Limitations section of the Instructions for Continued Airworthiness. These maintenance actions are mandator

be revised with the approval of the Seattle FAA ACO.Some of the component life limits in this listing will be temporary, due to qualification testing or endurance testing inadequacies 

certification, and will be removed when Boeing has satisfied the certification requirements for these components. Service Bullet

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 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

1. Electrical Subsystems

1a. RPDU Differential Protection Current 

Transformer

7001044H02 Boeing is seeking a design solution for this component 

that will remove the life limit requirement. When 

available, a Service Bulletin will be issued recommending installation of the new part.

8 Ye

1b. Main and APU Battery Enclosure 

Vent Burst Disc

JS-0-0089-000 All 787 Airplanes/Incorporation of Service Bulletin

B787-81205-SB500003-00

5,000 Fligh

2. Environmental Controls

2a. Supplemental Cooling Unit 7011015H02 Service Bulletin to be released for new part which will 

not have this life limitation.

4 Ye

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787 AIRWORTHINESS LIMITATIONS

3. Flight Controls

3a. Electro Mechanical Spoiler Actuator C99144-004 Service Bulletin (SB 787-27-0003) to be released for 

new part which will not have this life limitation.

12,000 Flig

3b. Power Drive Unit Gearbox P667A4001-01 Service Bulletin (SB 787-27-0002) to be released for 

new part which will not have this life limitation.

24,000 Flig

4. Hydraulics

4a.(i) Static-Dissipative Hydraulic Isolator CA489-06B Line Number (LN) 7-34. Full life expected rather than 

the life limit listed pending completion of system endurance tests.

27,000 Flig

4a.(ii) Static-Dissipative Hydraulic Isolator CA489-06D Line Number (LN) 35-54. Full life expected rather than 

the life limit listed pending completion of system endurance tests.

27,000 Flig

Line Number (LN) 55 and on. Full life expected rather 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 

listed pending completion of system endurance tests.

27,000 Flig

4b.(ii) Static-Dissipative Hydraulic Isolator CA489-08D Line Number (LN) 35-54. Full life expected rather than 

the life limit listed pending completion of system endurance tests.

27,000 Flig

Line Number (LN) 55 and on. Full life expected rather than the life limit listed pending completion of system endurance tests.

4c.(i) Static-Dissipative Hydraulic Isolator CA489-12B LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

ITEM 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

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4c.(ii) Static-Dissipative Hydraulic Isolator CA489-12D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

4d.(i) Static-Dissipative Hydraulic Isolator CA490-06B LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4d.(ii) Static-Dissipative Hydraulic Isolator CA490-06D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

4e.(i) Static-Dissipative Hydraulic Isolator CA490-08C LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4e.(ii) Static-Dissipative Hydraulic Isolator CA490-08D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

4f.(i) Static-Dissipative Hydraulic Isolator CA490-10B LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4f.(ii) Static-Dissipative Hydraulic Isolator CA490-10D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

4g.(i) Static-Dissipative Hydraulic Isolator CA491-04B LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4g.(ii) Static-Dissipative Hydraulic Isolator CA491-04D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

4h.(i) Static-Dissipative Hydraulic Isolator CA491-06B LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4h.(ii) Static-Dissipative Hydraulic Isolator CA491-06D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

ITEM 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

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787 AIRWORTHINESS LIMITATIONS

4j.(i) Static-Dissipative Hydraulic Isolator CA491-08C LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4j.(ii) Static-Dissipative Hydraulic Isolator CA491-08D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

4k.(i) Static-Dissipative Hydraulic Isolator CA491-10B LN 7-33. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4k.(ii) Static-Dissipative Hydraulic Isolator CA491-10D Line Number (LN) 34 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

4l.(i) Static-Dissipative Hydraulic Isolator CA491A-06B LN 7-34. Full life expected rather than the life limit 

listed pending completion of system endurance tests.

27,000 Flig

4l.(ii) Static-Dissipative Hydraulic Isolator CA491A-06D Line Number (LN) 35 and on. Full life expected rather 

than the life limit listed pending completion of system endurance tests.

27,000 Flig

5. Landing Gear

5a.(i) Nose Wheel Steering Valve module 2-8300-4 Service Bulletin to be released for new part long 

before life limit. Will only impact a few early airplanes.

13,750 Flig

5a.(ii) Nose Wheel Steering Valve module 2-8300-5 Service Bulletin to be released for new part long 

before life limit. Will only impact a few early airplanes.

13,750 Flig

5b. Main Landing Gear Door Uplock 

Mechanism

2-8325-4 (LH)

2-8326-4 (RH)

Limited to production LN 4-19. Service Bulletin to be released.

13,750 Flig

5c. Main Landing Gear Door Uplock 

Mechanism

2-8325-50 (LH)

2-8326-50 (RH)

Limited to production LN 20 and on. Service Bulletin to be released.

13,750 Flig

5d. Main Landing Gear Door Uplock 

Actuator

2-8309-3 P/N 2-8309-4, which is not life-limited, is the preferred 

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.

3,500 Fligh

ITEM 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

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6. Propulsion - Rolls Royce Trent 1000

6a. Primary Exhaust Nozzle 725Z4100-9 P/N 725Z4100-11, which is not life-limited, is the 

preferred spare for P/N 725Z4100-9. Boeing Service Bulletin B787-81205-SB780006 provides warranty information and replacement instructions.

5,300 Fligh

6b. Primary Exhaust 

Forward Centerbody

725Z4200-7 P/N 725Z4200-11, which is not life-limited, is the 

preferred spare for P/N 725Z4200-7. Boeing Service Bulletin B787-81205-SB780006 provides warranty information and replacement instructions.

5,300 Fligh

6c. Primary Exhaust Nozzle – 

Lightweight

725Z4100-5 P/N 725Z4100-11, which is not life-limited, is the 

preferred spare for P/N 725Z4100-5. Boeing Service Bulletin B787-81205-SB780006 provides warranty information and replacement instructions.

5,300 Fligh

6d. Primary Exhaust 

Forward Centerbody – Lightweight

725Z4200-9 P/N 725Z4200-11, which is not life-limited, is the 

preferred spare for P/N 725Z4200-9. Boeing Service Bulletin B787-81205-SB780006 provides warranty information and replacement instructions.

5,300 Fligh

7. Propulsion - Exhaust System General Electric GEnx-1B

7a. Primary Exhaust Nozzle 721Z4100-7 Additional testing scheduled to develop full life 

structure allowables.

5,300 Fligh

7b. Primary Exhaust Nozzle 721Z4100-3 Additional testing scheduled to develop full life 

structure allowables.

5,300 Fligh

7c. Primary Exhaust 

Forward Centerbody

721Z4200-3 Additional testing scheduled to develop full life 

structure allowables.

5,300 Fligh

7d. Primary Exhaust 

Forward Centerbody

721Z4200-5 Additional testing scheduled to develop full life 

structure allowables.

5,300 Fligh

7e. Primary Exhaust Aft Centerbody 721Z4300-3 Additional testing scheduled to develop full life 

structure allowables.

5,300 Fligh

ITEM 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

FEB 2013
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787 AIRWORTHINESS LIMITATIONS

8. Propulsion – Thrust Reverser Actuation System (TRAS) – Trent 1000

8a.(i) Actuator, Locking 725Z3161-175 Service Bulletin to be released for new part which will 

not have this life limitation.

5,500 Fligh

8a.(ii) Actuator, Locking 725Z3161-215 Service Bulletin to be released for new part which will 

not have this life limitation.

5,500 Fligh

8b. T-PC Assy 725Z3161-211 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8c. Deploy Hose, Short 725Z3161-195 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8d. Deploy Tube 725Z3161-155 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8e. Stow Tube 725Z3161-123 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8f. Stow Tube (LW T/R) 725Z3161-203 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8g. Stow Tube 725Z3161-125 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8h. Stow Tube (LW T/R) 725Z3161-205 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8j. Flexible Shaft, Side 720Z3161-179 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8k. Flexible Shaft, Side 720Z3161-181 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8l. Flexible Shaft, Crossover 725Z3161-207 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8m. Track Lock 725Z3161-177 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

ITEM 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

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8n. Feedback Unit 725Z3161-151 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8p. Feedback Unit 725Z3161-153 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

8q. Manual Drive Unit 720Z3161-167 Service Bulletin to be released for new part which will 

not have this life limitation.

5,500 Fligh

8r. Hydraulic Control Unit 720Z3161-213 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9. Propulsion – Thrust Reverser Actuation System – GEnx-1B

9a. Actuator, Locking 721Z3161-215 Service Bulletin to be released for new part which will 

not have this life limitation.

5,500 Fligh

9b. T-PC Assy 721Z3161-211 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9c. Deploy Hose, Short 721Z3161-195 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9d. Deploy Tube 721Z3161-155 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9e. Stow Tube 721Z3161-123 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9f. Stow Tube 721Z3161-125 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9g. Flexible Shaft, Side 720Z3161-179 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9h. Flexible Shaft, Side 720Z3161-181 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9j. Flexible Shaft, Crossover 721Z3161-207 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

ITEM 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

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787 AIRWORTHINESS LIMITATIONS

9k. Track Lock 721Z3161-177 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9l. Feedback Unit 721Z3161-151 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9m. Feedback Unit 721Z3161-153 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

9n. Manual Drive Unit 720Z3161-167 Service Bulletin to be released for new part which will 

not have this life limitation.

5,500 Fligh

9p. Hydraulic Control Unit 720Z3161-213 Full life expected rather than the life limit listed 

pending completion of TRAS system endurance tests.

5,500 Fligh

10. Propulsion – Power Door Opening System (PDOS) – Trent 1000

10a. PDOS Power Pack 725Z3191-27 Additional testing scheduled to develop full life design. 27,500 Flig

10c. Thrust Reverser Hold Open Rod 725Z3192-9 Additional testing scheduled to develop full life design. 5,500 Fligh

11. Propulsion – PDOS – GEnx-1B

11a. PDOS Power Pack 725Z3191-27 Additional testing scheduled to develop full life design. 27,500 Flig

11c. Thrust Reverser Hold Open Rod 721Z3192-9 Additional testing scheduled to develop full life design. 5,500 Fligh

12. Pressurized Doors

12a. Emergency Power Assist System 

(EPAS) Pressure Reservoir Assembly

41004654-4 P/N 41004654-5, which has no life limitation, is the 

preferred spare for P/N 41004654-4. 

2 Ye

ITEM 

NUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE L

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

E. OTHER AIRWORTHINESS LIMITATIONS – SYSTEMS AND STRUCTURES

These System and Structures Airworthiness Limitations are a result of Model 787-8 airplane certification activities with the U.S. 

Airworthiness Limitations section of the Instructions for Continued Airworthiness. These maintenance actions are mandatory. T

Limitations may only be revised with the approval of the Seattle FAA ACO.SYSTEM AIRWORTHINESS LIMITATION NO. 1INSPECTION OF THE FUEL OIL HEAT EXCHANGER FOLLOWING FUEL TANK ENTRY – 787-8 AIRPLANES WITH TREN(FAA EXEMPTION 10199)1. Following center wing tank purging and maintenance activity inside the center wing fuel tank, perform the following tasks if 

center tank: a. Prior to accumulating 20 flight hours after fuel has been added to the center tank, perform a borescope inspection for 

contamination of the left engine Fuel/Oil Heat Exchanger front face per AMM 79-21-11, Task 79-21-11-00A-280C-A. If 

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 

contamination of the right engine Fuel/Oil Heat Exchanger front face per AMM 79-21-11, Task 79-21-11-00A-280C-A. Isystem contamination is found, troubleshoot the source of the contamination and remove unacceptable contaminates 

2. Following a left or right engine low pressure fuel filter replacement due to the ENG FUEL FILTER L(R) EICAS message, pe

a. Perform a borescope inspection for abnormal or significant contamination of the corresponding engine Fuel/Oil Heat E

AMM 79-21-11, Task 79-21-11-00A-280C-A. If abnormal or significant fuel system contamination is found, troubleshoosystem contamination.

AUG 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

Operation of a Model 787-8 airplane after December 31, 2016 is prohibited unless a modification to provide indication to the fligcontamination is installed in accordance with a method approved by the Seattle FAA ACO. The FAA approval must specifically 

airworthiness limitation.SYSTEM AIRWORTHINESS LIMITATION NO. 2ENGINE OIL CONSUMPTION RATES – 787-8 AIRPLANES WITH TRENT 1000 ENGINESThe approved maximum normal oil consumption rate for the Trent 1000 engine installed on the Model 787-8 airplane has been 

(0.50 liter) per hour.The maximum oil consumption rate is used to show compliance with 14 CFR 25.1011(b), and is a limitation to ensure the maximdoes not exceed each installed engine's usable oil quantity, thereby preventing a common mode loss of all engine thrust. The mendurance is 26 flight hours and is calculated with the minimum crew, minimum equipment, no payload and the maximum quanreserves. The engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity o

number of flight hours; oil consumption calculations over less than 10 flights can give an incorrect value.Operation of a Model 787-8 with an engine oil consumption rate higher than these limits is not authorized, except as allowed un

authorized under 14 CFR 21.197 and 21.199.

AUG 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

SYSTEM AIRWORTHINESS LIMITATION NO. 3INSPECTION OF THE FUEL PUMP STRAINER FOLLOWING CENTER WING FUEL TANK ENTRY – 787-8 AIRPLANES W

(FAA EXEMPTION 10268)1. Following center wing fuel tank purging and maintenance activity inside the center wing fuel tank, perform the following tas

the center tank:a. After the next flight check for the presence of the ENG FUEL STRAINER L(R) EICAS status message and interrogate 

Computing Function (CMCF) to check for the presence of the FUEL BOOST STRAINER L(R) impending bypass mainTroubleshoot 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 Straine

the left engine per AMM 73-11-04, Task 73-11-04-00B-280A-A. Collect any material removed from the fuel pump strai

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 Straine

the right engine per AMM 73-11-04, Task 73-11-04-00B-280A-A. Collect any material removed from the fuel pump strasource of the fuel system contamination.

If the ENG FUEL STRAINER L(R) EICAS status message or the FUEL BOOST STRAINER L(R) impending bypass maintenan

abnormal or significant contamination is found on the fuel pump strainer, troubleshoot the source of the fuel system contaminat

contamination troubleshooting requires removal of the Main Fuel/Oil Heat Exchanger per AMM 79-21-01, Task 79-21-01-00A-52

for signs of contamination of the fuel circuit.Operation of a Model 787-8 airplane after December 31, 2016 is prohibited unless a modification to provide indication to the fligcontamination is installed in accordance with a method approved by the Seattle FAA ACO. The FAA approval must specifically 

airworthiness limitation.

AUG 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

SYSTEM AIRWORTHINESS LIMITATION NO. 4ENGINE OIL CONSUMPTION RATES – 787-8 AIRPLANES WITH GEnx-1B ENGINES

The approved maximum normal oil consumption rate for the GEnx-1B engine installed on the Model 787-8 airplane has been e

(0.43 liter) per hour.The maximum oil consumption rate is used to show compliance with 14 CFR 25.1011(b), and is a limitation to ensure the maximdoes not exceed each installed engine's usable oil quantity, thereby preventing a common mode loss of all engine thrust. The mendurance is 25 flight hours and is calculated with the minimum crew, minimum equipment, no payload and the maximum quanreserves. The engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity o

number of flight hours; oil consumption calculations over less than 10 flights can give an incorrect value.Operation of a Model 787-8 with an engine oil consumption rate higher than these limits is not authorized, except as allowed un

authorized under 14 CFR 21.197 and 21.199.SYSTEM AIRWORTHINESS LIMITATION NO. 5ENGINE POST-SHUTDOWN FUEL VAPOR VENTING – 787-8 AIRPLANES WITH GEnx-1B ENGINESOperation of a Model 787-8 airplane with GEnx-1B engine after December 31, 2014 is prohibited unless a modification to eliminFuel Vapor Venting is installed in accordance with GE’s GEnx-1B S/B 73-0011.• Airplane Applicability:

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

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 

956106, 956109 through 956130, 956140 through 956151, 956154, 956155, 956157, 956160 through 956169, 956171 thro

956188, 956192, 956194 through 956196.

APR 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

STRUCTURES AIRWORTHINESS LIMITATION NO. 1Background: The 787-8 fuel tank access doors are compliant with 25.963 as impact resistant doors are installed in locations wh

tire or engine fragment impacts. In addition to clear marking, the 787 doors were designed to have a physical barrier preventing 

installed in locations requiring impact resistant doors. Due to a design change, early 787-8 Line Numbers had the physical featu

features are being reincorporated into production units, beginning at Line Number 60. All units have the stencilling and correct 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 an

• Airplane Applicability: 787-8 Production Line Numbers 7 through 59.Main Fuel Tank Access Panel InspectionConcern: Potential installation of a non-impact resistant fuel tank access door in a location where an impact resistant fuel tank aMitigations: 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 in accordance with Boeing AMM B787-A-28-11-01-00A-520A-A (

the engine nacelle).

2. Verify that all impact resistant doors have the stencil "IMPACT RESISTANT DOOR" applied to the exterior surface as shown 

AMM B787-A-28-11-01-00A-520A-A.

3. Verify that all impact resistant doors each have 24 fastener holes as shown in accordance with Boeing AMM B787-A-28-11

NOTE: All fuel tank access hole locations outboard of the engine nacelle contain non-impact resistant doors that have 23 fast

NOV 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

Center Fuel Tank Access Panel InspectionConcern: Potential installation of a non-impact resistant fuel tank access door in a location where an impact resistant fuel tank aMitigations: 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 in accordance with Boeing AMM B787-A-28-11-02-00A-520A-A 

of the engine nacelle).

2. Verify that all impact resistant doors have the stencil "IMPACT RESISTANT DOOR" applied to the exterior surface in accord

AMM B787-A-28-11-02-00A-520A-A.

3. Verify that all impact resistant doors each have 24 fastener holes as shown in accordance with Boeing AMM B787-A-28-11

NOTE: All fuel tank access hole locations outboard of the engine nacelle contain non-impact resistant doors that have 23 fast

NOV 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

STRUCTURES AIRWORTHINESS LIMITATION NO. 2Background: The main landing gear forward trunnion support upper housing increases the vertical fusing capability of the forwa

landing gear. Four bearing pads are located between the main landing gear forward trunnion upper housing and the main landhousing and are attached to the upper housing. During fatigue testing, at approximately 22,000 flight-cycles, the bearing pads w

and retaining features were found fractured. The loss of the bearing pads from between the main landing gear forward trunnion landing gear forward trunnion housing will reduce the vertical fusing capability of the forward trunnion of the main landing gear. 

premature fusing and loss of the main landing gear during a take-off roll with an airplane at maximum take-off weight. The highexperienced by the landing gear are during take-off roll with an airplane at maximum take-off weight and certain runway conditi

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, 

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 fo

migrated or missing bearing pads. For inspection zone and access reference, see D011Z009-03 MPD Section 2, Item NumCard 57-522-01).

SEP 2012
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

APPENDIX A. POST-THRESHOLD INTERVALS FOR STRUCTURES AND ZONAL TA

This appendix provides operators the intervals for selected structures and zonal tasks of the 787 MPD, Document D011Z009-0

respectively. Included here are those tasks which provide sufficient fatigue damage detection opportunity for PSEs to completel

14 CFR 25.571. The intervals indicated for each task are those that must be used upon the airplane reaching the supplementathreshold, as these were the intervals defined at original type certification utilized to satisfy the damage tolerance requirements 

escalation is not permitted at this time, this appendix provides the operator with a convenient reference to the required post-thr

Section 2 and 3 tasks are allowed to be escalated in the future. The items listed below must use the post-threshold repeat intedefined 787-8 threshold of 44,000 flight cycles or 22 years, whichever occurs first. This is necessary in order to ensure the mai

with the damage tolerance requirements for the 787 aircraft.

MRB / MPD 

Item Number Task Description Inspecti

27-300-00 Horizontal Stabilizer Ballscrew, Primary and Secondary Ball Nuts DE32-815-01 Left Main Landing Gear and Landing Gear Doors EXT - ZO32-825-02 Right Main Landing Gear and Landing Gear Doors EXT - ZO52-500-00 Bulk Cargo Compartment Door EXT - 

52-502-00 Bulk Cargo Compartment Door INT - 52-504-00 Forward Large Cargo Compartment Door EXT - 

52-506-00 Forward Large Cargo Compartment Door INT - 52-508-00 Aft Large Cargo Compartment Door EXT - 

OCT 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

52-510-00 Aft Large Cargo Compartment Door INT - 52-512-00 Upper Half of Fuselage, Left Side (Passenger Entry Doors) INT - 52-512-01 Upper Half of Fuselage, Left Side (Passenger Entry Doors) Stop Fittings EXT - 

52-514-00 Upper Half of Fuselage, Right Side (Passenger Entry Doors) INT - 

52-514-01 Upper Half of Fuselage, Right Side (Passenger Entry Doors) Stop Fittings EXT - 

52-805-01 Bulk Cargo Door EXT - ZO52-815-02 Forward Cargo Compartment Door EXT - ZO52-820-02 Forward Cargo Compartment Door INT - ZO52-825-02 Aft Cargo Compartment Door EXT - ZO52-830-02 Aft Cargo Compartment Door INT - ZO52-835-01 Left No. 1 Entry Door - Section 41 EXT - ZO52-840-01 Left No. 1 Entry Door - Section 41 INT - ZO52-845-01 Left No. 2 Entry Door - Section 43 EXT - ZO52-850-01 Left No. 2 Entry Door - Section 43 INT - ZO52-855-01 Left No. 3 Entry Door - Section 46 EXT - ZO52-860-01 Left No. 3 Entry Door - Section 46 INT - ZO52-865-01 Left No. 4 Entry Door - Section 47 EXT - ZO52-870-01 Left No. 4 Entry Door - Section 47 INT - ZO52-875-02 Right No. 1 Entry Door - Section 41 EXT - ZO

MRB / MPD 

Item Number Task Description Inspecti

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

52-880-02 Right No. 1 Entry Door - Section 41 INT - ZO52-885-02 Right No. 2 Entry Door - Section 43 EXT - ZO52-890-02 Right No. 2 Entry Door - Section 43 INT - ZO52-895-02 Right No. 3 Entry Door - Section 46 EXT - ZO52-900-02 Right No. 3 Entry Door - Section 46 INT - ZO52-905-02 Right No. 4 Entry Door - Section 47 EXT - ZO52-910-02 Right No. 4 Entry Door - Section 47 INT - ZO53-500-00 Body Station 63.55 to Body Station 338.50 INT - 

53-502-00 Nose Landing Gear Wheel Well INT - 53-504-00 Nose Landing Gear Wheel Well EXT - 

53-506-00 Body Station 338.50 to Body Station 873.00, Stringer 22L to BL 0 INT - 

53-507-00 Forward Cargo Compartment, Right EXT - 

53-508-00 Body Station 338.50 to Body Station 873.00, Stringer 22R to BL 0 INT - 

53-510-00 Forward Keel Beam, BS 867.0 to BS 1077.0 INT - 

53-512-00 Area Above Center Wing Section, Left & Right INT - 53-514-00 Keel Beam, Mid Section (BS 1073.0 to BS 1209) EXT - 

MRB / MPD 

Item Number Task Description Inspecti

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-516-00 Area Above Main Landing Gear Wheel Well, Left & Right INT - 53-518-00 Main Landing Gear (MLG) Wheel Well, Left & Right EXT - 53-520-00 Aft EE Bay, Left & Right INT - 53-522-00 Aft Cargo Compartment & Area Below Aft Cargo Compartment, Left INT - 

53-524-00 Aft Cargo Compartment & Area Below Aft Cargo Compartment, Right INT - 

53-526-00 Aft Cargo Compartment & Area Below Aft Cargo Compartment, Right EXT - 

53-528-00 Bulk Cargo Compartment, Area Below Bulk Cargo Compartment & Area Aft of Bulk Cargo Compartment, Left INT - 

53-530-00 Bulk Cargo Compartment, Area Below Bulk Cargo Compartment & Area Aft of Bulk Cargo Compartment, Left EXT - 

53-532-00 Bulk Cargo Compartment, Area Below Bulk Cargo Compartment & Area Aft of Bulk Cargo Compartment, Right INT - 

53-534-00 Wing to Body Forward & Overwing Fairing, Left INT - 53-536-00 Wing to Body Forward & Overwing Fairing, Right INT - 53-538-00 Wing to Body Underwing & Aft Fairing, Left INT - 53-540-00 Wing to Body Underwing & Aft Fairing, Right INT - 53-542-00 Flight Deck, Left & Right INT - 

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
D011Z009-03-01

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787 AIRWORTHINESS LIMITATIONS

53-544-00 Passenger Compartment, Left INT - 53-546-00 Passenger Compartment, Left EXT - 

53-547-00 Passenger Compartment, Left INT - 53-548-00 Passenger Compartment, Right INT - 53-550-00 Passenger Compartment, Right EXT - 

53-551-01 Passenger Compartment, Right INT - 53-552-00 Area Above Passenger Compartment, Left & Right INT - 53-553-00 Area Above Passenger Compartment, Left & Right INT - 53-554-00 Passenger Compartment, Left INT - 53-555-00 Passenger Compartment, Left INT - 53-556-00 Passenger Compartment, Right INT - 53-557-00 Passenger Compartment, Right INT - 53-558-00 Area Above Passenger Compartment, Left & Right INT - 53-559-00 Area Above Passenger Compartment, Left & Right INT - 

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-560-00 Passenger Compartment, Left INT - 53-562-00 Passenger Compartment, Left EXT - 

53-563-00 Passenger Compartment, Left INT - 53-564-00 Passenger Compartment, Right INT - 53-566-00 Passenger Compartment, Right EXT - 

53-567-00 Passenger Compartment, Right INT - 53-568-00 Area Above Passenger Compartment, Left & Right INT - 53-569-00 Area Above Passenger Compartment, Left & Right INT - 53-803-00 Lower Half of the Fuselage EXT - ZO53-806-00 Radome INT - ZO53-809-00 Areas Forward, Above, and Outboard of the NLG Wheel Well INT - ZO53-812-00 Areas Forward, Above, and Outboard of the NLG Wheel Well INT - ZO53-815-00 Nose Gear Wheel Well - as viewed from the ground EXT - ZO53-818-00 Nose Gear Wheel Well - as viewed from within the Wheel Well INT - ZO53-822-00 Forward Electronic Equipment Bay INT - ZO53-827-00 Forward Cargo Compartment INT - ZO53-830-00 Areas Below Forward Cargo Compartment Floor INT - ZO

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

53-834-00 Environmental Control System Distribution Bay INT - ZO53-836-00 Keel Beam Area from BS 849 to BS 1382 INT - ZO53-839-00 Areas Above the Wing Center Section and Below the Passenger Floor Panels INT - ZO53-842-00 Wing Center Section INT - ZO53-854-01 Left Main Landing Gear Wheel Well - as viewed from within the Wheel Well INT - ZO53-860-02 Right Main Landing Gear Wheel Well - as viewed from within the Wheel Well INT - ZO53-863-00 Aft Electronic Equipment Bay INT - ZO53-869-00 Aft Cargo Compartment INT - ZO53-872-00 Areas Below the Aft Cargo Compartment Floor Panels INT - ZO53-878-00 Bulk Cargo Compartment INT - ZO53-885-00 Areas Aft of the Bulk Cargo Compartment INT - ZO53-888-01 Forward Wing to Body Fairing Area - Left INT - ZO53-891-02 Forward Wing to Body Fairing Area - Right INT - ZO53-894-01 Wing to Body Overwing Fairing - Left INT - ZO53-897-02 Wing to Body Overwing Fairing - Right INT - ZO53-912-00 Upper Half of the Fuselage, Section 41 through 47, BS 232.5 to BS 1878, Floor WL 200 to Top of Fuselage 

Centerline BL 0

EXT - ZO

53-924-00 Passenger Compartment - Section 41 BS 232.5 to BS 597 INT - ZO53-930-00 Overhead Flight Crew Rest Compartment - Section 41 INT - ZO53-976-00 External - Fuselage Area Aft of the Pressure Bulkhead EXT - ZO53-977-00 Internal - Fuselage Area Aft of the Pressure Bulkhead INT - ZO53-978-00 APU Compartment - Body Section 48 EXT - ZO

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

53-984-00 APU Compartment INT - ZO54-500-00 Powerplant Left - Forward and Aft Engine Mount (GEnx) INT - 54-502-00 Powerplant Left - Forward and Aft Engine Mount (Trent 1000) INT - 54-504-00 Powerplant Right - Forward and Aft Engine Mount (GEnx) INT - 54-506-00 Powerplant Right - Forward and Aft Engine Mount (Trent 1000) INT - 54-508-00 Forward Nacelle Pylon Fairing INT - 

54-510-00 Pylon Forward & Aft Torque Box - Left Nacelle Pylon (GEnx) INT - 54-512-00 Pylon Forward & Aft Torque Box - Left Nacelle Pylon (Trent 1000) INT - 54-514-00 Aft Pylon Fairing INT - 

54-516-00 Aft Pylon Fairing INT - 54-518-00 Forward Nacelle Pylon Fairing INT - 

54-520-00 Pylon Forward & Aft Torque Box - Right Nacelle Pylon (GEnx) INT - 54-522-00 Pylon Forward & Aft Torque Box - Right Nacelle Pylon (Trent 1000) INT - 54-524-00 Aft Pylon Fairing INT - 

54-526-00 Aft Pylon Fairing INT - 54-815-01 Forward Torque Box - Left Nacelle Strut EXT - ZO54-820-01 Forward Torque Box - Left Nacelle Strut INT - ZO54-825-01 Aft Torque Box - Left Nacelle Strut EXT - ZO

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

54-830-01 Aft Torque Box - Left Nacelle Strut INT - ZO54-855-02 Forward Torque Box - Right Nacelle Strut EXT - ZO54-860-02 Forward Torque Box - Right Nacelle Strut INT - ZO54-865-02 Aft Torque Box - Right Nacelle Strut EXT - ZO54-870-02 Aft Torque Box - Right Nacelle Strut INT - ZO54-890-01 Forward Nacelle Strut Fairing - Left Nacelle Strut INT - ZO54-895-01 Forward Torque Box - Left Nacelle Strut EXT - ZO54-900-01 Forward Torque Box - Left Nacelle Strut INT - ZO54-905-01 Aft Torque Box - Left Nacelle Strut EXT - ZO54-910-01 Aft Torque Box - Left Nacelle Strut INT - ZO54-935-02 Forward Nacelle Strut Fairing - Right Nacelle Strut INT - ZO54-940-02 Forward Torque Box - Right Nacelle Strut EXT - ZO54-945-02 Forward Torque Box - Right Nacelle Strut INT - ZO54-950-02 Aft Torque Box - Right Nacelle Strut EXT - ZO54-955-02 Aft Torque Box - Right Nacelle Strut INT - ZO55-500-00 Fuselage Body Section 48 INT - 55-502-00 Fuselage Body Section 48 EXT - 

55-504-00 Fuselage Body Section 48 EXT - 

55-506-00 Vertical Stabilizer, Front Spar to Rear Spar INT - 

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

55-508-00 Vertical Stabilizer, Front Spar to Rear Spar EXT - 

55-510-00 Vertical Stabilizer, Rear Spar to Trailing Edge INT - 55-512-00 Rudder INT - 

55-514-00 Rudder INT - 55-516-00 Horizontal Stabilizer Center Section, Left & Right INT - 55-516-01 Horizontal Stabilizer Center Section, Left & Right INT - 55-518-00 Horizontal Center Section, Left & Right EXT - 

55-520-00 Horizontal Center Section, Left & Right EXT - 

55-522-00 Left Horizontal Stabilizer, Front Spar to Rear Spar INT - 

55-524-00 Left Horizontal Stabilizer, Front Spar to Rear Spar INT - 

55-526-00 Left Horizontal Stabilizer, Rear Spar to Trailing Edge INT - 

55-528-00 Left Horizontal Stabilizer, Rear Spar to Trailing Edge INT - 

55-530-00 Left Elevator INT - 

55-532-00 Left Elevator INT - 

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

55-534-00 Right Horizontal Stabilizer, Front Spar to Rear Spar INT - 55-536-00 Right Horizontal Stabilizer, Front Spar to Rear Spar INT - 55-538-00 Right Horizontal Stabilizer, Rear Spar to Trailing Edge INT - 55-540-00 Right Horizontal Stabilizer, Rear Spar to Trailing Edge INT - 55-542-00 Right Elevator INT - 

55-544-00 Right Elevator INT - 55-809-00 Vertical Stabilizer Auxiliary Spar to Rear Spar EXT - ZO55-812-00 Vertical Stabilizer Auxiliary Spar to Front Spar INT - ZO55-821-00 Vertical Stabilizer Rear Spar to Trailing Edge EXT - ZO55-824-00 Vertical Stabilizer Rear Spar to Trailing Edge INT - ZO57-500-00 Wing Center Section, Left and Right INT - 57-502-00 Leading Edge to Front Spar - Inboard of Canted Rib INT - 57-504-00 Leading Edge to Front Spar - Outboard of Canted Rib INT - 

57-506-00 Center Fuel Tank INT - 57-508-00 Center Fuel Tank, Dry Bay, Main Tank INT - 

MRB / MPD 

Item Number Task Description Inspecti

SEP 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-510-00 Main Tank INT - 57-512-00 Main Tank INT - 57-514-00 Surge Tank, Inspar Area INT - 57-515-00 Surge Tank, Inspar Area INT - 

57-516-00 Wing Tip - Rib 40 to Closure Rib INT - 57-517-00 Inboard and Outboard Wing Trailing Edge INT - 57-518-00 Rear Spar to Landing Gear Support Beam to Trailing Edge INT - 

57-520-00 Rear Spar to Landing Gear Support Beam EXT - 

57-522-00 Rear Spar to Landing Gear Support Beam INT - 57-526-00 Landing Gear Support Beam to Trailing Edge INT - 57-528-00 Inboard Flap, Left Wing INT - 57-532-00 Outboard Flap, Left Wing INT - 57-534-00 Aileron, Left Wing INT - 57-536-00 Leading Edge to Front Spar INT - 

MRB / MPD 

Item Number Task Description Inspecti

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

57-538-00 Leading Edge to Front Spar INT - 57-540-00 Center Fuel Tank INT - 57-542-00 Center Fuel Tank, Dry Bay, Main Tank INT - 57-544-00 Main Tank INT - 57-546-00 Main Tank INT - 57-548-00 Surge Tank, Inspar Area INT - 57-549-00 Surge Tank, Inspar Area INT - 

57-550-00 Wing Tip INT - 57-551-00 Inboard and Outboard Wing Trailing Edge INT - 57-552-00 Rear Spar to Landing Gear Support Beam to Trailing Edge INT - 

57-554-00 Rear Spar to Landing Gear Support Beam EXT - 

57-556-00 Rear Spar to Landing Gear Support Beam INT - 57-560-00 Landing Gear Support Beam to Trailing Edge INT - 57-562-00 Inboard Flap, Right Wing INT - 

MRB / MPD 

Item Number Task Description Inspecti

FEB 2013
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

57-566-00 Outboard Flap, Right Wing INT - 57-568-00 Aileron, Right Wing INT - 57-826-01 Left Wing Inspar Area (Fuel Tanks), Upper and Lower Wing – Inboard of Wing BL 860 (Rib 32) to Wing to Body 

Fairings

EXT - ZO

57-830-01 Dry Bay - Left Wing INT - ZO57-834-01 Wing Inspar Area Outboard of Rib 32 to Rib 40 – Upper and Lower Wing – Left Wing EXT - ZO57-854-01 Inboard Trailing Edge Flap – Left Wing EXT - ZO57-866-01 Outboard Trailing Edge Flap – Left Wing EXT - ZO57-870-01 Outboard Aileron – Left Wing EXT - ZO57-920-02 Right Wing Inspar Area (Fuel Tanks), Upper and Lower Surfaces – Inboard of Wing BL 860 (Rib 32) to Wing to 

Body Fairings

EXT - ZO

57-924-02 Right Wing Dry Bay INT - ZO57-928-02 Wing Inspar Area Outboard of Rib 32 to Rib 40 – Upper and Lower Surfaces – Right Wing EXT - ZO57-948-02 Inboard Trailing Edge Flap – Right Wing EXT - ZO57-960-02 Outboard Trailing Edge Flap – Right Wing EXT - ZO57-964-02 Outboard Aileron – Right Wing EXT - ZO

MRB / MPD 

Item Number Task Description Inspecti

FEB 2013
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

APPENDIX B. DISCREPANT STRUCTURE REPORT FORM

Discrepant Structure Report Forms are required for the reporting of all significant structural discrepancies found on all inspectiothe fatigue program in D011Z009-03, Section 2. Should any operator or Boeing desire a change in the reporting procedure, the

all participating operators, Boeing and the FAA at any time for review of the proposed changes.The Discrepant Structure Report Form is shown on the following pages.

SEP 2011
787 AIRWORTHINESS LIMITATIONS

D011Z009-03-01

SEP 2011 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 
D011Z009-03-01

BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details 

787 AIRWORTHINESS LIMITATIONS

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

modification(s) to the discrepant structure.

associated discrepancies on the same aircraft, related experience with this discrepancy on any aircraft, and previous

Attach sketch, photos, and text as required to describe defect and specific location. When applicable give details of 

7

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7B. SIZE OF DISCREPANCY: INCHES, OR CENTIMETERS

FINAL MEASUREMENT (IF DIFFERENT) ____________________________________ DATE________________

CRACK LENGTH INITIALLY DETECTED ____________________________________ DATE________________

AREA ___________________ X _____________________________________ DEPTH_____________________

7C. DISCREPANT PART:

________________________

FAIRING

FLAP TRACK

LANDING GEAR BEAM

RIB

SPAR

WING DRY-BAY AREA/COMPT.

WING CENTER SECTION

FLOOR

KEEL BEAM

WINDOW FORGING

FRAME AROUND OPENING

PRESSURE BULKHEAD

FRAME/BULKHEAD

DELAMINATED

DEFORMED

CRACKED

CORRODED

CONTAMINATED

LEAK

ADJUSTED

IMPROPERLY

DETACHED

DENTED

WORN

STUCK

OUT-OF-TOLERANCE

MISSING

LOOSE

___________

___________

___________

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BUSHING P NI ______________________

7C. DISCREPANT PART:

BODY LANDING GEAR

WING LANDING GEAR

MAIN LANDING GEAR

NOSE LANDING GEAR

COMPARTMENT___________

NACELLE/PYLON

HORIZ. STAB. STA.________

VERT. STAD. STA.________

WING STA. NO.__________

BODY STA. NO.__________

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_________________________________ _________________________________ EXTER OI R OUTBOARD RIGHT AFT LOWER

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ORIGINATED BY DATE

SEP 2011