787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-1787AIRWORTHINESS LIMITATIONS (AWLs)D011Z009-03-01APRIL 2013This document has EAR data with an Export Control Classification Number (ECCN) of 9E991.Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used fordevelopment, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.Boeing claims copyright in each page of thisdocument on to the extent that the pagecontains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collectivework. This document includes proprietary information owned by the Boeing Company and/or one or more third parties. Treatment ofthe document and the information it contains is governed by contract withBoeing. For more information, contact the Boeing Company, P.O.Box 3707, Seattle WA 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, BBJ, DC-8,DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-blue Boeing livery are all trademarks owned by The Boeing Company; no trademark license is granted in connection with thisdocument unless provided in writing by Boeing.COMPILED AND PUBLISHED BY:MAINTENANCE PROGRAMS ENGINEERINGCOMMERCIAL AVIATION SERVICESBOEING COMMERCIAL AIRPLANE GROUPSEATTLE, WASHINGTONAPR 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-2787 AIRWORTHINESS LIMITATIONSTHIS PAGE INTENTIONALLY LEFT BLANKBLANK787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3TABLE OF CONTENTSREVISIONS .................................................................................................................................................................................................................................. 1.0-5LIST OF EFFECTIVE PAGES .....................................................................................................................................................................................................1.0-11REFERENCES ........................................................................................................................................................................................................................... 1.0-13A. SCOPE................................................................................................................................................................................................................................... 1.0-15B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONALLIMITS.............................................................................................................................. 1.0-15C. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURALFATIGUE INSPECTIONS....................................................................................... 1.0-18D. AIRWORTHINESS LIMITATIONS – LIFE LIMITS.................................................................................................................................................................. 1.0-77E. OTHER AIRWORTHINESS LIMITATIONS – SYSTEMS AND STRUCTURES ................................................................................................................... 1.0-109APPENDIX A. POST-THRESHOLD INTERVALS FOR STRUCTURES ANDZONAL TASKS .................................................................................................1.0-116APPENDIX B. DISCREPANT STRUCTURE REPORT FORM................................................................................................................................................. 1.0-130JUL 2012D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4787 AIRWORTHINESS LIMITATIONSTHIS PAGE INTENTIONALLY LEFT BLANKBLANK787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5REVISIONSREVISION AND REVISIONDESCRIPTION APPROVALAUGUST 2011Original ReleaseSubmitted by: Ray Smith (Boeing) Approved by: Ken Schroer(Seattle FAA ACO)SIGNATURE ON FILE8/19/2011SEPTEMBER 16, 2011Revised Threshold (787-8 Airplanes) section by changing the 20 year interval to 22 yearsin two locations.Moved two Notes in the Threshold (787-8 Airplanes) section to a location better suited fortheir content.Revised the Lock Link Assembly item in Table 3 by adding a “1” in the Notes column torefer to Table Note 1.Revised the list of Systems Life-Limited Parts by adding life limitations for the PassengerEntry Door Emergency Power Assist System Pressure Reservoir Assembly.The listing of Supplemental Structural Fatigue Inspections was added as a result of thecompleted damage tolerance assessment. The appropriate front matter text was alsorevised in support of the addition.Revised the first paragraph in Appendix A by adding direction for operators working withtasks that may be allowed tobe escalated inthe future.Submitted by: Ray Smith (Boeing) Approved by: Ken Schroer(Seattle FAA ACO)SIGNATURE ON FILE9/19/2011OCTOBER 2011For this revision, minor changes towording were madein several areas.Revised the Airplane Operational Limitation Table in the Freedom From WidespreadFatigue Damage section by updating the Accumulated Cycles – Full-Scale Fatigue Test to18,843 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 andincluding them in each PSE, asapplicable, within the table.Updated the illustrations for Figures 7 and 8, and added an improved illustration forFigure 13.Revised the introductory paragraph inAppendix A to provide clarification.Submitted by: Ray Smith (Boeing) Approved by: (Seattle FAA ACO)SIGNATURE ON FILE10/7/2011APR 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6787 AIRWORTHINESS LIMITATIONSNOVEMBER 2011Revised Section B introductory paragraph to correct subsection references.Revised the Airplane Operational Limitation Table in the Freedom From WidespreadFatigue Damage section by updating the Accumulated Cycles – Full-Scale Fatigue Test to21,895 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 1from 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 renumberedFootnotes 7 and 8 accordingly.Deleted PSE 53-31-34 “Passenger Entry Door 2 - Edge Frame”, “Edge Frame Web atBS 682 S-19 (stop fitting 3A Interface)” as this detail was redundant to the two otherentries for thissame PSE detail.Clarified the Table 1 DTR Check Form Title and DTR Location information forPSE 53-58-03.Revised the DTR Check Form Title for three PSE 55-33-10 items by adding “(L/N 7and on)”.Added three new PSE 57-10-05 details toTable 1, effectivefor L/N 34 and on.Added the following statement to Footnote 5 for Table 1: “If the applicable publishedinspection procedure cannot be accomplished, an alternative FAA accepted proceduremust 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 HydraulicIsolators.Added Nose Wheel Steering Valvemodule, P/N 2-8300-5 limitation.Added a limitation for the Trent 1000 Package /B/ Locking Actuator, P/N 725Z3161-215and the GEnx Locking Actuator limitation P/N was changed from 721Z3161-175 to721Z3161-215.Removed Life Limitation for item 10b. Fan Cowl Aft Hold Open Rod (HOR) 725Z2161-103and 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 forclarification.Submitted by: Ray Smith (Boeing) Approved by: Julie Alger(Seattle FAA ACO BASOO)SIGNATURE ON FILE12/12/2011REVISION AND REVISIONDESCRIPTION APPROVALAPR 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-7DECEMBER 2011Revised the table of Life-Limited Items in the Systems Life-Limited Parts section by addingItem 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 sectionby changing “life this limitation”to “this life limitation” to make the statement grammaticallycorrect.Submitted by: Ray Smith (Boeing) Approved by: Martin Boone Jr.(Seattle FAA ACO)SIGNATURE ON FILE12/19/2011DECEMBER 2011 R1Revised the Life-Limited Parts table by re-inserting Systems Life Limitations for Trent 1000item 10b, Fan Cowl Aft Hold Open Rod(HOR) 725Z2161-103 and GEnx Hold Open Rodsitem 11b, Fan Cowl Aft HOR 721Z2161-103 in support of Airplane Certification activities.Submitted by: Ray Smith (Boeing) Approved by: Angelos Xidias(Seattle FAA BASOO)SIGNATURE ON FILE12/22/2011JUNE 2012Revised Section C by moving the Note regarding escalation of MPD Tasks from theThreshold subsection to the Introduction subsection. Added a reference to Appendix A tothe second paragraph of the Introduction subsection, and revised the last sentence of thethird paragraph for consistency.Revised the first sentence of the first and third paragraphs in the Threshold subsection ofSection C for consistency.For Table 1 in Section C, the following changes were made:Added new PSE 53-11-07 DTR Location "AftEdge Frame BS 327.5- Web at NutplateRetainer", effective for L/N 55 and on.Revised existing PSE 53-41-05B DTR Location "Lug Base Corner Fillet Radius" to beapplicable 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 forL/N 71 and on.Revised existing PSE 57-10-02 L/N applicability from "Side of Body Splice - Lower SurfaceLHS (L/N 22-67), RHS (L/N 21-65)" to "Sideof Body Splice - Lower Surface LHS (L/N 22and on), RHS (L/N 21 and on)".(Continued on next page)Submitted by: Ray Smith (Boeing) Approved by: Ken Schroer(Seattle FAA BASOO)SIGNATURE ON FILE6/21/2012REVISION AND REVISIONDESCRIPTION APPROVALAPR 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-8787 AIRWORTHINESS LIMITATIONSJUNE 2012, ContinuedRevised PSEs 57-53-08A "Outboard Flap Box"and 57-53-15A "Aileron Box" ApplicabilityThresholds from "5,550" to "5,500".For Table 4 in Section D, clarified Shock Strut Outer Cylinder P/N 511Z3001-5/-6,implemented starting at787-8 L/N 55, as preferred spare. Added Shock Strut InnerCylinder 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 ofSection D by adding Items 2b through 2i, Power Electronics Cooling System (PECS) RamHeat Exchanger and Forward Cargo Air Conditioning (FCAC) Ram Heat Exchanger (forairplanes equipped with the FCAC option).Revised Section D, Systems Life LimitedParts, by adding item6e, Primary ExhaustNozzle, and 6f, Primary Exhaust Forward Centerbody. Revised Items 10b, 10c, 11b, and11c to eliminate the acronym "HOR" forclarity. Revised Item 12a ApplicabilitySpecifications to reflect availability of replacement part.Revised Section D, Structures Life LimitedParts by revising "Horizontal Stabilizer PivotPins" for greater clarity, and changing the Noteto reflect earlier production incorporation ofnon-life-limited pins.Revised Structures Airworthiness Limitation No. 2 in Section E for greater clarity and torevise MPD reference to 57-522-00 with associated Task Card 57-522-01.Continued from previous page Continued from previous pageJULY 2012Revised Section D, Systems Life-Limited Parts, by deleting Item 1b, Variable FrequencyStarter/Generator (VFSG), and1c, Auxiliary Starter/Generator (ASG). Added Item 2j,Power Electronics Cooling System (PECS) Pump.Revised Section D, Systems Life-Limited Parts, to modify thequantity of parts per airplanefor Items 4a.(ii) and 4b.(ii), Static-Dissipative Hydraulic Isolator.Revised Section E, Structures AirworthinessLimitation No. 2, Airplane Applicability, tothose airplanes delivered prior to implementation of the bearing pad durabilityimprovement design change.Submitted by: Ray Smith (Boeing) Approved by: Doug Tsuji(Seattle FAA BASOO)SIGNATURE ON FILE8/7/2012REVISION AND REVISIONDESCRIPTION APPROVALAPR 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-9SEPTEMBER 2012Revised the data for the MLG Truck Assembly inTable 4 of Section D by deleting PartNumber515Z3009-2, since this part is not life-limited.Revised the Note in the Structures Life-Limited Parts section of Section D to reflect therelease 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 forItem 5d, Main Landing Gear Door Uplock sincethe airplane applicability originally noted for this part is no longer accurate.Deleted Item 10b, Fan Cowl Aft Hold OpenRod, since this part is not life-limited.Deleted Item 11b, Fan Cowl Aft Hold OpenRod, since this part is not life-limited.Revised Item 12a, Emergency Power Assist System (EPAS) Pressure Reservoir Assemblyto reflect the release of BoeingService Letter 787-SL-52-001.Added “and 60” to the list of 787-8 Production Line Numbers provided in StructuresAirworthiness Limitation No. 2.Submitted by: Ray Smith (Boeing)SIGNATURE ON FILEFAA BASOO10/25/2012FEBRUARY 2013Revised the table shown in the Freedom From Widespread Fatigue Damage section inSection B by updating the Accumulated Cycles - Full-Scale Fatigue Test to 61,059 FatigueTest 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 57-53-15Afrom the PSE Table and Table 1,as these PSEs no longer require directed inspections.Deleted Note 7 from Table 1 as itreferred to these deleted items.Revised Section D by updating the Nose and Main Landing Gear safe life limits andassociated descriptions. Revised Figures 2 through 5. Deleted Figure 6, then renumberedthe remaining figures. Revised figure references in text and Table 4 to match new figurenumbering. Revised Table 4 to update figure references, revise the Part Description forthe 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 ofSection D by deleting Items 2b through 2j, Power Electronics Cooling System (PECS) RamHeat Exchanger and Forward Cargo Air Conditioning (FCAC) Ram Heat Exchanger (forairplanes equipped with the FCAC option) based on successful completion of componentpressure-impulse fatigue life testing.(Continued on next page)Submitted by: Rod von Rotz (Boeing)SIGNATURE ON FILEFAA BASOO4/4/2013REVISION AND REVISIONDESCRIPTION APPROVALAPR 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-10787 AIRWORTHINESS LIMITATIONSFEBRUARY 2013, ContinuedRevised the Applicability Specifications for Items 6a - 6d in Section D to reflect availabilityof non-life-limited replacement parts and associated service bulletin. Deleted Items 6e,Primary Exhaust Nozzle, and 6f, PrimaryExhaust Forward Centerbody, as testingcompleted to substantiate the redesigned P/Ns 725Z4100-11 and 725Z4200-11demonstrated that a life limitation was not required. Deleted the reference to BoeingService 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 AirworthinessLimitations – Systems and Structures, by adding Airplane Line Number and Engine SerialNumber effectivity for airplanes and engineswithout a Fuel Accumulator (FSVA) installed.The following changes were made to Appendix A:Revised the Post-Threshold Repeat Intervalfor Item 53-507-00 from 12000 FC/6 YR to6000 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 withthe 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 beconsistent with the current MPD listing.Continued from previous page Continued from previous pageAPRIL 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 Mainand APU Battery installations.Revised System Airworthiness Limitation No. 5 in Section E, Other AirworthinessLimitations – Systems and Structures, by correcting the engine serial numbers for engineswithout a Fuel Accumulator (FSVA) installed.Submitted by: Ray Smith(Boeing)SIGNATURE ON FILEFAA BASOO4/16/2013REVISION AND REVISIONDESCRIPTION APPROVALAPR 2013Section Page Date Section Page Date Section Page Date Section Page Date Section Page DateD011Z009-03-01BOEING PROPRIETARY - 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Copyright (c) - Unpublished Work - See title page for details Page 1.0-12787 AIRWORTHINESS LIMITATIONSTHIS PAGE INTENTIONALLY LEFT BLANKBLANK787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-13REFERENCESAPPLICABLE 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 ProgramManagement throughReliability MethodsFAA Advisory Circular 20-114, Manufacturers Service DocumentsAir Transport Association of America (ATA) Maintenance SteeringGroup (MSG-3), Operator/Manufacturer Scheduled Maintenance Developmentdocument, MSG-3 Revision 2005.1, January 2005Air Transport Association of America (ATA) Specification for Manufacturers Technical Data, A.T.A.Specification No. 100, October 31, 1991,"Airline Requirements for Aircraft Zoning"Boeing Document D011Z009-03, 787 Maintenance Planning 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 MaintenanceReview Board Report Document, 22 March 2010Boeing Document B787-81205-A0101-00, Aircraft Maintenance Manual (AMM)SEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-14787 AIRWORTHINESS LIMITATIONSTHIS PAGE INTENTIONALLY LEFT BLANKBLANK787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-15A. SCOPEThe scheduled maintenance requirements described in this documentresult from Model 787-8 airplane certification activities with the U.S. Federal AviationAdministration (FAA). Accordingly, this FAA approved Airworthiness Limitations document is cross-referenced in the Model 787-8Type Certificate DataSheet. These maintenance actions are mandatory.This Airworthiness Limitations document is FAA approved and specifies maintenance required under Sec. 43.16 and 91.403 of the Federal AviationRegulations, unless an alternative program has been FAA approved.B. AIRWORTHINESS LIMITATIONS – AIRPLANE OPERATIONAL LIMITSThis section summarizes the airplane operational limits imposedon the 787-8. The operational limitation imposed on each 787-8is the lowest of theindividual limitations as defined in the Temporary OperationalLimit and Freedom From Widespread Fatigue Damage subsections below.TEMPORARY OPERATIONAL LIMITThe FAA has agreed to the following three-stage approach for Boeing to compile and publish the information necessary to accomplish the supplementalstructural fatigue inspections.• Stage 1 results in publishing the baseline inspection program which consists of the 787 Maintenance Planning Data (MPD) document, D011Z009-03,Structures and Zonal Programs at the time of certification. Stage 1 is complete.• Stage 2 results in publishing the Supplemental Structural Fatigue Inspection thresholds. Stage 2 is complete. Until Stage 3is complete, an operational limitis imposed on every 787 airplane equal to 75% of the lowest threshold defined in Table 1 for which the inspection procedures and DTR Check Forms arenot published.• Stage 3 results in publishing the DTR Check Forms and the procedures necessary to accomplish the Supplemental Structural Fatigue Inspections. OnceStage 3 is complete, the Stage 2 temporary operationallimit will be removed.NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-16787 AIRWORTHINESS LIMITATIONSThis approach is illustrated in the table below:Stage Description Publication Date Details of Publication Threshold Temporary Operational Limit1 Baseline InspectionProgram Data published.Prior to issuance of the787-8 TC.MPD Structures and ZonalPrograms at time ofcertification.Not Applicable. Not Applicable.2 Supplemental structuralfatigue inspectionthresholds published.3,000 total flight cycles, 10,000total flight hours, or 18 monthsfrom issuance of the 787-8 TC,whichever comes first.Thresholds for all PSEsidentified.Published in Table 1 foreach PSE requiringsupplemental inspection75% of the lowest thresholddefined in Table 1 for which theinspection procedures and DTRCheck Forms are not published.3 DTR Check Forms andNDT Manual Procedurespublished.Prior to Stage 2 operationallimit.NDT Manual: Inspectionprocedure details (includinginspection equipment,standards, probes, etc.) aredeveloped and documentedand are validated and availableto the operators. DTR CheckForms for items defined inTable 1.Same as Stage 2. None.SEP 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-17FREEDOM 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 could occur. It must bedemonstrated with sufficient full-scale fatigue test evidence that widespread fatigue damage will not occur within the design service goal of theairplane. The type certificate may be issued prior to completion offull-scale fatigue testing, provided the Administrator hasapproved a plan forcompleting the required tests, and the airworthiness limitationssection of the instructions for continued airworthiness required by Sec. 25.1529 ofthis part specifies that no airplane may be operated beyond a numberof cycles equal to 1⁄2 the number of cycles accumulated on the fatigue testarticle, 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 iscomplete, the followingoperational limitation isimposed 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 engineering data that supports thestructural maintenance program that corresponds to the period of time, stated as a number of total accumulated flight cycles orflight hours or both, duringwhich 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. When established, the 787 limitof validity will be included in this document.ApplicabilityAccumulated Cycles –Full-Scale Fatigue Test FleetOperational Limitation787-8 Aircraft 61,059 Fatigue Test Cycles 30,529 Flight CyclesFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-18787 AIRWORTHINESS LIMITATIONSC. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSINTRODUCTIONThe Structural Maintenance Program and the Zonal Inspection Programapproved in the 787-8 Maintenance Review Board Report (MRBR), DocumentD011Z009-02, and contained in the 787 MPD, Document D011Z009-03, describe an initial baseline Structural Maintenance Program for all StructuralSignificant Items (SSIs). These programs were developed in accordance with the guidelines of MSG-3, Revision 2005.1, and alsopartially satisfy therequirements of 14 CFR 25.571 by providing accidental damage and environmental deterioration detection opportunity, and in somecases fatigue damagedetection 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 certification is not permitted at this timeas compliance to 14 CFR 25.571 requirements for accidental damageto composite structure was based on the initial repeat interval considered atcertification. Escalation of the Structures and Zonal MPD tasks may be possible in the future subsequent to Boeing/FAA discussions regardingparameters under which escalation of 787 MPD Section 2 and 3 tasks is permissible.The Supplemental Structural Fatigue Inspections listed in thisdocument are for those PSEs that do not receive adequate fatiguedamage detectionopportunity from the initial baseline Structural Maintenance and Zonal Inspection Programs. (Such 787 MPD Section 2 inspectiontasks havingcorresponding Supplemental Structural Fatigue Inspections will be identified by the letter "F" (for fatigue)in the Program (PGM) column.) The SupplementalStructural Fatigue Inspections defined herein shall be accomplishedin addition to the baseline Structural Maintenance Program.PSEs for which thedamage tolerance requirements are satisfied by the MPD Section 2Structural Maintenance Programor Section 3 Zonal Inspection Program are listed inAppendix A.The Supplemental Structural Fatigue Inspection Program has beendeveloped using the Boeing Damage Tolerance Rating (DTR) System. Through theDTR System, the inspections and repeat intervals necessary toprovide adequate fatigue damage detection are determined. The DTR System defines arequired DTR (a numerical value) that must be achieved for eachPSE. DTR Check Forms definingthe inspection intervals, inspection options, and therequired DTR will be provided ina future Boeing document. TheSupplemental Structural Fatigue Inspections must be accomplished prior to exceeding thedefined threshold for each PSE.See Section D for PSEs certified per 14 CFR25.571(c) as safe-life structure.JUN 2012787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-19There is no separate 787 Corrosion Prevention and Control Program (CPCP) as each MPD Section 2 inspection requires that the structural areas beinginspected are also evaluated for corrosion. All tasks defined therein are necessary to maintain the aircraft to Corrosion Level 1 or better.NOTE: Supplemental Structural Fatigue Inspections necessitated by major non-conformances occurring during airplane production are contained in DocumentD011Z009-03-02, 787 Airworthiness Limitations (AWLs) – Line NumberSpecific. Revised inspection requirements and inspection intervals will belisted in Document D011Z009-03-02 as applicable to individualproduction line number airplanes. These line number-specific inspections must beincluded in the applicable operator's maintenance program.The Airworthiness Limitations - Supplemental Structural FatigueInspections may only be revisedwith the approval of the Seattle FAA Aircraft CertificationOffice (ACO). If the inspections cannot be accomplished due torepairs and/or modifications, an alternate inspection approvedby the Seattle FAA ACOmust 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 requirementsof 14 CFR25.571(b) and 14 CFR 26.43(c) or 14 CFR 26.43(d), and3. The part which is repaired contains the lead crack as identified on the associated DTR Check Form for the applicable Supplemental Structural FatigueInspection.For this condition, the inspection requirements approved for therepair plus the inspection requirements of this section for any areas beyond the repair areacceptable alternative inspections.THRESHOLD (787-8 AIRPLANES)The Supplemental Structural Fatigue Inspections must be accomplished prior to accumulation of a certain number of flights (threshold). The threshold foreach PSE requiring Supplemental Structural Fatigue Inspectionsis defined in Table 1, "Airworthiness Limitations – SupplementalStructural FatigueInspections". The threshold for PSEs for which the damage tolerancerequirements are satisfied byMPD Section 2, Structural Maintenance Program orSection 3, Zonal Inspection Program, is44,000 flight cycles or 22 years, whichever occurs first (see Appendix A).JUN 2012D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-20787 AIRWORTHINESS LIMITATIONSNOTE: Supplemental inspection thresholds andrepeat intervals are measuredin flight cycles or flight hours that a particular PSE detail has accumulatedregardless of what the airframeas a whole has accumulated.Most PSE details will never be replaced and therefore have accumulated the same flightcycles and flight hours asthe airframe. Some PSE details will be replaced, such as when installing removable structural components (repairable/rotable/expendables) or installing used structural parts as part of a repair. In these cases, the accumulated flight cycles and flight hours of thereplacement PSE details may be different from that ofthe airframe theyhave now been installed on.The operatormust accountfor this in determiningwhen inspections must be done.Each PSE requiring a Supplemental Structural Fatigue Inspection iscategorized as eitherGroup 1 or Group 2.For the 787-8, inspection thresholds arelimited to a maximum of 33,000 flight cycles for Group 1 and a maximum of 44,000 flight cycles for Group 2. The definition foreach group is as follows:Group 1:• Single load path structure; or• Multiple load path structure that provides insufficient opportunity for visual detection of a crack because the crack originates in a hidden structural elementand the majority of the crack growth period resides within the hidden (non-visible) member; or• Multiple load path structure in which the lead crack would not be directly visible during internal or external normal maintenance inspections.Group 2:• Remaining unobstructed PSEs which require a Supplemental Structural Fatigue Inspection.The Supplemental Structural Fatigue Inspections must be accomplished prior to exceeding the defined thresholds as stated in Table 1. In addition to thethresholds described in Table 1, a calendar threshold of 22 years applies to all Supplemental Structural Fatigue Inspections.Some PSE details are sensitive to flightlength; such details are identified by "FLS" (Flight Length Sensitive) in the Threshold column of Table 1. Thethreshold for FLS Items must be determinedfrom the FLS Threshold Curves of Figure1, based upon the actual airplane utilization in terms of flight hoursand flight cycles.Adjustments for training flights can be made by considering a fullstop landing or two touch-and-go landings equivalent to oneflight cycle.JUN 2012787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-21NOTE: For reference, the PSEs listed below,as also indicated in Table 1, have athreshold less than 33,000 Flight Cycles.PSE DTR Check Form Title DTR Location Threshold53-41-05B MLG Hanger Link Aft Lug - BS 1209(L/N 4 - 70)Forward and Aft Flanges common toWheel Well Longeron Extension 21,86057-13-02A Overwing Beams Web Pocket at BL 11BS 1021-1104, 1071-1104 BL 39 BS 1011-1031,1071-1104, BL 66 BS 948-979, 1011-1041, 1081-110411,790FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-22787 AIRWORTHINESS LIMITATIONSFigure 1. FLIGHT LENGTH SENSITIVE (FLS) THRESHOLD CURVEUSE 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 offlight cycles and flight hours accumulated on the PSE detail.3. Locate the intersection ofFlight Hours and Flight Cyclesfor the PSE detail on the graph.4. If the point determined by Step 3 lies inside the Threshold Curve for the group from Step 1, the detail has not reached the Inspection Threshold. If thepoint falls outside the curve for the specified group, the threshold has been exceeded. Operators must accomplish the inspection prior to exceeding thethreshold. Find the appropriate DTR Check Form (to be published in a future Boeing document) for the FLS PSE detail based on the average hours perflight for the detail.05,00010,00015,00020,00025,00030,00035,00040,00045,00050,0000 20,000 40,000 60,000 80,000 100,000 120,000 140,000Flight Hours

Flight CyclesGroup 2Group 1GROUP 1GROUP 233,000 FC,49,500 FH7,500 FC,101,300 FH44,000 FC,66,000 FH10,000 FC,135,000 FHNOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-23REPEAT INSPECTION INTERVALThe repeat interval for the Supplemental Structural Fatigue Inspection of each PSE detail is established from its respective DTR Check Form (to bepublished in a future Boeing document). The DTR Check Forms are the result of the damage tolerance assessment/evaluation documented during typecertification of the airplane. Revision to the required DTR Check Form or the DTR Curve is not allowed without the prior approval from the Seattle FAA ACO.Some DTR Check Forms provide options for the type of inspectionto be carried out (Detailed Visual, High Frequency Eddy Current,X-ray, etc.), thedirection of inspection (Internal, External, etc.), and the corresponding interval of the repeat inspection. However, for a given DTR location, addition of deltaDTR from more than one inspection method (instrumented or visual) is not allowed in the same zone, at the same interval. Also,General Visual andDetailed Visual Inspections are considered a single inspection unless accomplished at different check intervals. They cannot simultaneously contributetowards an achieved DTR if accomplished at the same check. Combination of delta DTR from the corresponding MPD Section 2 taskand a singlesupplemental inspection method is allowedif the MPD Section 2 task inspection occursmore frequently, or at intervals which will not coincide with thesupplemental inspections. Where a high total DTR is obtainedoperators can consider a phased inspection within their fleet forthat specific task only.Optional inspection methods, where offered, provide operators flexibility in accommodating the supplemental inspections to bestsuit their aircraft operatingplan and maintenance check intervals.If the threshold for the PSE detail designates"FLS", the average hours per flight (cumulative flight hours divided by cumulative flight cycles) shall becalculated for the detail. The repeat inspection interval andinspection requirements are then based on the DTR Check Form with the correspondingaverage 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" and aform without an hour labelare 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 the average hours per flightcalculated for a prior inspection interval, the current average hours per flight shall be used for determining the appropriate DTR Check Form.SEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-24787 AIRWORTHINESS LIMITATIONSREPORTING RESULTS OFSTRUCTURAL INSPECTIONSAll cracks or other fatigue damagefound during these inspections shall be reported within ten (10)days directly to the Manager of the Seattle ACO, theTransport Airplane Directorate, the FAA, and to Boeing Commercial Airplane Group using the Discrepant Structure Report Form. Refer to Appendix B forthe required report form (any suitable alternativewhich 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 beyond 0.20-inch around thefastener at locations that are tobe inspected. Remove any additional sealant which impairs visibility of the structure adjacent to the fastener cap, filletor brush sealant. This requirement applies to post-threshold inspection of PSEs for which the MPD Section 2 or 3 tasks satisfythe required DTR.2. For PSEs requiring Supplemental Structural Fatigue Inspections, requirements to remove fastener cap, fillet or brush sealantare defined on the DTRCheck Forms (to be published in a future Boeing Document).3. Sealant and corrosion protection finishesshould be removed only when specified in the inspection task. Upon completion of the inspection task, restoresealant in accordance with the AMM section or other reference noted below. Sealant restoration common to the fuel tanks is subject to airworthinesslimitations identified in Document D011Z009-03-04, Special Compliance Items/Airworthiness Limitations. Adherence to the airworthiness limitationsrequirements of D011Z009-03-04 is required to preventthe 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 application. The applicationrequirements in the AMM are subject to airworthiness limitations identified in Document D011Z009-03-04. Adherence to these airworthinesslimitation 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 (BMS 5-167 Type ICoating - Heat Resistant Secondary Fuel Barrier) outside the fuel tank.If sealant inside the fuel tank is removed for inspection, caremust be taken to remove any sealant debris in the fuel tank.SEP 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-25Locations where sealant is removed for inspections must have the sealant restored to drawing or AMM requirements (and any applicable ServiceBulletins 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 identifieseach PSE detail for which oneor more DTR Check Forms will be provided (to bepublished in a future Boeing document).Each item is listed by PSE Number, DTRCheck Form Title, DTRLocation, and Airplane Applicability/Threshold. Where there is more than one listing for agiven PSE Number, the DTR Check Form Title and location is theunique identifier. Appendix A identifies PSE details for which the required DTR is satisfied by theinspection tasks of the Structural Maintenance Program(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 impliesall 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 = AirplaneCumulative Line Number, where mentioned with DTR Check Form Title,identifies certain DTR Check Forms to specific airplaneline numbers.SEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-26787 AIRWORTHINESS LIMITATIONSTABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-827-41-16A 787-8 HSTA (HorizontalStabilizer Trim Actuator)C99145 Ballscrew Assy (CA39590)Ballscrew Flange and Threads 133,000(5)27-41-16B 787-8 HSTA (HorizontalStabilizer Trim Actuator)C99145 Ballscrew Assy (CA39590)Ballnut Trunnion 133,000(5)27-41-16C 787-8 HSTA (HorizontalStabilizer Trim Actuator)C99145-001 Upper Gimbal Pin Assy (CA29233)Section 48 133,000(5)52-34-01C3 Forward Large Cargo Door Shear Fitting Shear Roller Main Lug 133,000(5)52-34-01C4 Forward Large Cargo Door Shear Fitting Shear Roller Auxiliary Lug 1FLS(5)52-36-01A Bulk Cargo Door Stops Corner ofthe critical section under the Stop Head 244,000(5)52-37-01C3 Aft Large Cargo Door Shear Fitting Shear Roller Main Lug 1FLS(5)52-37-01C4 Aft Large Cargo Door Shear Fitting Shear Roller Auxiliary Lug 1FLS(5)53-11-01 Skin/Stringer/Frame Assembly Forward of BS232.5 Inner Splice Strap at Mid AB Post / Upr AB PostJoint (BS 182.0, BL 0.0, WL 277)244,000(5)53-11-01 Skin/Stringer/Frame Assembly Forward of BS232.5 Outer Splice Strap at Upr CD Post / CD PostExtension Joint (BS 192, LBL 29, WL 280)133,000(5)53-11-01 Skin/Stringer/Frame Assembly Forward of BS 232.5Outer Splice Strap at QF Sill / FH1 Sill ExtensionJoint (BS 193, LBL 67, WL 233)133,000(5)53-11-01 Skin/Stringer/Frame Assembly Forward of BS232.5 Outer Splice Angle at CD Post Extension Joint(BS 217, LBL 25, WL 293)244,000(5)53-11-01 Skin/Stringer/Frame Assembly Forward ofBS 232.5 Frame / Post Inner Chord at J1-E1 Frame(BS 192.0, LBL 15.0, WL 280)244,000(5)NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-2753-11-01 Skin/Stringer/Frame Assembly Forward of BS232.5 Cab EF Post Outer Chord at Cab QH1 Sill OCSplice hardpoint (BS 195, BL 66, WL 235)133,000(5)53-11-01 Skin/Stringer/Frame Assembly Forward ofBS 232.5 J1-E1 Frame Web at Outboard Door Stop Ftgattachment (BS 193, RBL 32, WL 275)244,000(5)53-11-01 Skin/Stringer/Frame Assembly Forward of BS232.5 Frame / Post Web at EF Center Frame / Mid ABPost Joint (BS 183, BL 0, WL 280)133,000(5)53-11-01Skin/Stringer/Frame Assembly Forward of BS 232.5 AB Post Inner Chord at BS 142, WL 249 244,000(5)53-11-01 Skin/Stringer/Frame Assembly Forwardof BS 232.5 AB Post Web at BS 142, WL 249 133,000(5)53-11-01 Skin/Stringer/Frame Assembly Forward ofBS 232.5 AB Post Outer Chord at BS 108, WL 226 244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Forward Extension ChordBS 138, BL 27.5, WL 125244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Forward Extension Chord SpliceBS 143, BL 27.5, WL 125244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Forward Extension ChordHidden at Splice BS 143, BL 27.5, WL 125244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22R (L/N 4-6)BS 148 Frame Shear Tie WL 217 244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Integration Strap at S-37 BS 276 133,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Aft Extension Fitting at S-37LBS 284244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Aft Extension Chord at S-37LBS 294244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-28787 AIRWORTHINESS LIMITATIONS53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Aft Extension Chord Hidden atExtension Fitting S-37L BS 287244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RNose Wheel Well Bulkhead Frame Splice BS 276WL 178244,000(5)53-11-03 Lower Lobe Skin Assembly Forward of BS 338.5between S-22L and S-22RIntercostal Webs at BS 276, BL 6, WL 107 244,000(5)53-11-03 Lower Lobe Skin/Stringer/Frame Lower StanchionFittings Assembly Forward of BS 338.5Passenger Floor Lower Stanchion Fitting BS 302,WL 137244,000(5)53-11-07 Passenger Entry Door 1 - Lower Main Sill (L/N 4-6) Lead Crack at Inner Chord Web Flange HiddenDetail at Splice - BS 267.71244,000(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 317.4244,000(5)53-11-07 Passenger Entry Door 1 - Lower Main Sill (L/N4-6) Lead Crack at Inner Chord Free Flange BS 267.71 244,000(5)53-11-07 Passenger Entry Door 1 - Lower Main Sill(L/N 4-6) Lead Crack at Splice Angle Free FlangeBS 267.71244,000(5)53-11-07 Passenger Entry Door 1 - Lower Main Sill Lead Crack at Outer Chord at Split Frame BS 302 244,000(5)53-11-07 Passenger Entry Door 1 - Lower Main Sill Lead Crack at Outer Chord at Girt Bar BS 284 &BS 322244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Forward Edge Frame at Lower Splice Joint,BS 276.5, WL180244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Forward Edge Frame at Upper Splice BS 276.5,BL 57.58, WL 291.12244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame at Lower Splice BS 327.5,BL 98.88, WL 175.1244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-2953-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 Inner Chord FreeFlange near Doorstop No. 1244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 Web Nutplates 244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame(L/N 55 and on)Aft Edge Frame BS 327.5 - Web at NutplateRetainer, S-20 to S-21133,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 - Web at Door StopFitting #1 Tension Bolt WL 207.5244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Forward Edge Frame Web at Passenger FloorFitting Fastener BS 276.5, BL 93.4, WL 190244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 near Doorstop #4 OuterChord Fastener common to skin244,000(5)53-11-07 Passenger Entry Door 1 - Edge Frame Aft Edge Frame BS 327.5 near Doorstop #4 OuterChord at Nutplate Retainer244,000(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 wherehidden by radius fillers244,000(5)53-11-10 Forward Large Cargo Door Cutout - EdgeFrame BS 545 Aft Edge Frame Inner Chord Edge ofFlange at S-31R244,000(5)53-11-10 Forward Large Cargo Door Cutout - EdgeFrame BS 545 Aft Edge Frame at Nutplates betweenS-32R and Lower Main Sill (WL 122)244,000(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 Clips133,000(5)53-11-10 Forward Large Cargo Door Cutout - EdgeFrame BS 545 Aft Edge Frame Web at Edge of MouseHole at S-21R244,000(5)53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame Outer Chord at Fastenersbetween S-21R and S-22R244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8JUN 2012D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-30787 AIRWORTHINESS LIMITATIONS53-11-10 Forward Large Cargo Door Cutout - Edge Frame BS 545 Aft Edge Frame Outer Chord at NutplateRetainer; S-31R and S-32R244,000(5)53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Inner Chord edge BS 448 244,000(5)53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill(L/N 4-26)Inner Chord Web flange BS 437 133,000(5)53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill(L/N 4-26)Inner Chord strap BS 436 133,000(5)53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Web at attachment to Outer Chord, BS 441 133,000(5)53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Outer Chord skin flange BS 433 and BS 477 133,000(5)53-11-11 Forward Large Cargo Door Cutout - Upper Main Sill Outer Chord with nut plate, BS 540 244,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureBS 537, Inner Chord Inboard Flange - lead crackat latch backup fitting fastener244,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureBS 537, Inner Chord Web leg - lead crack at latchbackup fitting fastener133,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureBS 545, Inner Chord fastener hole at edge frame 133,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureInner Chord at BS 537 133,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureSill Web hidden by Shear Backup Fitting BS 496 244,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureOuter Chord skin fastener BS 521 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3153-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureEdge Frame Hidden Chord detail at BS 545 133,000(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 112.5 244,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureLower Split Frame at Inner Chord Splice Strap,BS 537244,000(5)53-11-12 Forward Large Cargo Door Cutout - Lower Main Sill& Latch Backup StructureLatch Backup Fitting at Split Frame attachment,BS 441244,000(5)53-11-15 Forward Equipment Access Door - Cutout/BackupStructureIntercostal Inner Chords at BS 142, RBL 13 andLBL 13244,000(5)53-11-15 Forward Equipment Access Door - Cutout/BackupStructureIntercostal Webs at BS 148, RBL 13 and LBL 13 244,000(5)53-11-17 Crew Window Cutout #1 - Window Frame Window Frame along AB Post 244,000(5)53-11-17 Crew Window Cutout #1 - Window Frame Window Frame along CD post 133,000(5)53-11-18 Crew Window Cutout #1 - Window Sills BD Sill Inner Chord at LBL 29.0 Intercostal Splice 244,000(5)53-11-18 Crew Window Cutout #1 - Window Sills BD Sill Web at LBL 29.0 Intercostal Splice 244,000(5)53-11-18 Crew Window Cutout #1 - Window Sills Window Sill Web at BS 160, LBL 26, WL 258 133,000(5)53-11-18 Crew Window Cutout #1 - Window Sills Window Sill Web at BS 163, LBL 29, WL 258 244,000(5)53-11-19 Crew Window Cutout #2 - Window Frame Window Frame along the QF Sill 244,000(5)53-11-19 Crew Window Cutout #2 - Window Frame Window Frame Outer Flange at Upper CD PostJoint (BS 169, LBL 36, WL 260)133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-32787 AIRWORTHINESS LIMITATIONS53-11-20 Crew Window Cutout #2 - Window Sills Cab EF Post Web at BS 193.0, LBL 59.0,WL 242.0244,000(5)53-13-01 Forward Pressure Bulkhead - Bulkhead Web Web circumferential direction - BS 106 244,000(5)53-13-02 Forward Pressure Bulkhead - Bulkhead Chord &SplicesOutboard joint common to bulkhead web, doubler,& angle chord - BS 107, BL 0, WL 132244,000(5)53-13-02 Forward Pressure Bulkhead - Bulkhead Chord &SplicesOutboard joint common to Bulkhead Web,Doubler, Angle Chord - BS 106, LBL 28, WL 143133,000(5)53-13-02 Forward Pressure Bulkhead - Bulkhead Chord &SplicesJoint common to Angle Chord, Y-Chord, and Skin.Forward fastener, BS 110.5, S-40L/R244,000(5)53-13-02 Forward Pressure Bulkhead - Bulkhead Chord &SplicesJoint common to Angle Chord, Y-Chord, BL14Header Intercostal and Skin BS 110.5133,000(5)53-17-01 Nose Wheel Well - Trunnion Support Fitting Frame Joint at WL 121.9, BS 265.5 1FLS(5)53-17-01 Nose Wheel Well - Trunnion Support Fitting Frame Joint at WL 121.9, BS 265.5, Free Flange 2FLS(5)53-17-01 Nose Wheel Well - Trunnion Support Fitting Beam Joint at WL 165, BS 265.5 244,000(5)53-17-02 Nose Wheel Well - Drag Brace Fitting Drag Brace Fitting Side Panel AttachmentBS 202.7 and BS 217.22FLS(5)53-17-02 Nose Wheel Well - Drag Brace Fitting Grease fitting hole, BS 202.7 and BS 217.2 1FLS(5)53-17-03 Nose Wheel Well - Retract Actuator Fitting Actuator Fitting Lug BS 276.5, WL 161.0,RBL 19.6133,000(5)53-18-01 Nose Wheel Well - Forward Bulkhead Panel Web at BS 148.0, between BL 28.25 and BL 52.5 244,000(5)53-18-01 Nose Wheel Well - Forward Bulkhead Panel Web at BS 148.0, BL 24.0, WL 121.7 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3353-18-01 Nose Wheel Well - Forward Bulkhead Panel Web - Inner Chord at BS 148.0, BL 49.0,WL 150.0244,000(5)53-18-01 Nose Wheel Well - Forward Bulkhead Panel Web at BS 148.0, BL 27.5, WL 132.0 under LowerBeam244,000(5)53-18-01 Nose Wheel Well - Forward Bulkhead PanelWeb at BS 148.0, BL 5.9, WL 118.0 underDoorstop Fittings244,000(5)53-18-01 Nose Wheel Well - Forward Bulkhead Panel Vertical Beams at free flange edges at BS 143.2,BL 11.0, WL 165.7244,000(5)53-18-0153-18-05Nose Wheel Well - Forward Bulkhead Panel Vertical Beam to Top Panel Stiffener joint atBS 148.0, BL 11.0, WL 165.7244,000(5)53-18-04 Nose Wheel Well - Side Panels Side Panel Beam #4 at free flange edges atBS 193.8, BL 33.2, WL 124.5244,000(5)53-18-04 Nose Wheel Well - Side Panels Side Panel Beam #4 to Stub Frame Joint atBS 193.8, BL 32.7, WL 122.9244,000(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 133244,000(5)53-18-04 Nose Wheel Well - Side Panels Along Beam No. 5 BS 202.75, WL 112.94 atLower Chord Joint133,000(5)53-18-05 Nose Wheel Well - Top Panel Top Panel Beam #7 at free flange edges atBS 232.5, BL 29.0, WL 168.5244,000(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)244,000(5)53-18-06 Nose Wheel Well - Aft Bulkhead Beams Aft Bulkhead Beam #4 attachment to Web andVertical Beam (BS 276.5, LBL 6.0, WL 115)244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-34787 AIRWORTHINESS LIMITATIONS53-18-07 Nose Wheel Well - Aft Bulkhead Web Nose Wheel Well Aft Bulkhead Web at BS 276,BL 86.5 & WL 170244,000(5)53-18-07 Nose Wheel Well - Aft Bulkhead Web Webat BS 276.5, between BL 28.25 and BL 76.0 244,000(5)53-18-07 Nose Wheel Well - Aft Bulkhead Web Web atBS 276.5, BL 0.0, WL 115.0, under BeamNo. 4244,000(5)53-18-07 Nose Wheel Well - Aft Bulkhead Web Web inner chord at BS 276.5,BL 75.0, WL 150.5 244,000(5)53-18-07 Nose Wheel Well - Aft Bulkhead Web Web atBS 276.5, BL 27.4, WL115.0, under BeamNo. 4244,000(5)53-18-07 Nose Wheel Well - Aft Bulkhead Web Web atBS 276.5, BL 15.0, WL115.0, under BeamNo. 4244,000(5)53-31-27 Underwing Longeron Back-up Fitting Underwing Longeron Back-up Fitting BS 849,BL 92.8, WL148.1244,000(5)53-31-27 Skin/Stringer/ShearTie Panel Assy (Section43) BS 657 Titanium Shear TieWeb Frame Joint 244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame Inner Chord at Edge Frame SpliceBS 682 S-10 to S-11244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame (L/N4-6) Edge Frame Inner Chord at BS 682 S17-18 244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame (L/N 7 andon)Edge Frame Inner Chord at BS 632 S11-12 244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame (L/N4-6) Edge Frame Web at BS 682 S-17 to S-18 244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame (L/N 7 andon)Edge Frame Web at BS 682 S-17 to S-18 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3553-31-34 Passenger Entry Door 2 - Edge Frame (L/N4-6) Edge Frame Web at BS 682 S-19 (stop fitting3A Interface)244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame (L/N 7 andon)Edge Frame Web at BS 682 S-19 (stop fitting3A Interface)244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame Web at latch fitting BS 682, S-18to S-19244,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame Outer Chord at Stow Bin Ftgattached BS 632, S11-12133,000(5)53-31-34 Passenger Entry Door 2 - Edge Frame Edge Frame outer chord BS 682, S-21 to S-22 244,000(5)53-31-34 Passenger Entry Door 2 - Upper Sill Upper Sill Inner Chord Splice at BS 632, S-13 244,000(5)53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Inner Chord at Stringer 2.5Splice244,000(5)53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Inner Chord BS 873, S-17 Splice 244,000(5)53-41-03 Front Spar Bulkhead Frame - BS873 Bulkhead Frame Inner Chord at TCL 244,000(5)53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Inner Chord at Stringer 3L-4L 244,000(5)53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Web at Stringer 2.5 Splice 244,000(5)53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Web Mouse Hole at TCL -Stringer 1244,000(5)53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Outer Chord and Web BS 873,S-17 Splice133,000(5)53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Outer Chord at Stringer 2 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-36787 AIRWORTHINESS LIMITATIONS53-41-03 Front Spar Bulkhead Frame - BS 873 Bulkhead Frame Outer Chord at Stringer 2-3 244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 BS 1209 - S-2.5 Bulkhead Inner Chord 244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Inner Chord BS 1209, S-17 splice 244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame Inner Chord at TCL LH andRH sides244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame to Bracket interface at TCL/S-1LHS side.244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Stringer 2.5 Web Splice location 244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Web BS 1209, S-17 Splice 244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 TCL-Stringer 1 244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Crown Bulkhead Fitting Outer Chord atStringer 17 Splice Region133,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame Outer Chord at Stringer 1 244,000(5)53-41-04 Aft Wheel Well Bulkhead Frame - BS 1209 Bulkhead Frame Outer Chord at Stringer 2-3 244,000(5)53-41-05A Forward Hanger Link Lug Section 44 - BS 1185 Flange at Bulkhead Frame joint 244,000(5)53-41-05A Forward Hanger Link Lug Section 44 - BS 1185 Lug Hole 133,000(5)53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 4-70) Lug Base Corner Fillet Radius 244,000(5)53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 71 and on) Lug Base Corner Fillet Radius 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8JUN 2012787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3753-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 4-70) Forward and Aft Flanges common to Wheel WellLongeron Extension121,860(5)53-41-05B MLG Hanger Link Aft Lug - BS 1209 (L/N 71 and on) Forward and Aft Flanges common to Wheel WellLongeron Extension133,000(5)53-41-07 Wheel Well Longeron Rear Spar Overwing Longeron BS 1024-1128(LHS/RHS) at Fasteners244,000(5)53-41-07 Wheel Well Longeron Rear Spar Overwing Longeron BS 1111-1117(LHS/RHS) at Fairing Strut Bracket133,000(5)53-41-07 Wheel Well Longeron RS OWL BS 1024-1128 (LHS/RHS) at Edges 244,000(5)53-41-07 Wheel Well LongeronBS 1194-1221 WWLE Vertical and HorizontalFlanges Hidden Details133,000(5)53-41-07 Wheel Well Longeron Wheel Well Longeron Horizontal Flange,BS 1121-11351FLS(5)53-41-07 Wheel Well Longeron Wheel Well Longeron Horizontal Flange,BS 1139-11411FLS(5)53-41-07-A Wheel Well Longeron Vertical Flange at attachment to splice plate anduplock fitting133,000(5)53-41-07B Wheel Well Longeron BS 1190-1257 Visible Fastener Holes Vertical andHorizontal Flanges244,000(5)53-41-07-B Wheel Well Longeron Vertical& Horizontal Flanges, BS 1120-1190Open Areas244,000(5)53-41-07-C Wheel Well Longeron Vertical Flange, BS 1137-1141 244,000(5)53-41-07-D Wheel Well Longeron Verticaland Horizontal Flanges, BS 1120-1201Hidden Areas133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8JUN 2012D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-38787 AIRWORTHINESS LIMITATIONS53-41-08 Bulkhead Frame / Transverse Beam Splice Bulkhead Upper Chord, BS 1113 & 1137 2FLS(5)53-41-08 Bulkhead Frame / Transverse Beam Splice Bulkhead Upper Chord at Outboard PedestalFitting Fastener, (BL ±103.4)244,000(5)53-41-08 BS 1113 to BS 1185 Bulkhead Frame BS 1161 Inner Chord at Stringer 22-23 244,000(5)53-41-11 Front Spar Underwing Longeron Fuselage and Wing Lower Panel Attachment 133,000(5)53-41-12 Front Spar Pickle Fork Fitting Pickle Fork outer chord and web BS 873,S-17 splice133,000(5)53-41-12 Front Spar Pickle Fork Fitting Fail-Safe Strap, S-18 to S-21 133,000(5)53-41-12 Front Spar Pickle Fork Fitting OuterChord Attachment to Fail-Safe Strap andSkin - Hidden Details - Stringer 19 to Stringer 21133,000(5)53-41-12 Front Spar Pickle Fork Fitting OuterChord Attachment to Fail-Safe Strap andSkin - Stringer 22 to Stringer 19244,000(5)53-41-12 Front Spar Pickle Fork Fitting Pickle Fork inner chord BS 873, S-17 splice 244,000(5)53-41-12 Front Spar Pickle Fork Fitting Inner Chord from WL 184 to Top of Pickle Fork 244,000(5)53-41-12 Front Spar Pickle Fork Fitting Stringer 19 and 20 Mouse Holes 244,000(5)53-41-12 Front Spar Pickle Fork Fitting Front Spar and Skin Attachments WL 165 toWL 189.5133,000(5)53-41-13 Trapezoidal Panel/Vertical Flex Tee Fastener Holes at Trapezoidal Panel/VerticalShear Tie Interface244,000(5)53-41-13 Trapezoidal Panel/Vertical Flex Tee Trapezoidal Panel Aft Horizontal Flange FastenerHoles, BS 1120 to 1140.4244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3953-41-13 Trapezoidal Panel/Vertical Flex Tee Lower Penetration, inspection applies to bothpenetrations244,000(5)53-41-13 Trapezoidal Panel/Vertical Flex Tee Stiffeners Horizontal, Vertical, and Diagonal StiffenersInboard and Outboard Surfaces244,000(5)53-41-13 Trapezoidal Panel / Vertical Flex Tee Fastener Holes at Vertical Shear Tie/TrapezoidalPanel Interface, (8) Fasteners Common to SplicePlate133,000(5)53-41-13 Trapezoidal Panel / Vertical Flex Tee Vertical Shear Ties, rebate and radius area 244,000(5)53-41-13 Trapezoidal Panel / Vertical Flex Tee Trapezoidal Panel fastener holes at Flex-T,Horizontal and Vertical flanges / Trap StiffenerBracket244,000(5)53-41-13 Trapezoidal Panel / Vertical Flex Tee Trapezoidal Panel fastener holes at Flex-T atBS 1089 and 1113 Frames244,000(5)53-41-13 Trapezoidal Panel / Vertical Flex Tee Flex T-Chord Fastener Hole and Trap PanelStiffener Brackets (Hidden Locations)133,000(5)53-41-13 Trapezoidal Panel / Vertical Flex Tee Visible Fastener Holes in Vertical Shear Tie (bothupper and lower)244,000(5)53-55-01 Pressure Deck-Stiffened WebGutter - Hidden Fastener detailsLBL 94.6 to RBL 94.6 BS 1077 to BS 1081 133,000(5)53-55-01 Pressure Deck-Stiffened Web Drainage Gutter, BL 66 to BL 90 Approximately atWL 180 and BS 1083244,000(5)53-55-01 Pressure Deck-Stiffened Web Outboard Pressure Pan framing member 133,000(5)53-55-01 Pressure Deck-Stiffened Web Inboard Pressure Pan framing member 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-40787 AIRWORTHINESS LIMITATIONS53-55-01 Pressure Deck Stiffened Web Fastener Hole on Splice Fitting (BS 1080) 133,000(5)53-55-01 Pressure Deck Stiffener Splice Fittings BS1113 Section 45 BL 11, 19, 25.75, 32.5, 46,52.75, 59.5, 74, 82244,000(5)53-55-01 Pressure Deck Splice Fittings Section 45 BS 1113, BL 39.5 & 66 133,000(5)53-55-01B Horizontal Pressure Deck to Wheel Well LongeronSplice Plate #3BS 1137-1161, BL +/-108.2 133,000(5)53-55-01B Horizontal Pressure Deck to Wheel Well LongeronSplice Fitting #3 (L/N 7 and on)BS 1137-1161, BL +/-108.2 244,000(5)53-55-02 Bulkhead Frame/Transverse Beam Splice Fitting Upper Chord 244,000(5)53-55-02 Bulkhead Frame/Transverse Beam Splice Fitting Web 244,000(5)53-55-02 Transverse Beams - Attachment to Keel Beam atH-FramesUpper Fittings BS 1113-1185, LBL 9, BL 0, RBL 9 133,000(5)53-58-01B Wheel Well Bulkhead - Upper Chord Angle - BS 1209, LBL 92 to RBL 92 244,000(5)53-58-01B Wheel Well Bulkhead - Upper Chord Gusset - BL 19, 39.5 & 66 LH and RH sides 244,000(5)53-58-01C AWWB Stiffener Splice BS 1209, WL 130 to WL 151, LBL 16 to RBL 16 133,000(5)53-58-01C AWWB Stiffener Splice BS 1209, WL116 to WL 158, LBL 16 to RBL 16,Typical Flange244,000(5)53-58-01C AWWB BL 0 Vertical Chord - Lower Section,Section A-A, Splice StrapsBS 1209, BL0, WL 106-120 244,000(5)53-58-01D AWWB BL 0 Vertical Chord - Lower Section,Section B-B, Chord FittingBS 1209, BL0, WL 106-113 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4153-58-01E AWWB BL 0 Vertical Chord - Lower Section,Section C-C, Chord FittingBS 1209, BL0, WL 98-106 244,000(5)53-58-02 Pressure Deck Vertical Beam Extension Splice -Extension LocationExtension Beam Web 244,000(5)53-58-02 Pressure Deck Vertical Beam Extension Splice Doubler & Tripler, BS 1205 to BS 1216 WL 179.7 -188, BL19, 39.5 & 66133,000(5)53-58-02 Pressure Deck Vertical Beam Extension Extension Beam Upper Chord, BS1185-1209,BL19, 39.5 & 66244,000(5)53-58-02-4 Pressure Deck SpliceBeam Extension Angle BL 19,39.5 & 66 LH and RH SidesWheel Well Bulkhead - Vertical Beams Scenario#1 Hole Crack244,000(5)53-58-02-4 Pressure Deck SpliceBeam Extension Angle BL 19,39.5 & 66 LH and RH SidesWheel Well Bulkhead - Vertical Beams Scenario#2 Edge Crack244,000(5)53-58-02A Vertical Beam Lower Clip - Base Flange Vertical Beam Lower Joint BL 19.0 Clip 244,000(5)53-58-02B Vertical Beam Lower Clip - Base Flange Vertical Beam Lower Joint BL 39.5 Clip 244,000(5)53-58-02C Vertical Beam Lower Clip - Base Flange Vertical Beam Lower Joint BL 66.0 Clip 244,000(5)53-58-03 Wheel Well Bulkhead Side Fitting BS 1209 Side Fitting Outer Chord Splice Regionat WL 238133,000(5)53-58-03 Wheel Well Bulkhead Side Fitting Side Fitting Inner Chord BS 1209, S-17 splice 244,000(5)53-58-03 Wheel Well Bulkhead Side Fitting Side Fitting Web BS 1209, S-17 splice 244,000(5)53-58-0353-58-04Aft Wheel Well Bulkhead Lower Chord and WheelWell Bulkhead Side FittingLower Chord and Side Fitting at splice details(Stringer 28 and 37)133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-42787 AIRWORTHINESS LIMITATIONS53-58-03A Wheel Well Bulkhead Side Fitting Outer Chord between WL 223 and the LowerSplice at WL 150133,000(5)53-58-03B Wheel Well Bulkhead Side Fitting Outer Chord between WL 210 and WL 180(Stringer 21 to Stringer 24)244,000(5)53-58-03B Wheel Well Bulkhead Side Fitting OuterChord, Bifurcation Area - Hoop Loading -Hidden Fasteners from WL 210 to WL 180(Stringer 21 to Stringer 24)133,000(5)53-58-03C Wheel Well Bulkhead Side Fitting OuterChord, Bifurcation Area - LongitudinalLoading - Fastener Holes between WL 210 toWL 1802FLS(5)53-58-03C Wheel Well Bulkhead Side Fitting OuterChord, Bifurcation Area - LongitudinalLoading - Hidden Fasteners between WL 210 toWL 180 (Stringer 21 to Stringer 24)1FLS(5)53-58-03D Wheel Well Bulkhead Side Fitting Pressure Deck Flange, Details Hidden UnderStiffeners at WL 186, BL 97 and BL 90133,000(5)53-58-03E Wheel Well Bulkhead Side Fitting BS 1209Web at Stringer 19 and 20, Lower MouseHoles244,000(5)53-58-03F Wheel Well Bulkhead Side Fitting Filletradii along Side Fitting Ribs at WLs 158, 165,171, and 179244,000(5)53-58-03G Wheel Well Bulkhead Side Fitting Upper Flap Fitting Interface Fastener HoleBending1FLS(5)53-58-03H Wheel Well Bulkhead Side Fitting Inner Chord above the Pressure Deck at WL 185to WL 210244,000(5)53-58-03K Wheel Well Bulkhead Side Fitting Fail-Safe Strap, Stringer 19 and 20 133,000(5)53-58-03L Wheel Well Bulkhead Side Fitting Fail-Safe Strap between Stringer 21 andStringer 25133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4353-58-03M Wheel Well Bulkhead Side Fitting Outer Chord - Hidden by Stringer Splice, BS 1209 133,000(5)53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Visible Stringer 19 and 20,BS 1209244,000(5)53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Outer Chord, betweenStringer 18 - 18.5, BS 1209133,000(5)53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Outer Chord, betweenStringer 18.5 - 21, BS 1209133,000(5)53-58-03M Wheel Well Bulkhead Side Fitting Fail-Safe Strap - Under Stringer Fitting, BS 1209 133,000(5)53-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Edge Crack, BS 1209 244,000(5)53-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Fillet Radius, BS 1209 244,000(5)53-58-03N Wheel Well Bulkhead Side Fitting Inner Chord Stiffener Radius, BS 1209 244,000(5)53-58-04A Aft Wheel Well Bulkhead Lower Chord Lower Chord at BL 39.5 Vertical BeamAttachment133,000(5)53-58-04B Aft Wheel Well Bulkhead Lower Chord Lower Chord at BS 1209, LBL 91 to RBL 91Typical Lower Chord Section133,000(5)53-58-04C Aft Wheel Well Bulkhead Lower Chord Lower Chord Splices at Stringer 28 andStringer 37244,000(5)53-58-04D Aft Wheel Well Bulkhead Lower Chord Lower Chord at BL 66.0 Vertical BeamAttachment - Critical Hidden Detail133,000(5)53-58-04E Aft Wheel Well Bulkhead Lower Chord Circumferential Cracking in the Chord Radius 244,000(5)53-58-05 Upper Flap Support Fitting Outer Fitting Clevis Lugs 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-44787 AIRWORTHINESS LIMITATIONS53-58-05 Upper Flap Support Fitting Base Flange Outer Fillets and Fasteners 2FLS(5)53-58-05 Upper Flap Support Fitting Base Flange Inner Fillets 1FLS(5)53-58-05 Lower Flap Support Fitting Aft Wheel Well Bulkhead BS 1208 244,000(5)53-58-05A Upper Flap Support Fitting Inner Fitting Clevis Lugs 133,000(5)53-59-01 Keel Beam Upper BL0 Web Attachment BS1089-1209 Upper Web Fastener Holes HiddenDetails133,000(5)53-59-01 Keel Beam BL 0 Web Attachment to Upper ChordBay 35BS 1161-1185 244,000(5)53-59-01 Keel Beam BL 0 Web Attachment to Upper Chordand Rear Spar BeamBS 1089-1161 244,000(5)53-59-01 BL 0 Web Penetrations (L/N 4-6) All Penetrations from BS 1088 to BS 1209, WL 97to WL 185133,000(5)53-59-01 BL 0 Web Penetrations (L/N 7 and on) AllPenetrations from BS 1088 to BS 1209, WL 97to WL 185244,000(5)53-59-01A Keel Beam BL 0 WebAttachment to Upper Chord &Aft Wheel Well Bulkhead Vertical ChordBS 1185 - 1209 244,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 4-19)A/H-Frames at BS 1089, LH and RH, LowerFastener Row133,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 20 and on)A/H-Frames at BS 1089, LH and RH, LowerFastener Row133,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 4-6)A/H-Frames at BS 1113, 1137, 1161 and 1185,LH and RH, Lower Fastener Row244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4553-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 7 and on)A/H-Frames at BS 1113, 1137, 1161 and 1185,LH and RH, Lower Fastener Row133,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 4-19)A/H-Frames at BS 1089 WL 100 through WL 105 244,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 20 and on)A/H-Frames at BS 1089 LH and RH, UpperFastener Row133,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 4-6)A/H-Frames at BS 1113, 1137, 1161 and 1185,LH and RH, Upper Fastener Row244,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 7-19)A/H-Frames at BS 1113, 1137, 1161 and 1185,WL 100 through WL 105244,000(5)53-59-02 Keel Beam - A/H-Frame Outer Chord to Keel ChordAttachments (L/N 20 and on)A/H-Frames at BS 1113, 1137, 1161 and 1185,LH and RH, Upper Fastener Row244,000(5)53-59-02 Keel Beam - A/H-Frame Inner Chord (L/N 4-19) BS 1089, BL0, WL 117 & 124 133,000(5)53-59-02 Keel Beam - A/H-Frame Inner Chord (L/N 20 andon)BS 1089, BL0, WL 117 & 124 133,000(5)53-59-02 BL0 Web at Keel Beam H-Frame Inner Chord(L/N 4-19)BS 1089 133,000(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 160 133,000(5)53-59-02 BL0 Web at Keel Beam H-Frame Inner Chord(L/N 4-19)BS 1113, 1137, 1161, and 1185 133,000(5)53-59-02 Keel Beam H-Frame Inner Chord (L/N 4-19) BS 1089 133,000(5)53-59-02 Keel Beam H-Frame Inner Chord (L/N 4-19) BS 1113, 1137, 1161, and 1185 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-46787 AIRWORTHINESS LIMITATIONS53-59-02 Keel Beam - H-Frames - Attachment to TransverseBeamsLower Fittings and H-Frame Upper ChordsBS 1113-1185, LBL 9, BL 0, RBL 9133,000(5)53-59-03 Keel Beam - Rear Spar Fittings BL 0 Pressure DeckSplice FtgBL 0, BS 1050-1100, WL 181 Base Flange 133,000(5)53-59-03 Keel Beam - Rear Spar Fittings BL 0 Pressure DeckSplice FtgBL 0, BS 1050-1100, WL 181 Vertical Flange 133,000(5)53-59-03 Keel Beam - Rear Spar Fitting At RearSpar Web (WL 131 to WL 180) and BL 0Web (WL 154 to WL 182)133,000(5)53-59-04 Main Landing Gear Torque Box Torque Box Forward and Aft Upper Chord andSide Web Hand Hole133,000(5)53-59-04 Main Landing Gear TorqueBox Tension Fitting and Hinge Fitting 133,000(5)53-59-04 Main Landing Gear Torque Box (L/N 4-19) Lower Tension Fitting 133,000(5)53-59-04 Main Landing Gear Torque Box (L/N 20 and on) Lower Tension Fitting 133,000(5)53-59-04a S45 MLG Door Hinge Fittings Forward, Mid, and Aft Hinges Lower Lug onboth sides133,000(5)53-59-04b MLG Door Hinges Fittings Fillet Radius Details Mid, Forward and Aft Hinge Fillets @ BS 1145,BS 1195, and BS 1089244,000(5)53-59-05A Underwing Vertical Webs Detail A Shear Web Boundaries BS 868-1075 CriticalLocation Bay 4 Lower244,000(5)53-59-05B Underwing Vertical Webs - Keel Beam FlangeDetail BKeel flange under clip in Bay 1 244,000(5)53-59-05C Underwing Vertical Webs - Stiffeners, Keel Sideof AttachmentCritical Location is #18 at BS 879 Analysis coversall similar details244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4753-59-07-2 Keel Chord Splice BS 867.7 and 1209, LBL 14 and RBL 14 133,000(5)53-59-07-3 Keel Ladder Vertical Supports Keel toVertical Support at Front Spar BS 868 &AWW Bulkhead BS 1209 LH & RH Side244,000(5)53-59-07-7 Rear Spar Lattice Fitting BS 1073.33 LBL 11.5 toRBL 11.5Lattice Fitting Lower Chord common to VaporBarrier Web1FLS(5)53-59-07-7 Rear Spar Lattice Fitting12 End Pad at Keel Chord Attachment 1FLS(5)53-61-01A Wheel Well Longeron Extension Backup Fitting BS 1233 Backup Fitting Fillet 244,000(5)53-61-01A Section 46 Aft EE Bay Door Surround Door SupportFlangeBS 1233 Stringer 39L - 39R 244,000(5)53-61-02 Circumferential Skin-Stringer Splice - BS1605 Upper Sill, BS 1593 - Str 22 RHS Inner Chord 244,000(5)53-61-03 Circumferential Skin-Stringer Splice - BS1209 BS 1209 Doubler, hidden by longeron 133,000(5)53-61-07 Passenger Entry Door 3 - Edge Frame Edge Frame Web at Door Stop BS 1304, S-19to S-202FLS(5)53-61-07 Passenger Entry Door 3 - EdgeFrame BS 1304, Stringer 22-23, LHS 244,000(5)53-61-07 Passenger Entry Door 3 - EdgeFrame BS 1354, Stringer 14-15, RHS 244,000(5)53-61-07 Passenger Entry Door 3 - EdgeFrame BS 1304, Stringer 20-21, RHS 244,000(5)53-61-07 Passenger Entry Door 3 - Edge Frame Edge Frame at Splice BS 1354, S-10 to S-11 244,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill BS 1465 Inner Chord 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-48787 AIRWORTHINESS LIMITATIONS53-61-09 Aft Large Cargo Door - Lower Main Sill Inner Chord at BS 1465 fastener hole atEdge Frame133,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill Inner Chord at BS 1569 Latch Back-Up Ftg 133,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill BS 1569 Inner Chord 133,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill BS 1569 Web where hidden by latch andbackup structure133,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill BS 1510 Web 133,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill Outer Chord at Edge Frame at BS 1465 133,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill BS 1545 Outer Chord at Latch Back-Up Fitting 133,000(5)53-61-09 Aft Large Cargo Door - Lower Main Sill BS 1562 Stringer 33 RHS Outer Chord 244,000(5)53-61-09 Aft Large Cargo Door - Upper Main Sill Inner Chord at BS 1556 at Hinge Back-up FittingFastener Hole244,000(5)53-61-09 Aft Large Cargo Door - Upper Main Sill Inner Chord, BS 1577 244,000(5)53-61-09 Aft Large Cargo Door - Upper Main Sill Inner Chord at Edge Frame BS 1577 244,000(5)53-61-09 Aft Large Cargo Door - Upper Main Sill BS 1577 Outer Chord at Edge Frame 133,000(5)53-61-09 Aft Large Cargo Door - Upper Main Sill BS 1574, Upper Sill RHS, Outer Chord 244,000(5)53-61-09 Aft Large Cargo Door - Upper Main Sill Outer Chord at BS 1569 where not hidden 244,000(5)53-61-09 Aft Large Cargo Door - Upper MainSill Sill Outer Chord at BS 1569 split frame 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4953-61-09 Aft Large Cargo Door - Edge Frame BS 1577 Stringer 26, RHS, Inner Chord 244,000(5)53-61-09 Aft Large Cargo Door - Edge Frame Pull-in Pin attachment at S-30R 244,000(5)53-61-09 Aft Large Cargo Door - Edge Frame BS 1577 Stringer 33 Edge Frame Web SillAttachment244,000(5)53-61-09 Aft Large Cargo Door - Edge Frame BS 1577 between S-23R and Upper Sill OuterChord244,000(5)53-61-09 Aft Large Cargo Door - Edge Frame BS 1577 at Upper Sill Outer Chord 244,000(5)53-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame Inner Chord and Web BS 1744S-12R to S-13R244,000(5)53-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame at Door Stop BS 1794, S-21L 244,000(5)53-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame Web BS 1794 at Upper Sill 133,000(5)53-71-07 Passenger Entry Door 4 - Edge Frame Edge Frame Outer Chord BS 1744, S-19L toS-20L244,000(5)53-71-08 Bulk Cargo Door - Lower Sill Lower Sill Inner Chord, BS 1644 to 1670 244,000(5)53-71-08 Bulk Cargo Door - Lower Sill Lower Sill Inner Chord, BS 1644 to 1670 Hiddenat Forward Edge Frame133,000(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-upFitting244,000(5)53-71-08 Bulk Cargo Door - Edge Frame Forward Edge Frame Inner Chord and WebBS 1670, S-30L at latch fitting133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-50787 AIRWORTHINESS LIMITATIONS53-71-08 Bulk Cargo Door - Edge Frame Edge Frame at Door Stop BS 1719, S-29 133,000(5)53-71-08 Bulk Cargo Door - Edge Frame Edge Frame Web BS 1670 at Lower Sill 133,000(5)53-71-08 Bulk Cargo Door - Edge Frame Edge Frame Outer Chord BS 1719, S-26L 244,000(5)53-81-04 Aft Pressure Bulkhead Assembly Y-Chord at Web attachment BS 1878, outboardfastener row244,000(5)53-81-04 Aft Pressure Bulkhead Assembly Y-Chord aft most fastener row common to skinand splice strap, BS 1878244,000(5)53-81-06 Circumferential Splice at Pivot Bulkhead Forward Chord Splice at S-13 Left 133,000(5)53-81-06 Circumferential Splice at Pivot Bulkhead Forward Crown Chord at S-9L 133,000(5)53-81-06 Circumferential Splice at Pivot Bulkhead Forward and Aft Keel Chords at S-35L 244,000(5)53-81-06 Circumferential Splice at Pivot Bulkhead Side Chord at fasteners common to pivot backupfitting, WL 248.5244,000(5)53-81-06 Circumferential Splice at Pivot Bulkhead Forward Side Chord at Skin Attachment toLongeron Fitting, WL 259133,000(5)53-81-06 Circumferential Splice at Pivot BulkheadForward Chord at Splice - S-13L, BS 2064.5 atUpper Stringer End Fitting244,000(5)53-81-06 Circumferential Splice at Pivot Bulkhead Side Chord Splice to Jack Fitting 244,000(5)53-81-08 Sec. 48 Horizontal Stabilizer Pivot Fitting Pivot Fitting Flange Common to Bulkhead Web atBS 2064.5244,000(5)53-81-08 Sec. 48 Horizontal Stabilizer Pivot Fittings Pivot Fitting Lug (BS 2064.5) 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5153-81-10 Horizontal Stabilizer Trim ActuatorFitting Assembly Primary Pins at BS 1942 133,000(5)53-81-10 Horizontal Stabilizer TrimActuator Fitting Assembly Primary / Secondary Lug at BS 1942 133,000(5)53-81-11 Section 48 Horizontal Stabilizer Cutout - LongeronFittingsUpper Longeron & Failsafe Fittings BoltsBS 2064.5133,000(5)54-51-01-B Pylon To Wing Fittings Rolls Royce Engine Pylon 244,000(5)54-51-01-B Pylon To Wing Fittings General Electric EnginePylon2FLS(5)54-51-02-A Upper Spar Assembly General Electric EnginePylonChord/Skin/Web Interface - Bays 1 - 3 2FLS(5)54-51-02-C Upper Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 0 - 3, InboardSide Only2FLS(5)54-51-02-D Upper Spar Assembly Rolls Royce EnginePylon Chord/Skin/Web Interface at Frames 1 & 2,Inboard Side Only1FLS(5)54-51-02-D Upper Spar Assembly General Electric EnginePylonChord/Skin/Web Interface at Frames 1 & 2 1FLS(5)54-51-02-F Upper Spar Assembly Rolls Royce EnginePylon Chord/Skin/Web Interface - Bays 4 & 5, InboardSide Only2FLS(5)54-51-02-F Upper Spar Assembly General Electric EnginePylonR3/R4 Chord - Bay 5 1FLS(5)54-51-02-G Upper Spar Assembly Rolls Royce Engine Pylon R1 Upper Spar Fitting 133,000(5)54-51-02-G Upper Spar Assembly General Electric EnginePylonR1 Upper Spar Fitting 1FLS(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-52787 AIRWORTHINESS LIMITATIONS54-51-03-B Side Skins Rolls Royce Engine Pylon Side Skin Cutouts 2FLS(5)54-51-03-B Side Skins General Electric Engine Pylon Side Skin Cutouts 2FLS(5)54-51-04-A1 Lower Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 1 - 3 2FLS(5)54-51-04-A1 Lower Spar Assembly General Electric EnginePylonChord/Skin/Web Interface - Bays 1 - 3 2FLS(5)54-51-04-A2 Lower Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 1 - 3 at Brackets 1FLS(5)54-51-04-A2 Lower Spar Assembly General Electric EnginePylonChord/Skin/Web Interface - Bays 1 - 3 at Brackets 1FLS(5)54-51-04-A3 Lower Spar Assembly General Electric EnginePylonChord/Skin/Web Interface - Bays 1 - 3 at PartialBracket Locations1FLS(5)54-51-04-B1 Lower Spar Assembly Rolls Royce Engine Pylon Chord/Skin/Web Interface - Bays 4 and 5 2FLS(5)54-51-04-B1 Lower Spar Assembly General Electric EnginePylonChord/Skin/Web Interface - Bays 4 and 5 2FLS(5)54-51-04-B2 Lower Spar Assembly Rolls Royce EnginePylon Chord/Skin/Web Interface - Bays 4 and 5 atBrackets1FLS(5)54-51-04-B2 Lower Spar Assembly General Electric EnginePylonChord/Skin/Web Interface - at Shear Fittings 1FLS(5)54-51-04-B3 Lower Spar Assembly General Electric EnginePylonChord/Skin/Web Interface - at Heat Shield 1FLS(5)54-51-05-A Forward Engine Mount Bulkhead Rolls RoyceEngine PylonTension Bolt Attachments 2FLS(5)54-51-06-B Frame 3 General Electric Engine Pylon Tension Bolt Attachments 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5354-51-09-A Aft Engine Mount Tension Fittings Rolls RoyceEngine Pylon2FLS(5)54-51-09-A Aft Engine Mount Tension Fittings General ElectricEngine Pylon2FLS(5)54-51-10-A Aft Strut Bulkhead Rolls Royce Engine Pylon Upper Mid Stiffener 244,000(5)54-51-10-A Aft Strut Bulkhead General Electric Engine Pylon Upper Mid Stiffener 244,000(5)54-51-11 Rolls Royce Forward Engine Mount Installation Mount Fitting, Mount Links, Engine Lugs,Attach Bolts2FLS(5)54-51-12 General Electric Forward Engine Mount Installation Mount Fitting, Mount Links, Engine Lugs,Attach Bolts2FLS(5)54-51-13 Rolls Royce Aft Engine Mount Installation EngineSerial Numbers: 10025 -10047Thrust Links, Fitting, Mount Links, Evener Bar,Engine Lugs, Attach Bolts2FLS(5)54-51-13 Rolls Royce Aft Engine Mount Installation Thrust Links, Fitting, Mount Links, Evener Bar,Engine Lugs, Attach Bolts2FLS(5)54-51-14 General Electric Aft Engine Mount Installation Thrust Links, Fitting, Mount Links, Evener Bar,Engine Lugs, Attach Bolts2FLS(5)55-10-01 T-Chord Upper Center Box Side Rear Spar - Pivot Strap 133,000(5)55-10-01 Upper T-Chord, MultisparBox Side (L/N 4-6) Front Spar 133,000(5)55-10-01 T-Chord Upper Multispar Box Side (L/N 4-6) Rear Spar - Pivot Strap 133,000(5)55-10-01 T-Chord Upper Center Box (L/N 4-6) Front Spar - Jackscrew Plate 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-54787 AIRWORTHINESS LIMITATIONS55-10-01 T-Chord Upper Front Spar Zone Multispar Box Side(L/N 7 and on)Front Spar 244,000(5)55-10-01 T-Chord Upper Front Spar Center Box SideJackscrew Plate (L/N 7 and on)Front Spar 2FLS(5)55-10-01 T-Chord Upper Front Spar Center Box Side(L/N 7 and on)Front Spar 244,000(5)55-10-02 T-Chord Lower Center Box Side Rear Spar - Pivot Strap 133,000(5)55-10-02 Lower T-Chord, MultisparBox side (L/N 4-6) Front Spar 133,000(5)55-10-02 T-Chord Lower Multispar Box Side (L/N 4-6) Rear Spar 133,000(5)55-10-02 T-Chord Lower Center Box (L/N 4-6) Front Spar - Jackscrew Plate 133,000(5)55-10-02 T-Chord Lower Front Spar Zone Multispar Box Side(L/N 7 and on)Front Spar 244,000(5)55-10-10 Pivot Fitting Upper Flange (L/N 4-6) Upper Flange 133,000(5)55-10-10 Lower Flange Pivot Fitting Lower Flange (L/N 4-6) Lower Flange 133,000(5)55-10-10 Pivot Fitting Web (L/N 4-6) Web 133,000(5)55-10-10 Pivot Fitting Lug (L/N 4-6) Lug 133,000(5)55-10-10 Pivot Fitting Upper Flange (L/N 7 and on) Pivot Fitting Upper Flange Center Box HorizontalStabilizer244,000(5)55-10-10 Pivot Fitting Lower Flange (L/N 7 and on) Pivot Fitting Lower Flange Center Box HorizontalStabilizer244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5555-10-10 Pivot Fitting Angle - Web Bolt (L/N 7 andon) Pivot Fitting Web bolt Center Box HorizontalStabilizer244,000(5)55-10-10 Pivot Fitting Lug Analysis (L/N 7 and on) Pivot Fitting Lug Center Box Horizontal Stabilizer 244,000(5)55-10-12 Upper Strap Pivot Side (L/N 4 - 6) Pivot Side 244,000(5)55-10-12 Lower Strap Pivot Side (L/N 4 - 6) Pivot Side 2FLS(5)55-10-12 Upper Strap Pivot side - Transversal Stress(L/N 7 and on)Upper Strap - Pivot Side - Horizontal StabilizerCenter Box244,000(5)55-10-12 Upper Strap Pivot Side Long Stress (L/N 7 and on) Pivot Side 244,000(5)55-10-12 Upper Strap (L/N 7 and on) T-Chord 244,000(5)55-10-12 Pivot Lower Strap Crack Growth-FX (L/N 7 and on) Pivot Strap Lower LHS - Horizontal StabilizerCenter Box244,000(5)55-10-12 Lower Strap Pivot Side Longitudinal Stress(L/N 7 and on)Pivot Side 244,000(5)55-10-12 Lower Strap T-Chord Side (L/N 7 and on) T-Chord zone 244,000(5)55-10-13 Pivot Outboard Angle (L/N 4 - 6) Pivot Side 244,000(5)55-10-13 Rear Spar Splice Pivot Side Vertical Stress(L/N 7 and on)Pivot Web Side 244,000(5)55-10-13 Rear Spar Splice Pivot Side Horizontal Stress(L/N 7 and on)Pivot Web Side 244,000(5)55-10-13 Rear Spar Splice Multispar Box Side Vertical Stress(L/N 7 and on)Multispar Box Side 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-56787 AIRWORTHINESS LIMITATIONS55-10-13 Rear Spar Splice Multispar Box Side HorizontalStress (L/N 7 and on)Multispar Box Side 244,000(5)55-10-14 Pivot Pin Outer Pivot 133,000(5)55-15-01 Jackscrew Fitting Upper Plate Front Side Front Side 2FLS(5)55-15-01 Jackscrew Fitting Upper Plate Multispar Box Side(L/N 4 - 6)Jackscrew Fitting Upper Plate Multispar Box Side 244,000(5)55-15-01 Jackscrew Upper Plate (L/N 7 and on) Jackscrew Upper Plate Middle Side 244,000(5)55-15-01 Jackscrew Upper Plate (L/N 7 and on)Jackscrew Upper Plate Multispar Box Side 244,000(5)55-15-02 Jackscrew Fitting Lower Plate Front Spar Side(L/N 4 - 6)Jackscrew Fitting Lower Plate Front Spar Side 244,000(5)55-15-03A Jackscrew Front Spar Web Splice (L/N 4-6) Center Box Side Flange 244,000(5)55-15-03A Jackscrew Web Splice (L/N 7 and on) Center Box Side (y direction), Center BoxHorizontal Stabilizer244,000(5)55-15-03A Jackscrew Web Splice (L/N 7 and on) Web Splice Multispar Box Side (y direction),Center Box Horizontal Stabilizer244,000(5)55-15-03B Jackscrew Front Spar Upr/Lwr Angle (L/N 4 - 6) 133,000(5)55-15-03B Jackscrew Upper Angle (L/N 7 and on) Upper Angle (Bolt UH1) Center Box HorizontalStabilizer244,000(5)55-15-03C Jackscrew Lower Angle (L/N 7 and on) Upper Angle (Bolt LH1) Center Box HorizontalStabilizer244,000(5)55-15-04 Jackscrew Terminal Fitting (L/N 7 and on) Web Splice Side y-direction Center Box HorizontalStabilizer244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5755-15-04 Jackscrew Terminal Fitting (L/N 7 and on) Web Splice Side x-direction Center Box HorizontalStabilizer244,000(5)55-15-04 Horizontal Stabilizer Center Box (L/N 7 and on) Jackscrew Terminal Fitting Rib Side (fy) 244,000(5)55-18-01 Jackscrew Inboard/Outboard Fittings L/R (L/N 4 - 6) Upper Horizontal Flange 244,000(5)55-18-01 Jackscrew Inboard/Outboard Fittings L/R (L/N 4 - 6) Lower Horizontal Flange 244,000(5)55-18-01 Jackscrew Inboard/Outboard Fittings L/R (L/N 4 - 6) Lug 244,000(5)55-18-01 Jackscrew Inboard/Outboard Fittings Upr HorizontalFlange (L/N 7 and on)Upper Flange 244,000(5)55-18-01 Jackscrew Inboard/Outboard Fittings Lwr HorizontalFlange (L/N 7 and on)Lower Flange 244,000(5)55-18-01 Jackscrew Inboard/Outboard Fittings (L/N 7 and on) Lug 2FLS(5)55-18-02 Jackscrew Outer Gimbal Nut Outer Pin 2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1, -2, -41st Forward 0.25" dia. fastener common to themain box skin panel2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1, -2, -4 (L/N 7 and on)Forward .25" Dia Chord Fasteners common to theMain Box Skin Panel2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1, -2, -4Aft 0.25" dia. chord fastener common to the mainbox skin panel2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1, -2, -4Aft 0.3125" dia. chord fastener common to themain box skin panel2FLS(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-58787 AIRWORTHINESS LIMITATIONS55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1, -2, -4 (L/N 7 and on)Forward .19" Dia Chord Field Fastener common toMain Box Skin Panel2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1, -2, -4 (L/N 7 and on)Aft .19" Dia Chord Field Fastener Common toMain Box Skin Panel2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1 (L/N 4-6)Forward .25" Dia Chord Fasteners common to theMain Box Skin Panel2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1 (L/N 4-6)Forward .19" Dia Chord Field Fastener common toMain Box Skin Panel2FLS(5)55-33-10 Main Torque Box - Closeout Rib 15P/N 212Z5115-1 (L/N 4-6)Aft .19" Dia Chord Field Fastener common to MainBox Skin Panel2FLS(5)55-37-01 Root Attach Fittings, Rear Spar, Left & RightP/N 212Z7101-1, -2, -3, -4Forward & Aft Tension Bolt Lugs 2FLS(5)55-37-01 Root Attach Fittings, Rear Spar, Left & RightP/N 212Z7101-1, -2, -3, -4Fitting web and stiffeners below Rib 1 WL 325to WL 3272FLS(5)55-37-01 Root Attach Fittings, Rear Spar, Left & RightP/N 212Z7101-1, -2, -3, -4Fitting web and stiffeners below Rib 1 WL 317to WL 3252FLS(5)55-37-01 Root Attach Fittings, Rear Spar, Left & RightP/N 212Z7101-1, -2, -3, -4Flange common to Fin Deck Fasteners 2FLS(5)55-37-02 Root Attach Fittings, Stringer 3 Left & RightP/N 212Z7111-1, -2, -3, -4Aft Tension Bolt Lug 2FLS(5)55-37-02 Root Attach Fittings, Stringer 3 Left & RightP/N 212Z7111-1, -2, -3, -4Stringer 3 Root Splice between WL 325 andW 331 (cut 4)2FLS(5)55-37-02 Root Attach Fittings, Stringer 3, Left and RightP/N 212Z7111-1, -2, -3, -410.41 inches below Rib 1centerline along centerstiffener centerline (cut 3)2FLS(5)55-37-02 Root Attach Fittings, Stringer 3, Left and RightP/N 212Z7111-1, -2, -3, -4Flange common to Fin Deck Fasteners 2FLS(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5955-37-03 Root Attach Fittings, Stringer 6, Left & RightEmpennage Vertical StabilizerForward Tension Bolt Lug 2FLS(5)55-37-03 Root Attach Fittings, Stringer 6, Left & RightEmpennage Vertical StabilizerStringer 6 Root Splice Between WL 328 andWL 3332FLS(5)55-37-03 Root Attach Fittings, Stringer 6, Left & RightEmpennage Vertical Stabilizer8.27" below Rib #1 centerline along centerstiffener centerline (Cut 3)2FLS(5)55-37-03 Root Attach Fittings, Stringer 6,Left & RightEmpennage Vertical StabilizerFlange Common to Fin Deck Fasteners 2FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightPN 212Z7131-1,-2, -3, -4Forward Tension Bolt Lug 2FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightPN 212Z7131-1,-2, -3, -4Fitting 1 Web and Flange adjacent to the FrontSpar Root Strap, WL 329 to WL 3332FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightPN 212Z7131-1,-2, -3, -4Flange common to Fin Deck Fasteners 2FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightPN 212Z7131-1,-2 (L/N 4-6)Fitting 1 Web and Stiffener below Forward TorqueBox Rib 1 attachment (cut 3)2FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightPN 212Z7131-1,-2 (L/N 4-6)Fitting 1 Web and Spar Flange Aft of the FrontSpar (cut 1)2FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightP/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)Fitting 1 Web and Spar Flange Aft of the FrontSpar, WL 321 to WL 3332FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightP/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)Fitting 1 Web and Stiffener below Forward TorqueBox Rib 1 attachment (cut 3) WL 323 to WL 3252FLS(5)55-37-04 Root Attach Fittings, Front Spar, Left & RightP/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)Fitting 1 Web and Spar Flange Aft of the FrontSpar, WL 317 to WL 3212FLS(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-60787 AIRWORTHINESS LIMITATIONS55-37-04 Root Attach Fittings, Front Spar, Left & RightP/N 212Z7131-1,-2,-3,-4 (L/N 7 and on)Fitting 1 Web & Stiffener below Forward TorqueBox Rib 1 Forward of the Front Spar, WL 320 toWL 3232FLS(5)55-37-05 Root Attach Tension Bolt Frame 4- Forward Tension Bolt - Vertical Fin 2FLS(5)57-10-01A Side of Body Splice - Upper Surface Critical SurfaceInspection AreasUpper Splice Plate - BS 1026.5 - 1076.5 RearSpar to Stringer 42FLS(5)57-10-01B Side of Body Splice - Upper Surface GeneralSurface Inspection AreasUpper Splice Plate - BS 873.0 - 1026.5 Front Sparto Stringer 5244,000(5)57-10-01C Side of Body Splice - Upper Surface Upper Splice Plate - BS 873.0 - 1076.5 AreasHidden by Pi Fittings - Section 111FLS(5)57-10-01D57-10-01ESide of Body Splice - Upper Surface Tee Chord andSplice PlateUpper Splice Plate - BS 873.0-1076.5 areashidden by Flex Tee at Pi Fittings1FLS(5)57-10-01D57-10-01ESide of Body Splice - Upper Surface Tee Chord andSplice PlateUpper Splice Plate - BS 873.0-1076.5 areashidden by Flex Tee1FLS(5)57-10-02 Side of Body Splice - Lower Surface Jack Pad Fitting bolt holes 244,000(5)57-10-02 Side of Body Splice - Lower Surface Sideof Body Rib Lower Chord visible fasteners atWeb attachment133,000(5)57-10-02 Side of Body Splice - Lower SurfaceLHS (L/N 4-21), RHS (L/N 4-20)Outboard Wing, Lower Chord and Splice Platefrom Front Spar to Rear Spar133,000(5)57-10-02 Side of Body Splice - Lower SurfaceLHS (L/N 22 and on), RHS (L/N 21 and on)Outboard Wing, Lower Chord and Splice Platefrom Front Spar to Rear Spar133,000(5)57-10-03-1 Side of Body Splice - Front Spar Terminal Fitting, Lower Cap Horizontal Flange 1FLS(5)57-10-03-2 Side of Body Splice - FrontSpar Terminal Fitting Vertical Flanges 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8JUN 2012787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6157-10-03-5 Side of Body Splice - Front Spar Terminal Fitting, Upper Cap Flange Common toSide of Body Rib133,000(5)57-10-03-9 Side of Body Splice - Front Spar Terminal Fitting, Upper Cap Flange Common toFront Spar Web133,000(5)57-10-04 Side of Body Splice - Rear Spar Rear Spar Terminal Fitting at attachment Side ofBody Rib Web - Hidden Areas1FLS(5)57-10-04 Side of Body Splice - Rear Spar Rear Spar Terminal Fitting at attachment Side ofBody Rib Web - Non-Hidden Areas133,000(5)57-10-04 Side of Body Splice - Rear Spar RearSpar Terminal Fitting lower horizontal &vertical flanges1FLS(5)57-10-04 Side of Body Splice - Rear Spar LowerSplice Plate holes common to rear sparlower chord244,000(5)57-10-05 Side of Body Splice - Rear Spar Side of Body Rib Web at Front & Rear SparTerminal Ftg & Upper and Lower Chords1FLS(5)57-10-05 Side of Body Rib Web penetration holes with satellite holes 244,000(5)57-10-05 Side of Body Rib Web penetrations without satellite holes 244,000(5)57-10-05 Side of Body Rib (L/N 4-6) Web to Access Door Detail (LHS/RHS) 133,000(5)57-10-05 Side of Body Rib (L/N 7 and on) Web to Access Door Detail (LHS/RHS) 244,000(5)57-10-05 Side of Body Rib (L/N 4-6) Vertical stiffeners No.1-12 to web joints(LHS/RHS)244,000(5)57-10-05 Side of Body Rib (L/N 34 and on) Web atBase of Integral Horizontal Stiffeners -Group 1244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-62787 AIRWORTHINESS LIMITATIONS57-10-05 Side of Body Rib (L/N 34 and on) Web atBase of Integral Horizontal Stiffeners -Group 2244,000(5)57-10-05 Side of Body Rib (L/N 34 and on) Web atBase of Integral Horizontal Stiffeners -Group 3244,000(5)57-10-06A Overwing Flex-T Flex-T Fastener Holes at Trapezoidal PanelVisible Locations244,000(5)57-10-06A Overwing Flex-T Flex-T Fastener Holes at Trapezoidal Panel -Hidden Locations133,000(5)57-10-06A Overwing Flex-T Flex-T web fastener holes hidden by FSOWL &RSOWL and locations in Note 2133,000(5)57-10-06A Overwing Flex-T Flex-T rebate edge at BS 933 Forward edge of #4and Aft edge of #5 Flex-T244,000(5)57-10-06A Overwing Flex-T Flex-T rebate edges at BS 882, 981, 1031, 1071,1085, and 1120244,000(5)57-10-06A Overwing Flex-T Flex-T rebate, from BS 883 to BS 1120 exceptFlex-T rebate edges244,000(5)57-10-06A Overwing Flex-T No. 1 Flex Tee Clevis Bore - BL 113.13, BS 1076 133,000(5)57-10-06A Overwing Flex-T No. 1 Flex Tee Clevis Neck - BL 113.13, BS 1076 244,000(5)57-10-06A Overwing Flex-T No. 2 Flex Tee Lug Bore - BL 113.4, BS 1076 133,000(5)57-10-06B Pi-Fitting - Frame BS 897-1089 Upper Flange Joint, Pi-Fittings #1-9 (LHS/RHS) 244,000(5)57-10-06B Pi-Fitting - Frame BS 897-1089 Upper flange radius, Pi-Fittings #1-9 (LHS/RHS) 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6357-10-06B Pi-Fitting - Frame BS 897-1089 Wall Flange JointL/N 4-6: BS 897, 945, 1017, 1041, 1065L/N 7 and on: BS 945, 1017, 1041, 10652FLS(5)57-10-06B Pi-Fitting - Frame BS 897-1089 Wall Flange, Fitting Base Radius Pi Fittings #1-9(LHS/RHS)244,000(5)57-10-06B Pi-Fitting - Frame BS 897-1089 All Base Joint Fasteners, Pi Fittings #1-9 133,000(5)57-10-06C Shear Fitting - Frame BS 897-1089 Vertical & Base Flange Radius 244,000(5)57-12-01A Rear Spar, Stiffener, Edge of Flange BL 11 (LHS/RHS) at WL 130 to 147 244,000(5)57-12-01A Rear Spar Stiffener, Free Flange Fasteners BL 11(LHS/RHS) at WL 140 to WL 157133,000(5)57-12-01a Rear Spar Stiffener, HoleSection BL 11 (LHS/RHS) atWL 94.5 - 98244,000(5)57-12-01A Rear Spar ManufacturingDoor Horizontal Stiffener 133,000(5)57-12-01B Rear Spar Access Doors Manufacturing Door Fastener Hole(Hidden Locations)133,000(5)57-12-01C Rear Spar - Miscellaneous Fittings Bracket, BL 74 and BL 59.5 (LHS/RHS) RBL 32.5,RBL 19 at WL 181.7244,000(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 181.7244,000(5)57-12-01C Rear Spar - Miscellaneous Fittings Inboard/Outboard OWB Fittings, BL 66(LHS/RHS) at WL 181.7133,000(5)57-12-01C Rear Spar - Miscellaneous Fittings (L/N 4-19) T-Clip at MLG Door Support Intercostal, LBL 90and RBL 90, WL 135244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-64787 AIRWORTHINESS LIMITATIONS57-12-01C Rear Spar - Miscellaneous Fittings (L/N4-19) Lug - R/S MLGD Support Ftg, LBL 90, RBL 90,LBL 102, RBL 102 Lug Area133,000(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 Area133,000(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 90244,000(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 Area1FLS(5)57-12-01C Rear Spar - Miscellaneous Fittings Rear Spar Back-up Angles, LBL and RBL 46 and82, WL 146244,000(5)57-12-01C Rear Spar - Miscellaneous Fittings Lower Beam Lug and Clevis Fitting, LBL andRBL 46 and 82, WL 144133,000(5)57-12-02A Front Spar - Stiffener BL 82,BL 90 (LHS/RHS) WL 136 to WL 192 244,000(5)57-12-02A Front Spar - Stiffener, Gage Steps BL 82, BL 90 (LHS/RHS) WL 196 to WL 192 244,000(5)57-12-02A Front Spar - Horizontal Stiffener Between BL 90 to BL 114, left and right 244,000(5)57-12-02B Front Spar - Miscellaneous Fittings Overwing Beam Fitting @ BL 11, 39.5, 66, 90,(LHS/RHS) at Front Spar Attachment244,000(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 doubler133,000(5)57-12-02B Front Spar - Miscellaneous Fittings Overwing Beam Fitting, Upper Flange @ BL 11,39.5, 66, 90, (LHS/RHS) at WL 194244,000(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 133244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6557-12-02B 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 133244,000(5)57-12-02B Front Spar - Miscellaneous Fittings Lower Beam Lugs and Clevis Fittings LBL andRBL 46 and 82, WL 144133,000(5)57-12-03a Front Spar Body Chord Skin Flange BL 30 - BL 104 1FLS(5)57-12-03a Front Spar Body Chord SkinFlange, Hidden Flange at BL 95 - 98 133,000(5)57-12-03a Front Spar Body Chord Web Side Flange BL 30 - BL 104 133,000(5)57-12-03a Front Spar Body Chord WebSide Flange, Hidden Fastener DetailsBL 30 - BL 104133,000(5)57-12-03a Front Spar Body Chord Web Flange @ BL 0 - BL 30 Hidden Details 133,000(5)57-12-03a Front Spar Body Chord Radius 244,000(5)57-12-03a57-12-03bFront Spar Body Chord Skin Flange at BL 0 - BL 30 133,000(5)57-12-03a57-12-03bFront Spar Body Chord Web Flange at BL 0 - BL 30 133,000(5)57-12-03b Front Spar Body Chord Splice Details Body Chord at BL 0 Splice - Web Flange atStiffener End Fittings133,000(5)57-12-03b Front Spar Body Chord Splice Details Pickle Fork and Front Body Chord at OutboardSplice - Skin Flange133,000(5)57-12-03b Front Spar Body Chord Splice Details Pickle Fork and Front Body Chord at OutboardSplice - Web Flange133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-66787 AIRWORTHINESS LIMITATIONS57-12-03b Front Spar Body Chord Splice Details BL0 Body Chord Splice - Skin Flange (LBL 5.3 toRBL 5.3)244,000(5)57-12-03b Front Spar Body Chord Splice Details BL 0 Body Chord Splice - Web Flange (LBL 5.3 toRBL 5.3)244,000(5)57-12-03b Front Spar Body Splice Chord Details Body Chord at BL 0 Splice - Skin Flange atStiffener End Fittings133,000(5)57-12-03b Front Spar Body Chord Splice Details Pickle Fork to Body Chord Splice Fitting 244,000(5)57-13-01a Spanwise Beams - Stiffener Spanwise Beam #1, #2, #3 at BL 46, BL 82(LHS/RHS)244,000(5)57-13-01a Spanwise Beams - Stiffener Base Flange Radius Spanwise Beam #1, #2, #3 atBL 46, BL 82 (LHS/RHS) at Top End244,000(5)57-13-01b Spanwise Beam Corner Fittings Forwardand Aft Corner Fittings at Lower Chord ofSpanwise Beams 1, 2, & 32FLS(5)57-13-02A Overwing Beams Seat Track (Upper Chord) - Web Attachment atBL11, 39.5, 66, and 902FLS(5)57-13-02A Overwing Beams Web at SeatTrack (Upper Chord) Attachment atBL 11, 39.5, 66 and 90244,000(5)57-13-02A Overwing Beams Lower Chord - Upper Skin Attachment at BL 11,39.5, 66, and 90133,000(5)57-13-02A Overwing Beams Lower Chord - Upper Skin Attachment @ BL 66,Overwing Beam hidden details @ BL 11, 39.5, 66,and 90133,000(5)57-13-02A Overwing Beams Aft Lower Chord,BL 90, (LHS and RHS) Fastenerholes common to Aft Lower Chord and SpliceFitting BS 1113244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6757-13-02A 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, 1081-1104111,790(5)57-13-02A Overwing Beams Lwr Chord - Hidden Detail, RS Splice Fittings atBL 11, 39.5, 66, and 90. Fastener Holes Commonto RS Splice Fitting and Lwr Chord133,000(5)57-13-02A Overwing Beams Seat Track at BS 1113 Splice Fitting, BL 11,BL 39.5, BL 66 (LHS/RHS)133,000(5)57-13-02B Overwing Beams - Miscellaneous Fittings RearSpar Splice Fittings - Horizontal Flange,BS 1072 to 1087 (LHS and RHS)133,000(5)57-13-02B Overwing Beams - Miscellaneous Fittings Splice Fitting, BS 1113 - BL11, 39.5, 66, and 90(LHS and RHS)244,000(5)57-13-02B Overwing Beams - Miscellaneous Fittings Drain Hole - BS 1113 Splice Ftg at BL66,Outboard BS 1113 splice fitting at RBL 66 andLBL 66133,000(5)57-13-02B Overwing Beams - Miscellaneous Fittings Overwing Beam Web, BS 1113 Splice Fittings -BL 11, 39.5, 66 (LHS and RHS)133,000(5)57-13-02C Overwing Beam - Tie Rods AluminumClevis Fittings - BS 1017, 1041, 1065,1077, 1089, and 1113, at BL 66 and 90(LHS and RHS)133,000(5)57-13-02C Overwing Beam - Tie Rods Rod endshaft - BS 1017, 1041,1065, 1077, 1089,and 1113 at inboard and outboard rod ends(LHS/RHS)133,000(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)1FLS(5)57-13-02C Overwing Beam - Tie Rods Outboard Rod End Clevis at Frames - ClevisBase, BS 1017, 1041, 1065, 1089 (LHS and RHS)244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-68787 AIRWORTHINESS LIMITATIONS57-13-02C Overwing Beam - Tie Rods Outboard Rod End Clevis at Frames - Lug Hole,BS 1017, 1041, 1065, 1089 (LHS and RHS)133,000(5)57-15-01 Lower Panel - Keel Attach Chord Bays 1, 2, 3 (BS 1039 to 1075), and 19 (BS 870to 882) (LHS/RHS)244,000(5)57-15-01 Lower Panel - Metallic Fittings (L/N 4-6) Section 11 Lower Panel Stringer 1 Forward/AftLHS/RHS fittings, all 5 fasteners per fitting133,000(5)57-15-01 Lower Panel - Metallic Fittings (L/N 4-6) Section 11 Lower Panel Stringer 1, End Fitting 244,000(5)57-21-02 Front Spar Splice (L/N 4-6) Wing Front Spar at Rib 14 1FLS(5)57-21-02 Front Spar Splice (L/N 4-6) Wing Front Spar at Rib 30 1FLS(5)57-21-02 Front Spar Splice Wing FrontSpar at Rib 39.5 (wing tip) 1FLS(5)57-21-04 Rear Spar Splice (L/N 4-6) Wing Rear Spar at Rib 19 1FLS(5)57-21-04 Rear Spar Splice (L/N 4-6) Wing Rear Spar at Rib 30 1FLS(5)57-21-04 Rear Spar Splice Wing RearSpar at Rib 39.5 (wing tip) 1FLS(5)57-22-01A Wing Tip Inspar Rib 40 Bay #3 Upper Chord 133,000(5)57-22-01B Wing Tip Inspar Rib 40 Bay #1 Front Spar Attachment 133,000(5)57-22-01C Wing Tip Inspar Ribs 41, 42, and 43 Bay #2 Upper Chord 133,000(5)57-22-01D Wing Tip Inspar Ribs 41, 42, and 43 Bay #2 Lower Chord 133,000(5)57-22-01E Wing Tip Inspar Ribs 41, 42, and 43 Bay #1 Front Spar Attachment 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6957-24-01 R4 Inboard Side Load Fitting Strut Joint Lug 1FLS(5)57-24-02 R3 Outboard Side Load Fitting Strut Joint Lug 1FLS(5)57-24-03 R2 Aft Pitch Load Fitting Diagonal Brace Joint Lug 1FLS(5)57-24-04 R1 Inboard/Outboard Forward Pitch Load Fittings Upper Link Joint Lug 1FLS(5)57-24-05 R7/R8 Side Load Fitting Side Link Joint Lug 1FLS(5)57-24-06C R3 Forward Backup Fitting at Rib 12 Fitting attachment to Rib 12 Web 1FLS(5)57-25-02J Lower Stringer Splice at Rib 35 Stringer L-13 and L-15 Fastener LBF-7 and LBF-8 1FLS(5)57-25-02L Lower Stringer-8 @ Rib 17 (L/N 4-6)Fastener Rows 7 and 8 (hidden details) Bothfittings are used in the analysis1FLS(5)57-27-01 MLG Forward Trunnion Side Load Backup Fitting Lower flange attachments to lower skin panel 244,000(5)57-27-02 MLG Drag Brace Lower Backup Fitting Upper flange of cross section H-H 2FLS(5)57-27-03 MLG Drag Brace Upper Backup Fitting Lower flange of cross section F-F 2FLS(5)57-27-05 MLG Drag Brace Upr/Lwr Rib 2 AttachClips Drag Brace Lower Backup Fitting to Rib 2Attachment Clip2FLS(5)57-30-01A Wing Tip Inboard Closure Rib Front and Rear Spar Lower Splice Joints 133,000(5)57-30-01B Wing Tip - Inboard Closure Rib Barrel Nut Housing 1FLS(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-70787 AIRWORTHINESS LIMITATIONS57-51-01A Fixed Trailing Edge Flap Support#3 (Inboard+Outboard)-Lower Flange-wingattachment Hinge Lugs (Inboard & Outboard) Ribs2FLS(5)57-51-01B Fixed Trailing Edge Auxiliary-C Fixed Trailing Edge Auxiliary-C Support 244,000(5)57-51-01C1A Auxiliary-D Mini-Cantilever Lower Joint Auxiliary-D Mini-Cantilever Lower Joint (Lug) 133,000(5)57-51-01C1B Auxiliary-D Mini-Cantilever Lower Joint Auxiliary-D Mini-Cantilever Lower Joint (Pin) 133,000(5)57-51-01C1C Auxiliary-D Mini-Cantilever Lower Joint Auxiliary-D Mini-Cantilever Lower Joint (Link Lug) 133,000(5)57-51-01C2 Auxiliary-D Backup Rib Lower Chord Auxiliary-D Backup Rib Lower Chord 244,000(5)57-51-01C3 Auxiliary-D Roller Rib Auxiliary-D Roller Rib (Aft of Backup Rib) 244,000(5)57-51-01D Spoiler 5 Main Support Fitting Lower Wing Skin Attachment 244,000(5)57-51-02 Fixed Trailing Edge Flaperon Support Structure Hinge Ribs, Cam Track Ribs, and Cam Track 244,000(5)57-51-03A Fixed Trailing Edge Flap Support #1 Ribs Flap Support #1 lower flange / wing skinattachments (Inboard + Outboard) Ribs244,000(5)57-51-03B Fixed Trailing Edge Flap Support #2 Ribs Flap Support #2 lower flange / wing skinattachments (Inboard + Outboard Ribs)244,000(5)57-51-04A Fixed Trailing Edge Aileron Hinge Rib #1 Hinge Rib #1 with failed Rib #2 244,000(5)57-51-04C Fixed Trailing Edge Aileron Hinge Rib #2 Hinge Rib #2 with failed Rib #3 244,000(5)57-51-04D Fixed Trailing Edge Aileron Hinge Rib #3 Hinge Rib #3 with failed Rib #4 244,000(5)57-51-04E Fixed Trailing Edge Aileron Hinge Rib #4 Hinge Rib #4 with failed Rib #3 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-7157-51-04F Fixed Trailing Edge Aileron Hinge Rib #5 Hinge Rib #5 with failed Rib #4 244,000(5)57-53-02 Inboard Flap Support 3 Carrier Fitting and Internal Fitting Bathtub BoltHoles, Qty. 6 total133,000(5)57-53-02 Inboard Flap Support #3 Carrier Fitting AttachmentBoltsAll BACB30LE9K Bolts (Qty 6) per notes onDTR Check Form133,000(5)57-53-02 Support 3 Carrier Fitting Lower Flange Edge Cracks 244,000(5)57-53-03A Inboard Flap Torque Tube Carrier Beam Attachment Lug 133,000(5)57-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Outer Torque Tube, Fitting 5 Attachment Lugs 133,000(5)57-53-03A Wing Trailing Edge - Inboard Flap -Torque Tube Inner Torque Tube, Pad-Up at Fitting 5 133,000(5)57-53-03A Wing Trailing Edge - Inboard Flap - TorqueTube Inner Torque Tube, Collar Fitting Attachment Lugs 133,000(5)57-53-03A Wing Trailing Edge - Inboard Flap- Torque Tube Outer Torque Tube, Drain Holes 133,000(5)57-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Outer Torque Tube, Flange at Fitting 5 133,000(5)57-53-03A Wing Trailing Edge - Inboard Flap - Torque Tube Outer Torque Tube, Pad-Up at Attachment toFitting 5133,000(5)57-53-03B Support 4 Torque Tube Shear Rib 4 (Fitting 4) Fitting 4 Fastener Holes at Collar Attachment 133,000(5)57-53-03B Support 4 Torque Tube Shear Rib 4 (Fitting 4) Torque Tube Cut Out 133,000(5)57-53-03B Support 4 Torque Tube Shear Rib 4 (Fitting 4) Upper Skin Flange Fastener Hole 133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-72787 AIRWORTHINESS LIMITATIONS57-53-03C Inboard Flap Fitting 5 Fitting 5 Lower Flange to Lower Skin fastenerholes, Quantity 8 total133,000(5)57-53-03C Inboard Flap Fitting 5 Outer torque tube bolt hole 133,000(5)57-53-03D Wing Trailing Edge - Inboard Flap - Torque Tube Inner Torque Tube Collar Flange 133,000(5)57-53-03D Wing Trailing Edge - Inboard Flap -Torque Tube Torque Tube Collar, Inner Torque TubeAttachment Lugs133,000(5)57-53-03E Wing Trailing Edge - Inboard Flap - Torque Tube Torque Tube Support Pin 133,000(5)57-53-04A Support 3 Carrier Fitting and Internal Fitting Bathtub Fillets 133,000(5)57-53-04B Inboard Flap Support 4 Support 4Carrier Beam Hinge Lug (B joint lugs) 133,000(5)57-53-04B Inboard Flap Support 4 Support 4Carrier Torque Tube Attachment AftJoint Lugs (138Z4041 & 138Z4044)133,000(5)57-53-04B Inboard Flap Support 4 Support 4 Carrier Beam Lower Flange 133,000(5)57-53-04B Inboard Flap Support 4 Support 4 Carrier Beam Aft Lug Field FastenerHoles133,000(5)57-53-04B Inboard Flap Support 4 Support 4 Carrier Beam Drain Holes 133,000(5)57-53-04C Inboard Flap Support 4 Support 4 Forward Flange Crack (Stressconcentration)244,000(5)57-53-04C Inboard Flap Support 4 Support 4 Vertical Bulk Head Lug (K Lug) 133,000(5)57-53-04C Inboard Flap Support 4 Support 4 Hinge Joint (B - Joint) 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-7357-53-04C Inboard Flap Support 4 Support 4 Pyramid Section 133,000(5)57-53-04C Inboard Flap Support 4 Lower Fastener Hole on Panel 138Z4058 244,000(5)57-53-04E Inboard Trailing Edge Flap Support #4 Inner Pin(Failed Outer Pin)Hinge "B" Pin 133,000(5)57-53-04F Inboard Trailing Edge Flap Support #4 Inner Pin(Failed Outer Pin)Upper Bulkhead Pin 133,000(5)57-53-04G Inboard Trailing Edge Flap Support #4 Inner Pin(Failed Outer Pin)Torque Tube to Carrier Beam Attachments 133,000(5)57-53-06A Auxiliary Supports Inboard Flap Auxiliary Supports 244,000(5)57-53-09A Outboard Flap Support #1 Carrier FittingAttachment BoltsAll BACB30LE8K Bolts (Qty 6) per notes onDTR Check Form133,000(5)57-53-09A Support 1 Carrier Fitting Lower Flange Edge Cracks 244,000(5)57-53-09A Support 1 Carrier Fitting C-Joint Clevis (Actuator Joint) 244,000(5)57-53-09B Outboard Flap Support #2 Carrier FittingAttachment BoltsAll BACB30US8K Bolts (Qty 6) per notes onDTR Check Form133,000(5)57-53-09B Support 2 Carrier Fitting Lower Flange Edge Cracks 244,000(5)57-53-09B Support 2 Carrier Fitting C-Joint Clevis (Actuator Joint) 244,000(5)57-53-09B Outboard Flap Support 2 Carrier Fitting and Internal Fitting Bathtub BoltHoles, Qty. 6 total133,000(5)57-53-10A Outboard Flap Support 1 Carrier Fitting and Internal Fitting Tension BoltHoles, Qty. 6 total133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-74787 AIRWORTHINESS LIMITATIONS57-53-10A Support 1 Carrier Fitting and Internal Fitting Bathtub Fillets 133,000(5)57-53-10B Support 2 Carrier Fitting and Internal Fitting Bathtub Fillets 133,000(5)57-53-12A Outboard Flap Auxiliary Supports and Deflection Control 244,000(5)57-53-13A Wing Trailing Edge - Aileron Hinge 1 Radius 244,000(5)57-53-13A Wing Trailing Edge - Aileron Hinge 1 Lug 133,000(5)57-53-13A Wing Trailing Edge - Aileron Hinge 1 Joint 244,000(5)57-53-13B Wing Trailing Edge - Aileron Hinge 2 Joint 244,000(5)57-53-13B Wing Trailing Edge - Aileron Hinge 2 Radius 244,000(5)57-53-13B Wing Trailing Edge - Aileron Hinge 2 Lug 133,000(5)57-53-13C Wing Trailing Edge - Aileron Hinge 3 Lug 133,000(5)57-53-13C Wing Trailing Edge - Aileron Hinge 3 Radius 244,000(5)57-53-13C Wing Trailing Edge - Aileron Hinge 3 Joint 244,000(5)57-53-13D Wing Trailing Edge - Aileron Hinge 4 Lug 133,000(5)57-53-13D Wing Trailing Edge - Aileron Hinge 4 Radius 244,000(5)57-53-13D Wing Trailing Edge - Aileron Hinge 4 Joint 244,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-7557-53-13E Wing Trailing Edge - Aileron Hinge 5 Lug 133,000(5)57-53-13E Wing Trailing Edge - Aileron Hinge 5 Radius 244,000(5)57-53-13E Wing Trailing Edge - Aileron Hinge 5 Joint 244,000(5)57-53-14A Wing Trailing Edge - Aileron Actuator 1 Actuator Lug 133,000(5)57-53-14A Wing Trailing Edge - Aileron Actuator 1 Link Lug 133,000(5)57-53-14A Wing Trailing Edge - Aileron Actuator 1 Radius 244,000(5)57-53-14A Wing Trailing Edge - Aileron Actuator 1 Joint 244,000(5)57-53-14B Wing Trailing Edge - Aileron Actuator 2 Actuator Lug 133,000(5)57-53-14B Wing Trailing Edge - Aileron Actuator 2 Link Lug 133,000(5)57-53-14B Wing Trailing Edge - Aileron Actuator 2 Radius 244,000(5)57-53-14B Wing Trailing Edge - Aileron Actuator 2 Joint 244,000(5)57-54-07A MLG Mini-Cantilever Fitting Auxiliary-D Lower Lug 1FLS(5)57-54-07B MLG Mini-Cantilever Fitting Lower Skin Attachment 2FLS(5)57-54-08 MLG Beam Bridge Fitting Mini-Cantilever Fitting Attachment 1FLS(5)57-54-14 MLG Forward Trunnion Outboard Vertical Fitting Rear Spar Web attachment between Ribs 7 and 8 2FLS(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-76787 AIRWORTHINESS LIMITATIONSTABLE NOTES:1. Blank entries in table indicate fieldis not applicable for that PSE/Check Form.2. Multiple listings under a single PSE are uniquely identified byCheck Form Title, Location, andModel-Series information. All inspections listed under a singlePSE Number for a given model must be performed.3. C/L or L/N in DTR Check Form Title indicates forms pertaining only to specific airplane line numbers.4. Thresholds designated as "FLS" are sensitive to flight length; see Figure 1. All other values shown are in flight cycles.5. No airplane may be operated beyond 75% of the stated threshold (or operational limit) until the applicable inspection procedures are published in the appropriatemanual, validated, and accepted by the FAA. If the applicable published inspectionprocedure cannot be accomplished, an alternative FAA accepted procedure mustbe used.6. In addition to the stated flight cycle threshold, a calendarthreshold of 22 years from dateof aircraft delivery applies toall Supplemental Structural Fatigue Inspections.57-54-20 MLG Drag Brace Down Lock Support Fitting Outboard Main Lug 2FLS(5)57-54-21A MLG Drag Brace Shackle Support Fitting Critical Cross Section B-B 2FLS(5)57-54-21B MLG Drag Brace Shackle Support Fitting Critical Cross Section G-G 2FLS(5)57-54-21C MLG Drag Brace Shackle Support Fitting Tension fastener attaching to lower backup fitting 1FLS(5)57-70-01A Monolithic Inboard Spoiler Beam Inboard Spoiler Beam Upper Chord 133,000(5)57-70-01B Inboard Spoiler Beam Inboard joint 244,000(5)57-70-01C Inboard Spoiler Beam Outboard joint 2FLS(5)57-70-01D Inboard Spoiler Beam Auxiliary-D Attachment Inboard Spoiler Beam / Auxiliary-D attachment 133,000(5)57-70-02A Mid Spoiler Beam Mid-Spoiler Beam Upper Chord 133,000(5)57-70-02B Mid Spoiler Beam Mid-Spoiler Beam Auxiliary-D/Flap Support 3Attachments133,000(5)TABLE 1. AIRWORTHINESS LIMITATIONS – SUPPLEMENTAL STRUCTURAL FATIGUE INSPECTIONSPSE(2)DTR CHECK FORM TITLE(3)DTR LOCATION GROUPAPPLICABILITYTHRESHOLDS(1, 4, 6)787-8FEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-77D. AIRWORTHINESS LIMITATIONS – LIFE LIMITSSTRUCTURAL 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 presented in this subsectiondefines the safe life limits, as a function of accumulated flight cycles and flight hours, for the main and nose landing gear and support structure.Nomenclature for applicability of landing gear parts is given in Table 2.TABLE 2. AIRPLANE APPLICABILITY NOMENCLATURENote: “k” in the MTGW (Ref) column denotes (x 1000 pounds).The nose landing gear safe life test has been completed. Themain landing gear and support structure safe life test is currently in progress; the safe lifelimits presented here are based on test results to date.The carbon fiber reinforced plastic portion of the main landinggear drag brace (513Z3101, 513Z3102) and side brace (514Z3101,514Z3102) are certifiedas 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 and Table 4Column Heading787-8 ZA004 - ZA006, ZA100 - ZA102ZA151 - ZA152, ZA500 - ZA505ZA534 - ZA535486k 787-8787-8MI (Mission Improvement) ZA103 - ZA150, ZA153 - ZA499ZA506 - ZA533, ZA536 - ZA999503.5k 787-8MIFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-78787 AIRWORTHINESS LIMITATIONSInstructions 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 atthe appropriate flight cycles and flighthours and locate the intersection.3. If the point determined in Step 2 lies inside the Safe Life Limit Curve, the part has not reached the safe life limit. If the point is on, above, or to the rightof the Safe Life Limit Curve, then the safe life limit has beenexceeded. Operators must replace parts prior to exceeding thesafe life limits.LANDING GEAR AND SUPPORT STRUCTURESAFE-LIFE LIMITFAA EASA787-8 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 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-79Figure 2. 787-8 NOSE LANDING GEAR SAFE-LIFE LIMITSSee Table 3 for a listing of Life-Limited Nose Landing Gear Parts.FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-80787 AIRWORTHINESS LIMITATIONSFigure 3. 787-8 MAINLANDING GEAR TRUCK ASSEMBLY SAFE-LIFE LIMITS(TESTING IN PROGRESS)See Table 4 for a listing of Life-Limited Main Landing Gear Truck Assembly Parts.FEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-81Figure 4. 787-8 MAIN LANDING GEAR SHOCK STRUT ASSEMBLY SAFE-LIFE LIMITS (TESTING IN PROGRESS)See Table 4 for a listing of Life-Limited Main Landing Shock Strut Assembly Parts.1Note: The Retract Actuator Head End Fuse Pin (P/N 511Z3022) hasa life limit of 55,000 Flight Cycles (there is no Flight Hourlimitation associated with this part).FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-82787 AIRWORTHINESS LIMITATIONSFigure 5. 787-8 MAIN LANDING GEAR SIDE AND DRAG BRACE ASSEMBLIES SAFE-LIFE LIMITS (TESTING IN PROGRESS)See Table 4 for a listing of Life-Limited Main Landing Gear Side and Drag Brace Assembly Parts.FEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-83Figure 6. 787-8 MAIN LANDINGGEAR SUPPORT FITTINGS SAFE-LIFELIMITS (TESTING IN PROGRESS)1 MLG Beam Outboard Support, MLG Forward Trunnion Support, MLG Drag Brace Support55411, 410522000, 14667198000, 14667020004000600080001000012000140001600018000200000 20000 40000 60000 80000 100000 120000 140000 160000 180000 200000FLIGHT HOURS

FLIGHT CYCLE SAll Other PartsAll PartsActuator Sup't Ftg LugAll Parts ExceptRetract Actuator Support Fitting, 126Z2503All PartsRetract Actuator SupportFitting, 126Z25031See Table 4 for a listing of Life-LimitedMain Landing Gear Support Fitting Parts.FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-84787 AIRWORTHINESS LIMITATIONSFigure 7. 787-8 MAINLANDING GEAR BEAM ASSEMBLY SAFE-LIFE LIMITS(TESTING IN PROGRESS)45000, 045000, 333322000, 146670, 14667020004000600080001000012000140001600018000200000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000FLIGHT HOURS

FLIGHT CYCLE SSee Table 4 for a listing of Life-LimitedMain Landing Gear Beam Assembly Parts.FEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-85787 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 has a3.0 inch trail from theshock strut centerline to the axle centerline. The NLG steering ishydraulically-actuated with the ability to disengage for full castoring of the gear. The shockstrut consists of a gas-oil design using a tapered metering pinand orifice plate for absorption of landing energy. The shockstrut has a total available strokeof 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 dragbrace in conjunction with a lock link mechanism. The Lock Link assembly locks the landinggear 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 actuator is connected to theOuter 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 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-86787 AIRWORTHINESS LIMITATIONSFigure 8. NOSE LANDING GEAR OVERVIEWFEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-87Figure 9. NOSE LANDING GEAR GEOMETRYFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-88787 AIRWORTHINESS LIMITATIONSTABLE 3. NOSE LANDING GEAR – LIST OF SAFE-LIFE PARTS AND ASSEMBLIESPart Description Part Name Part NumberAirplane Applicability(Maximum Taxi Gross Weight – Reference Only)Notes787-8(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 End521Z3017-1 Pin, RetractionActuator, Head End521Z3018-1 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 SystemAssemblySteer 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 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-89TABLE 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 52xZxxxxx-2 is right side.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 through 9900.Lock Link Assembly Aft Lock Link 523Z3004-1, -2* 1Forward Lock Link 523Z3003-1 Pin, Lock Link Aircraft 523Z3015-1 Pin, Lock Link Apex 523Z3013-1 Shock Strut InternalComponentsOrifice 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 ASSEMBLIESPart Description Part Name Part NumberAirplane Applicability(Maximum Taxi Gross Weight – Reference Only)Notes787-8(486k)787-8MI(503.5k)SEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-90787 AIRWORTHINESS LIMITATIONS787 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. The MLG truck beamassembly measures 51 inches wide, wheel centerline to wheel centerline, by 57.5 inches long, axle centerline to axle centerline. The MLG is installed in theairplane with an initial rake angle of 7 degrees aft and a camberangle of 0.75 degree inboard. The shock strut is an air/oiltype design, which uses atapered 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 MLG geometry is shown inFigure 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 is down and locked:• 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 single member landing gearbeam 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 end of the gear beam isattached 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 link mechanism on each strut.The MLG retracts inboard about the trunnion centerline using a linear actuator connected betweena retract fitting that residesnear the mini cant fitting, andan integral lug on the inboard side of the outer cylinder barrel.The forward trunnion is connected to the rear spar at the forward trunnion fitting, which isrigidly mounted to the rear spar and allows the landing gear to rotate into the retracted position.FEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-91The MLG support fittings consisted of three major assemblies as shown in Figure 12: MLG Beam Outboard Support, Forward TrunnionSupport, and DragBrace Support Fittings.The general arrangement of the main landing gear beam assembly isshown in Figure 13. The MLG beam assembly consists of a MLGbeam, hanger link,an upper stabilizer brace, and a lower stabilizer brace. The MLG beamis approximately 160 incheslong 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 aircraft. The lower, inboard endof the MLG beam also attaches to the side brace. The outboardend of the MLG beam attaches toload distribution plates that also attach to a minicantilevered 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 of the MLG beam attaches tothe upper stabilizer brace, whilethe lower middle area ofthe MLG beam attachesto the lower stabilizer brace. Fuse pins areused to attach the stabilizerbraces to fittings on the rear spar.The MLG beam reacts loads at the aft trunnion and the side braceand transfers these loads into the body of the aircraft (through the hanger link) and intothe wing rear spar.FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-92787 AIRWORTHINESS LIMITATIONSFigure 10. MAIN LANDING GEAR OVERVIEWFEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-93Figure 11. MAIN LANDING GEAR GEOMETRYFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-94787 AIRWORTHINESS LIMITATIONSFigure 12. 787-8MAIN LANDING GEARSUPPORT FITTINGSMLG Fwd Trunnion Support AssemblyMLG Beam O/B Support AssemblyMLG Drag Brace Downlock Support FittingMLG Drag Brace Support FittingO/B Wing Rear SparUpFwdO/B(LH Wing Shown, RH Wing Opposite)FEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-95Figure 13. GENERAL ARRANGEMENTOF MAIN LANDING GEAR ASSEMBLYUpper Aft HangerLink Pin151Z2300Hanger LinkUpper ForwardHanger Link PinUpper StabilizerForward Pin151Z1321Upper StabilizerBraceAft Fitting151Z3301Upper Stabilizer Brace151Z1300Main Landing Gear BeamForward and AftLoad DistributionPlatesLower HangerLink PinMLG SideBrace InterfaceMLG Aft TrunnionInterface151Z3300Lower StabilizerBrace Aft Fitting151Z1320 LowerStabilizer BraceLower StabilizerForward PinUpOutboardForwardFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-96787 AIRWORTHINESS LIMITATIONSTABLE 4. MAIN LANDING GEAR – LISTOF SAFE-LIFE PARTS AND ASSEMBLIESPart Description Part NamePart NumberAirplane Applicability(Maximum Taxi Gross Weight – Reference Only)Notes787-8(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* 1MLG Shock StrutAssembly(See Figure 4 forSafe-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*2Torsion 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* 5Gland 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 SEP 2012787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-97MLG Side and DragBrace Assemblies(See Figure 5 forSafe-life limits)Spindle, Drag Brace 513Z3004-1 Pin, Shackle, Drag Brace 513Z3005-2,-3* 3Nut, 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* 4Spindle, 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 – LISTOF SAFE-LIFE PARTS AND ASSEMBLIESPart Description Part NamePart NumberAirplane Applicability(Maximum Taxi Gross Weight – Reference Only)Notes787-8(486k)787-8MI(503.5k)FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-98787 AIRWORTHINESS LIMITATIONSMLG BeamOutboard Support(See Figure 6 forSafe-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 ForwardTrunnion Support(See Figure 6 forSafe-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 – LISTOF SAFE-LIFE PARTS AND ASSEMBLIESPart Description Part NamePart NumberAirplane Applicability(Maximum Taxi Gross Weight – Reference Only)Notes787-8(486k)787-8MI(503.5k)FEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-99TABLE 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 side.Where non-paired part numbers are listed, the samepart 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 is the preferred spare forall 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 forSafe-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 – LISTOF SAFE-LIFE PARTS AND ASSEMBLIESPart Description Part NamePart NumberAirplane Applicability(Maximum Taxi Gross Weight – Reference Only)Notes787-8(486k)787-8MI(503.5k)FEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-100787 AIRWORTHINESS LIMITATIONSSTRUCTURES LIFE-LIMITED PARTSThe replacement times established for thelife-limited parts listed below result fromModel 787-8 airplane certification activities with the FAA and are part ofthe Airworthiness Limitations section of the Instructions for Continued Airworthiness.These maintenance actions are mandatory. These life limits may onlybe 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 shall be replaced withP/Ns 311Z6401-5 (Inner Pivot Pin) and 311Z6402-5 (Outer Pivot Pin). The P/N 311Z6401-5 and 311Z6402-5 pivot pins, and the correspondingInstallation Requirements Model P/N IR044Z0001-5 are not life-limited. Instructions for replacement of the pivot pins are provided in AMM 55-17-01.Service Bulletin 787-55-0001 provides warranty information and replacement instructions. The calendar life limit applies from date of airplane delivery.COMPONENTLIFE LIMITHorizontal Stabilizer Pivot Pins (LH & RH) as configured per Boeing InstallationRequirements Model (IR044Z0001-3):Inner Pivot Pin (311Z6401-3)Outer Pivot Pin (311Z6402-3)12,000 landings or 2,200 days, whichever comes firstSEP 2012787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-101SYSTEMS LIFE-LIMITED PARTSThe replacement times established for thelife-limited parts listed below result fromModel 787-8 airplane certification activities with the FAA and are part ofthe Airworthiness Limitations section of the Instructions for Continued Airworthiness.These maintenance actions are mandatory. These life limits may onlybe revised with the approval of the Seattle FAA ACO.Some of the component life limitsin this listing will be temporary, due to qualification testing or endurancetesting inadequacies at the time of airplanecertification, and will be removed when Boeing has satisfied the certificationrequirements for thesecomponents. Service Bulletins will be issued for someitems that will allow retrofit of a newcomponent that does not have a life limit.Calendar-based life limits apply from date of airplane delivery, unless otherwise noted.ITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANE1. Electrical Subsystems1a. RPDU Differential Protection CurrentTransformer7001044H02 Boeing is seeking a design solution for this componentthat will remove the lifelimit requirement. Whenavailable, a Service Bulletin will be issuedrecommending installation of the new part.8 Years 91b. Main and APU Battery EnclosureVent Burst DiscJS-0-0089-000All 787 Airplanes/Incorporation of Service BulletinB787-81205-SB500003-005,000 Flight Cycles 22. Environmental Controls2a. Supplemental Cooling Unit 7011015H02 Service Bulletin to be released for new part which willnot have this life limitation.4 Years Up to 4 maximum(2 basic, 2 optional)APR 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-102787 AIRWORTHINESS LIMITATIONS3. Flight Controls3a. Electro Mechanical Spoiler Actuator C99144-004 Service Bulletin (SB 787-27-0003) to be released fornew part which will not have this life limitation.12,000 Flight Cycles 43b. Power Drive Unit Gearbox P667A4001-01 ServiceBulletin (SB 787-27-0002) to be released fornew part which will not have this life limitation.24,000 Flight Cycles 24. Hydraulics4a.(i) Static-Dissipative Hydraulic Isolator CA489-06B Line Number (LN) 7-34. Full life expected rather thanthe life limit listed pendingcompletion of systemendurance tests.27,000 Flight Hours 1 LW Main Tank2 RW Main Tank1 RW Surge Tank4a.(ii) Static-Dissipative Hydraulic Isolator CA489-06D Line Number (LN) 35-54. Full life expected rather thanthe life limit listed pendingcompletion of systemendurance tests.27,000 Flight Hours 1 LW Main Tank2 RW Main Tank1 RW Surge TankLine Number (LN) 55 and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.1 LW Main Tank4b.(i) Static-Dissipative Hydraulic Isolator CA489-08C LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 5 LW Main Tank4 RW Main Tank2 Center Tank4b.(ii) Static-Dissipative Hydraulic Isolator CA489-08D Line Number (LN) 35-54. Full life expected rather thanthe life limit listed pendingcompletion of systemendurance tests.27,000 Flight Hours 5 LW Main Tank4 RW Main Tank2 Center TankLine Number (LN) 55 and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.5 LW Main Tank6 RW Main Tank1 RW Surge Tank2 Center Tank4c.(i) Static-Dissipative Hydraulic Isolator CA489-12B LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 1 LW Main Tank1 RW Main Tank3 Center TankITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANEJUL 2012787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-1034c.(ii) Static-Dissipative HydraulicIsolator CA489-12D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 1 LW Main Tank1 RW Main Tank3 Center Tank4d.(i) Static-Dissipative Hydraulic Isolator CA490-06B LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 1 LW Main Tank1 RW Main Tank4d.(ii) Static-Dissipative Hydraulic Isolator CA490-06D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 1 LW Main Tank1 RW Main Tank4e.(i) Static-Dissipative Hydraulic Isolator CA490-08C LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 1 Center Tank4e.(ii) Static-Dissipative Hydraulic Isolator CA490-08D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 1 Center Tank4f.(i) Static-Dissipative Hydraulic Isolator CA490-10B LN 7-34. Full life expectedrather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 1 Center Tank4f.(ii) Static-Dissipative Hydraulic Isolator CA490-10D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 1 Center Tank4g.(i) Static-Dissipative Hydraulic Isolator CA491-04B LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 1 LW Main Tank1 RW Main Tank4g.(ii) Static-Dissipative Hydraulic Isolator CA491-04D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 1 LW Main Tank1 RW Main Tank4h.(i) Static-Dissipative Hydraulic Isolator CA491-06B LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 6 LW Main Tank7 RW Main Tank4h.(ii) Static-Dissipative Hydraulic Isolator CA491-06D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 6 LW Main Tank7 RW Main TankITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANEJUL 2012D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-104787 AIRWORTHINESS LIMITATIONS4j.(i) Static-Dissipative Hydraulic Isolator CA491-08C LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 1 LW Main Tank4j.(ii) Static-Dissipative Hydraulic Isolator CA491-08D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 1 LW Main Tank4k.(i) Static-Dissipative Hydraulic Isolator CA491-10B LN 7-33. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 2 Center tank4k.(ii) Static-Dissipative HydraulicIsolator CA491-10D Line Number (LN) 34and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 2 Center tank4l.(i) Static-Dissipative Hydraulic Isolator CA491A-06B LN 7-34. Full lifeexpected rather than the life limitlisted pending completion of system endurance tests.27,000 Flight Hours 2 LW Surge Tank1 RW Surge Tank1 RW Dry Bay4l.(ii) Static-Dissipative Hydraulic Isolator CA491A-06D Line Number (LN) 35and on. Full life expected ratherthan the life limit listedpending completion of systemendurance tests.27,000 Flight Hours 2 LW Surge Tank1 RW Surge Tank1 RW Dry Bay5. Landing Gear5a.(i) Nose Wheel Steering Valve module 2-8300-4 Service Bulletin to be released for new part longbefore life limit. Will only impact a few early airplanes.13,750 Flight Cycles 15a.(ii) Nose Wheel Steering Valvemodule 2-8300-5 Service Bulletin to be released for new part longbefore life limit. Will only impact a few early airplanes.13,750 Flight Cycles 15b. Main Landing Gear Door UplockMechanism2-8325-4 (LH)2-8326-4 (RH)Limited to production LN 4-19. Service Bulletin to bereleased.13,750 Flight Cycles 2(1 for each Part No.)5c. Main Landing Gear Door UplockMechanism2-8325-50 (LH)2-8326-50 (RH)Limited to production LN 20 and on. Service Bulletin tobe released.13,750 Flight Cycles 2(1 for each Part No.)5d. Main Landing Gear Door UplockActuator2-8309-3 P/N 2-8309-4, which is not life-limited, is the preferredspare for P/N 2-8309-3. Boeing Service BulletinsB787-81205-SB320003-00 and B787-81205-SB320004-00 provide warranty information andreplacement instructions.3,500 Flight Cycles 2ITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANENOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-1056. Propulsion - Rolls Royce Trent 10006a. Primary Exhaust Nozzle 725Z4100-9 P/N 725Z4100-11, which is not life-limited, is thepreferred spare for P/N 725Z4100-9. Boeing ServiceBulletin B787-81205-SB780006 provides warrantyinformation and replacement instructions.5,300 Flight Cycles 26b. Primary ExhaustForward Centerbody725Z4200-7 P/N 725Z4200-11, whichis not life-limited, is thepreferred spare for P/N 725Z4200-7. Boeing ServiceBulletin B787-81205-SB780006 provides warrantyinformation and replacement instructions.5,300 Flight Cycles 26c. Primary Exhaust Nozzle –Lightweight725Z4100-5 P/N 725Z4100-11, whichis not life-limited, is thepreferred spare for P/N 725Z4100-5. Boeing ServiceBulletin B787-81205-SB780006 provides warrantyinformation and replacement instructions.5,300 Flight Cycles 26d. Primary ExhaustForward Centerbody – Lightweight725Z4200-9 P/N 725Z4200-11, whichis not life-limited, is thepreferred spare for P/N 725Z4200-9. Boeing ServiceBulletin B787-81205-SB780006 provides warrantyinformation and replacement instructions.5,300 Flight Cycles 27. Propulsion - Exhaust System General Electric GEnx-1B7a. Primary Exhaust Nozzle 721Z4100-7 Additional testing scheduled to develop full lifestructure allowables.5,300 Flight Cycles 27b. Primary Exhaust Nozzle 721Z4100-3 Additional testing scheduled to develop full lifestructure allowables.5,300 Flight Cycles 27c. Primary ExhaustForward Centerbody721Z4200-3 Additional testing scheduled to develop full lifestructure allowables.5,300 Flight Cycles 27d. Primary ExhaustForward Centerbody721Z4200-5 Additional testing scheduled to develop full lifestructure allowables.5,300 Flight Cycles 27e. Primary Exhaust Aft Centerbody 721Z4300-3 Additional testing scheduled to develop full lifestructure allowables.5,300 Flight Cycles 2ITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANEFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-106787 AIRWORTHINESS LIMITATIONS8. Propulsion – Thrust Reverser Actuation System (TRAS) – Trent 10008a.(i) Actuator, Locking 725Z3161-175 Service Bulletin to be released for new part which willnot have this life limitation.5,500 Flight Cycles 88a.(ii) Actuator, Locking 725Z3161-215 Service Bulletin to be released for new part which willnot have this life limitation.5,500 Flight Cycles 88b. T-PC Assy 725Z3161-211 Full life expectedrather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28c. Deploy Hose, Short 725Z3161-195 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28d. Deploy Tube 725Z3161-155 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 48e. Stow Tube 725Z3161-123 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28f. Stow Tube (LW T/R) 725Z3161-203 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28g. Stow Tube 725Z3161-125 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28h. Stow Tube (LW T/R) 725Z3161-205 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28j. Flexible Shaft, Side 720Z3161-179 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28k. Flexible Shaft, Side 720Z3161-181 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28l. Flexible Shaft, Crossover 725Z3161-207 Full lifeexpected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28m. Track Lock 725Z3161-177 Full life expectedrather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 2ITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANENOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-1078n. Feedback Unit 725Z3161-151 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28p. Feedback Unit 725Z3161-153 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 28q. Manual Drive Unit 720Z3161-167 Service Bulletin to be released for new part which willnot have this life limitation.5,500 Flight Cycles 48r. Hydraulic Control Unit 720Z3161-213 Full lifeexpected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29. Propulsion – Thrust Reverser Actuation System – GEnx-1B9a. Actuator, Locking 721Z3161-215 Service Bulletin to be released for new part which willnot have this life limitation.5,500 Flight Cycles 89b. T-PC Assy 721Z3161-211 Full life expectedrather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29c. Deploy Hose, Short 721Z3161-195 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29d. Deploy Tube 721Z3161-155 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 49e. Stow Tube 721Z3161-123 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29f. Stow Tube 721Z3161-125 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29g. Flexible Shaft, Side 720Z3161-179 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29h. Flexible Shaft, Side 720Z3161-181 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29j. Flexible Shaft, Crossover 721Z3161-207 Full lifeexpected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 2ITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANESEP 2012D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-108787 AIRWORTHINESS LIMITATIONS9k. Track Lock 721Z3161-177 Full life expectedrather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29l. Feedback Unit 721Z3161-151 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29m. Feedback Unit 721Z3161-153 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 29n. Manual Drive Unit 720Z3161-167 Service Bulletin to be released for new part which willnot have this life limitation.5,500 Flight Cycles 49p. Hydraulic Control Unit 720Z3161-213 Full life expected rather than the life limit listedpending completion of TRAS system endurance tests.5,500 Flight Cycles 210. Propulsion – Power Door Opening System (PDOS) – Trent 100010a. PDOS Power Pack 725Z3191-27 Additional testing scheduled to develop full life design. 27,500 Flight Cycles 210c. Thrust Reverser Hold Open Rod 725Z3192-9 Additional testing scheduled to develop full life design. 5,500 Flight Cycles 411. Propulsion – PDOS – GEnx-1B11a. PDOS Power Pack 725Z3191-27 Additional testing scheduled to develop full life design. 27,500 Flight Cycles 211c. Thrust Reverser Hold Open Rod 721Z3192-9 Additional testing scheduled to develop full life design. 5,500 Flight Cycles 412. Pressurized Doors12a. Emergency Power Assist System(EPAS) Pressure ReservoirAssembly41004654-4 P/N 41004654-5, which has no life limitation, is thepreferred spare for P/N 41004654-4.2 Years 8ITEMNUMBER LIFE LIMITED ITEM PART NUMBER APPLICABILITY SPECIFICATIONS LIFE LIMITQUANTITYPER AIRPLANEFEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-109E. OTHER AIRWORTHINESS LIMITATIONS – SYSTEMS AND STRUCTURESThese System and Structures Airworthiness Limitations are a result of Model 787-8 airplane certification activities with the U.S. FAA and are part of theAirworthiness Limitations section of the Instructions for Continued Airworthiness. These maintenance actions are mandatory. These AirworthinessLimitations may only be revised withthe approval of the Seattle FAA ACO.SYSTEM AIRWORTHINESSLIMITATION NO. 1INSPECTION OF THE FUEL OIL HEAT EXCHANGER FOLLOWING FUELTANK ENTRY – 787-8 AIRPLANES WITH TRENT 1000 ENGINES(FAA EXEMPTION 10199)1. Following center wing tank purging and maintenance activity inside the center wing fuel tank, perform the following tasks iffuel has been added to thecenter tank:a. Prior to accumulating 20 flight hours after fuel has been addedto the center tank, perform a borescope inspection for abnormal or significantcontamination of the left engine Fuel/Oil Heat Exchanger front face per AMM 79-21-11, Task 79-21-11-00A-280C-A. If abnormal orsignificant fuelsystem contamination is found, troubleshoot the source of the fuel system contamination.b. Prior to accumulating 40 flight hours after fuel has been addedto the center tank, perform a borescope inspection for abnormal or significantcontamination of the right engine Fuel/OilHeat Exchanger front face per AMM 79-21-11, Task 79-21-11-00A-280C-A. If abnormal or significant fuelsystem contamination is found, troubleshoot the source of the contamination and remove unacceptable contaminates from the fuelsystem.2. Following a left or right engine low pressure fuel filter replacement due to the ENG FUEL FILTER L(R) EICAS message, performthe following task:a. Perform a borescope inspection for abnormal or significant contamination of the correspondingengine Fuel/Oil Heat Exchangerfront face perAMM 79-21-11, Task 79-21-11-00A-280C-A. If abnormal or significant fuel systemcontamination is found,troubleshoot the sourceof the fuelsystem contamination.AUG 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-110787 AIRWORTHINESS LIMITATIONSOperation of a Model 787-8 airplane after December 31, 2016 is prohibited unless a modification to provide indication to the flight crew of gross fuelcontamination is installed in accordance with a method approved bythe Seattle FAA ACO. The FAA approval must specifically reference thisairworthiness limitation.SYSTEM AIRWORTHINESSLIMITATION NO. 2ENGINE OIL CONSUMPTION RATES – 787-8AIRPLANES WITH TRENT 1000 ENGINESThe approved maximum normal oil consumptionrate for the Trent 1000 engine installed on the Model 787-8 airplane has been established as 0.53 quart(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 maximum airplane fuel endurancedoes not exceed each installed engine'susable oil quantity, thereby preventing a common mode loss of all engine thrust. The maximum airplane fuelendurance is 26 flight hours and is calculated with the minimum crew, minimum equipment, no payload and the maximum quantity ofusable fuel withoutreserves. The engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity of oil consumed by the totalnumber 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 under a special flight permitauthorized under 14 CFR 21.197 and 21.199.AUG 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-111SYSTEM AIRWORTHINESSLIMITATION NO. 3INSPECTION OF THE FUEL PUMP STRAINER FOLLOWING CENTER WING FUEL TANK ENTRY – 787-8 AIRPLANES WITH GEnx-1B ENGINES(FAA EXEMPTION 10268)1. Following center wing fuel tank purging and maintenance activity inside the center wing fueltank, perform the following tasks if fuel has been added tothe center tank:a. After the next flight check for the presence of the ENG FUEL STRAINER L(R) EICAS status message and interrogate the Central MaintenanceComputing Function (CMCF) to check for the presence of the FUEL BOOST STRAINER L(R) impending bypass maintenance message.Troubleshoot the source of the fuel systemcontamination if the messages are present.b. Prior to accumulating 20 flight hours after fuel has been addedto the center tank, perform the Main Fuel Pump Strainer Inspection procedure onthe left engine per AMM 73-11-04, Task 73-11-04-00B-280A-A. Collect any material removed from the fuel pump strainer to troubleshoot thesource of the fuel system contamination.c. Prior to accumulating 40 flight hours after fuel has been addedto the center tank, perform the Main Fuel Pump Strainer Inspection procedure onthe right engine per AMM 73-11-04, Task 73-11-04-00B-280A-A. Collect any material removed from the fuel pump strainer to troubleshoot thesource of the fuel system contamination.If the ENG FUEL STRAINER L(R) EICAS statusmessage or the FUEL BOOST STRAINER L(R) impending bypass maintenance message is present, or ifabnormal or significant contamination is found on the fuel pumpstrainer, troubleshoot the source of the fuel system contamination. Fuel systemcontamination troubleshooting requires removal of the Main Fuel/Oil Heat Exchanger per AMM 79-21-01, Task 79-21-01-00A-520A-A,and visual inspectionfor 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 flight crew of gross fuelcontamination is installed in accordance with a method approved bythe Seattle FAA ACO. The FAA approval must specifically reference thisairworthiness limitation.AUG 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-112787 AIRWORTHINESS LIMITATIONSSYSTEM AIRWORTHINESSLIMITATION NO. 4ENGINE OIL CONSUMPTION RATES – 787-8 AIRPLANES WITHGEnx-1B ENGINESThe approved maximum normal oil consumptionrate for the GEnx-1B engine installed on the Model 787-8 airplane has been established as 0.45 quart(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 maximum airplane fuel endurancedoes not exceed each installed engine'susable oil quantity, thereby preventing a common mode loss of all engine thrust. The maximum airplane fuelendurance is 25 flight hours and is calculated with the minimum crew, minimum equipment, no payload and the maximum quantity ofusable fuel withoutreserves. The engine oil consumption rate is normally calculated over a period of 10 to 20 flights by dividing the total quantity of oil consumed by the totalnumber 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 under a special flight permitauthorized under 14 CFR 21.197 and 21.199.SYSTEM AIRWORTHINESSLIMITATION NO. 5ENGINE POST-SHUTDOWN FUELVAPOR 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 eliminate Engine Post-shutdownFuel 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, 75,77, 82, and 84 were deliveredwith engines that must have GE’s GEnx-1B S/B 73-0011 incorporated before December 31, 2014.• Engine ApplicabilityGEnx-1B Engines that must have GE’s GEnx-1B S/B 73-0011 incorporated prior to December 31, 2014: GEnx-1B Engines Serial Numbers956102 through956106, 956109 through 956130, 956140 through 956151, 956154,956155, 956157, 956160 through 956169, 956171 through 956178, 956181 through956188, 956192, 956194 through 956196.APR 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-113STRUCTURES AIRWORTHINESS LIMITATION NO. 1Background: The 787-8 fuel tank access doors are compliant with 25.963 as impact resistant doors are installed in locations where they could be subject totire or engine fragment impacts. In addition to clear marking,the 787 doors were designed to have a physical barrier preventing non-impact doors beinginstalled in locations requiring impact resistant doors. Due to a design change, early 787-8 Line Numbers had the physical features omitted. These physicalfeatures are being reincorporated into production units, beginning at Line Number 60. All units have the stencilling and correct door installation at time ofdelivery. 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 mainand center fuel tank access door removal and re-installation.• 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 access door is required.Mitigations: At the specified inspectioninterval and when fuel tank access doors have been removed and installed:1. Identify required main tank impact resistant door locationsin accordance with Boeing AMM B787-A-28-11-01-00A-520A-A (all door locations inboard ofthe engine nacelle).2. Verify that all impact resistant doors have the stencil "IMPACT RESISTANT DOOR" applied to the exterior surface as shown in accordance with BoeingAMM B787-A-28-11-01-00A-520A-A.3. Verify that all impact resistant doors each have 24 fastenerholes as shown in accordance with Boeing AMM B787-A-28-11-01-00A-520A-A.NOTE: All fuel tank access hole locations outboard of the engine nacelle contain non-impact resistant doors that have 23 fastener holes or less.NOV 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-114787 AIRWORTHINESS LIMITATIONSCenter 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 access door is required.Mitigations: At the specified inspectioninterval 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 (all door locations inboardof the engine nacelle).2. Verify that all impact resistant doors have the stencil "IMPACT RESISTANT DOOR" applied to the exterior surface in accordancewith BoeingAMM B787-A-28-11-02-00A-520A-A.3. Verify that all impact resistant doors each have 24 fastenerholes as shown in accordance with Boeing AMM B787-A-28-11-02-00A-520A-A.NOTE: All fuel tank access hole locations outboard of the engine nacelle contain non-impact resistant doors that have 23 fastener holes or less.NOV 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-115STRUCTURES AIRWORTHINESS LIMITATION NO. 2Background: The main landing gear forward trunnion support upperhousing increases the verticalfusing capability of the forward trunnion of the mainlanding gear. Four bearing pads are located between the main landing gear forward trunnion upper housing and the main landinggear forward trunnionhousing and are attached to the upper housing. During fatiguetesting, at approximately 22,000 flight-cycles, the bearing padswere found partially migratedand retaining features were found fractured. The loss of the bearing pads from between the main landing gear forward trunnionupper housing and the mainlanding gear forward trunnion housing will reduce the vertical fusing capability of the forward trunnionof the mainlanding gear. This could result in thepremature fusing and loss of the main landing gear during a take-off roll with an airplane at maximum take-off weight. The highest vertical loadsexperienced by the landing gear are during take-off roll with anairplane at maximum take-off weight and certain runway conditions. The loss of the mainlanding gear would result in significant damage to the surrounding structure.Support Fitting Bearing Pad, Main Landing Gear Forward Trunnion Inspection• Threshold: 2 YR/3,500 Flight Cycles (whichever comes first)• Interval: 2 YR/3,500 Flight Cycles (whichever comes first)• Airplane Applicability: 787-8 Production Line Numbers 7, 8, 9, 23, 24, 29, 31,33, 35, 37, 38, 40, 41,42, 46, 47, 48, 51, 54,56, and 60, unless terminatingaction 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 betweenthe main landing gear forward trunnion upper housing and forwardtrunnion housing formigrated or missing bearing pads. For inspection zone and access reference, see D011Z009-03 MPD Section 2, Item Number 57-522-00 (TaskCard 57-522-01).SEP 2012D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-116787 AIRWORTHINESS LIMITATIONSAPPENDIX A. POST-THRESHOLD INTERVALS FOR STRUCTURES AND ZONAL TASKSThis appendix provides operators the intervals for selected structures and zonal tasksof the 787 MPD, Document D011Z009-03, Sections 2 and 3,respectively. Included here arethose tasks which provide sufficient fatigue damage detectionopportunity forPSEs to completely satisfy the requirements of14 CFR 25.571. The intervals indicated for each task are those that must be used upon the airplane reaching the supplementalfatigue inspectionthreshold, as these were the intervals defined at original type certification utilized to satisfy the damage tolerance requirements of 14 CFR 25.571. Whileescalation is not permitted at this time, this appendix providesthe operator with a convenient reference to the required post-threshold intervals if MPDSection 2 and 3 tasks are allowed to be escalated in the future. The items listed below must use the post-threshold repeat interval upon reaching thedefined 787-8 threshold of 44,000 flight cycles or 22 years, whichever occurs first. This is necessary in order to ensure themaintenance program complieswith the damage tolerance requirements for the 787 aircraft.MRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat Interval27-300-00 Horizontal Stabilizer Ballscrew, Primary and Secondary Ball Nuts DET 2000 FH12 MO32-815-01 Left Main Landing Gear and Landing Gear Doors EXT - ZON (GV) 3 YR32-825-02 Right Main Landing Gear and Landing Gear Doors EXT - ZON (GV) 3 YR52-500-00 Bulk Cargo Compartment DoorEXT - DET 6000 FC3 YR52-502-00 Bulk Cargo Compartment DoorINT - DET 24000 FC12 YR52-504-00 Forward Large Cargo Compartment DoorEXT - DET 6000 FC3 YR52-506-00 Forward Large Cargo Compartment DoorINT - DET 24000 FC12 YR52-508-00 Aft Large Cargo Compartment DoorEXT - DET 6000 FC3 YROCT 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-11752-510-00 Aft Large Cargo Compartment DoorINT - DET 24000 FC12 YR52-512-00 Upper Half of Fuselage, Left Side(Passenger Entry Doors) INT - DET 24000 FC12 YR52-512-01 Upper Half of Fuselage, Left Side (Passenger Entry Doors) Stop Fittings EXT - DET 6000 FC3 YR52-514-00 Upper Half of Fuselage, Right Side(Passenger Entry Doors) INT - DET 24000 FC12 YR52-514-01 Upper Half of Fuselage, Right Side (Passenger Entry Doors) Stop Fittings EXT - DET 6000 FC3 YR52-805-01 Bulk Cargo DoorEXT - ZON (GV) 3 YR52-815-02 Forward Cargo Compartment DoorEXT - ZON (GV) 3 YR52-820-02 Forward Cargo Compartment DoorINT - ZON (GV) 12 YR52-825-02 Aft Cargo Compartment DoorEXT - ZON (GV) 3 YR52-830-02 Aft Cargo Compartment DoorINT - ZON (GV) 12 YR52-835-01 Left No. 1 Entry Door - Section 41EXT - ZON (GV) 3 YR52-840-01 Left No. 1 Entry Door - Section 41INT - ZON (GV) 12 YR52-845-01 Left No. 2 Entry Door - Section 43EXT - ZON (GV) 3 YR52-850-01 Left No. 2 Entry Door - Section 43INT - ZON (GV) 12 YR52-855-01 Left No. 3 Entry Door - Section 46EXT - ZON (GV) 3 YR52-860-01 Left No. 3 Entry Door - Section 46INT - ZON (GV) 12 YR52-865-01 Left No. 4 Entry Door - Section 47EXT - ZON (GV) 3 YR52-870-01 Left No. 4 Entry Door - Section 47INT - ZON (GV) 12 YR52-875-02 Right No. 1 Entry Door - Section 41EXT - ZON (GV) 3 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-118787 AIRWORTHINESS LIMITATIONS52-880-02 Right No. 1 Entry Door - Section 41INT - ZON (GV) 12 YR52-885-02 Right No. 2 Entry Door - Section 43EXT - ZON (GV) 3 YR52-890-02 Right No. 2 Entry Door - Section 43INT - ZON (GV) 12 YR52-895-02 Right No. 3 Entry Door - Section 46EXT - ZON (GV) 3 YR52-900-02 Right No. 3 Entry Door - Section 46INT - ZON (GV) 12 YR52-905-02 Right No. 4 Entry Door - Section 47EXT - ZON (GV) 3 YR52-910-02 Right No. 4 Entry Door - Section 47INT - ZON (GV) 12 YR53-500-00 Body Station 63.55 to Body Station 338.50INT - DET 24000 FC12 YR53-502-00 Nose Landing Gear Wheel WellINT - DET 24000 FC12 YR53-504-00 Nose Landing Gear Wheel WellEXT - DET 12000 FC6 YR53-506-00 Body Station 338.50 to Body Station 873.00, Stringer 22L to BL 0 INT - DET 24000 FC12 YR53-507-00 Forward Cargo Compartment, RightEXT - DET 6000 FC3 YR53-508-00 Body Station 338.50 to Body Station 873.00, Stringer 22R to BL 0 INT - DET 24000 FC12 YR53-510-00 Forward Keel Beam, BS 867.0 to BS 1077.0INT - DET 12000 FC6 YR53-512-00 Area Above Center Wing Section, Left & Right INT - DET 24000 FC12 YR53-514-00 Keel Beam, Mid Section (BS 1073.0 to BS 1209) EXT - DET 12000 FC6 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalFEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-11953-516-00 Area Above Main Landing Gear Wheel Well, Left & Right INT - DET 24000 FC12 YR53-518-00 Main Landing Gear (MLG) Wheel Well, Left & Right EXT - DET 12000 FC6 YR53-520-00 Aft EE Bay, Left & RightINT - SDET 24000 FC12 YR53-522-00 Aft Cargo Compartment & Area BelowAft Cargo Compartment, Left INT - DET 24000 FC12 YR53-524-00 Aft Cargo Compartment & Area BelowAft Cargo Compartment, Right INT - DET 24000 FC12 YR53-526-00 Aft Cargo Compartment & Area BelowAft Cargo Compartment, Right EXT - DET 12000 FC6 YR53-528-00 Bulk Cargo Compartment, Area BelowBulk Cargo Compartment & Area Aft of BulkCargo Compartment, Left INT - DET 24000 FC12 YR53-530-00 Bulk Cargo Compartment, Area BelowBulk Cargo Compartment & Area Aft of BulkCargo Compartment, Left EXT - DET 12000 FC6 YR53-532-00 Bulk Cargo Compartment, Area BelowBulk Cargo Compartment & Area Aft of BulkCargo Compartment, Right INT - DET 24000 FC12 YR53-534-00 Wing to Body Forward & Overwing Fairing, Left INT - DET 24000 FC12 YR53-536-00 Wing to Body Forward & Overwing Fairing, Right INT - DET 24000 FC12 YR53-538-00 Wing to Body Underwing & Aft Fairing, LeftINT - DET 24000 FC12 YR53-540-00 Wing to Body Underwing & Aft Fairing, RightINT - DET 24000 FC12 YR53-542-00 Flight Deck, Left & RightINT - DET 24000 FC12 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-120787 AIRWORTHINESS LIMITATIONS53-544-00 Passenger Compartment, LeftINT - DET 24000 FC12 YR53-546-00 Passenger Compartment, LeftEXT - DET 12000 FC6 YR53-547-00 Passenger Compartment, LeftINT - GEN 24000 FC12 YR53-548-00 Passenger Compartment, RightINT - DET 24000 FC12 YR53-550-00 Passenger Compartment, RightEXT - DET 12000 FC6 YR53-551-01 Passenger Compartment, RightINT - GEN 24000 FC12 YR53-552-00 Area Above Passenger Compartment, Left & Right INT - DET 24000 FC12 YR53-553-00 Area Above Passenger Compartment, Left & Right INT - GEN 24000 FC12 YR53-554-00 Passenger Compartment, LeftINT - DET 24000 FC12 YR53-555-00 Passenger Compartment, LeftINT - GEN 24000 FC12 YR53-556-00 Passenger Compartment, RightINT - DET 24000 FC12 YR53-557-00 Passenger Compartment, RightINT - GEN 24000 FC12 YR53-558-00 Area Above Passenger Compartment, Left & Right INT - DET 24000 FC12 YR53-559-00 Area Above Passenger Compartment, Left & Right INT - GEN 24000 FC12 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-12153-560-00 Passenger Compartment, LeftINT - DET 24000 FC12 YR53-562-00 Passenger Compartment, LeftEXT - DET 12000 FC6 YR53-563-00 Passenger Compartment, LeftINT - GEN 24000 FC12 YR53-564-00 Passenger Compartment, RightINT - DET 24000 FC12 YR53-566-00 Passenger Compartment, RightEXT - DET 12000 FC6 YR53-567-00 Passenger Compartment, RightINT - GEN 24000 FC12 YR53-568-00 Area Above Passenger Compartment, Left & Right INT - DET 24000 FC12 YR53-569-00 Area Above Passenger Compartment, Left & Right INT - GEN 24000 FC12 YR53-803-00 Lower Half of the FuselageEXT - ZON (GV) 3 YR53-806-00 RadomeINT - ZON (GV) 6 YR53-809-00 Areas Forward, Above, and Outboardof the NLG Wheel Well INT - ZON (GV) 6 YR53-812-00 Areas Forward, Above, and Outboardof the NLG Wheel Well INT - ZON (GV) 12 YR53-815-00 Nose Gear Wheel Well - as viewed from the ground EXT - ZON (GV) 6 MO53-818-00 Nose Gear Wheel Well - as viewedfrom within the Wheel Well INT - ZON (GV) 3 YR53-822-00 Forward Electronic Equipment BayINT - ZON (GV) 12 YR53-827-00 Forward Cargo CompartmentINT - ZON (GV) 12 YR53-830-00 Areas Below Forward Cargo Compartment Floor INT - ZON (GV) 6 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-122787 AIRWORTHINESS LIMITATIONS53-834-00 Environmental Control SystemDistribution Bay INT - ZON (GV) 12 YR53-836-00 Keel Beam Area from BS 849 to BS 1382INT - ZON (GV) 6 YR53-839-00 Areas Above the Wing Center Section and Below the Passenger Floor Panels INT - ZON (GV) 12 YR53-842-00 Wing Center SectionINT - ZON (GV) 12 YR53-854-01 Left Main Landing Gear Wheel Well - as viewed from within the Wheel Well INT - ZON (GV) 3 YR53-860-02 Right Main Landing Gear Wheel Well - as viewed from within the Wheel Well INT - ZON (GV) 3 YR53-863-00 Aft Electronic Equipment BayINT - ZON (GV) 6 YR53-869-00 Aft Cargo CompartmentINT - ZON (GV) 12 YR53-872-00 Areas Below the Aft Cargo Compartment Floor Panels INT - ZON (GV) 6 YR53-878-00 Bulk Cargo CompartmentINT - ZON (GV) 12 YR53-885-00 Areas Aft of the Bulk Cargo CompartmentINT - ZON (GV) 12 YR53-888-01 Forward Wing to Body Fairing Area - LeftINT - ZON (GV) 6 YR53-891-02 Forward Wing to Body Fairing Area - Right INT - ZON (GV) 6 YR53-894-01 Wing to Body Overwing Fairing - LeftINT - ZON (GV) 12 YR53-897-02 Wing to Body Overwing Fairing - RightINT - ZON (GV) 12 YR53-912-00 Upper Half of the Fuselage, Section 41 through 47, BS 232.5 to BS 1878, Floor WL 200 to Top of FuselageCenterline BL 0EXT - ZON (GV) 6 YR53-924-00 Passenger Compartment - Section 41BS 232.5 to BS 597 INT - ZON (GV) 6 YR53-930-00 Overhead Flight Crew Rest Compartment - Section 41 INT - ZON (GV) 6 YR53-976-00 External - Fuselage Area Aft ofthe Pressure Bulkhead EXT - ZON (GV) 6 YR53-977-00 Internal - Fuselage Area Aft of the Pressure Bulkhead INT - ZON (GV) 6 YR53-978-00 APU Compartment - Body Section 48EXT - ZON (GV) 6 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-12353-984-00 APU CompartmentINT - ZON (GV) 3 YR54-500-00 Powerplant Left - Forward andAft Engine Mount (GEnx) INT - DET ENG CNG54-502-00 Powerplant Left - Forward and AftEngine Mount (Trent 1000) INT - DET ENG CNG54-504-00 Powerplant Right - Forward and Aft Engine Mount (GEnx) INT - DET ENG CNG54-506-00 Powerplant Right - Forward and AftEngine Mount (Trent 1000) INT - DET ENG CNG54-508-00 Forward Nacelle Pylon FairingINT - DET 12000 FC6 YR54-510-00 Pylon Forward & Aft Torque Box - Left Nacelle Pylon (GEnx) INT - DET ENG CNG54-512-00 Pylon Forward & Aft Torque Box - Left Nacelle Pylon (Trent 1000) INT - DET ENG CNG54-514-00 Aft Pylon FairingINT - DET 12000 FC6 YR54-516-00 Aft Pylon FairingINT - DET 24000 FC12 YR54-518-00 Forward Nacelle Pylon FairingINT - DET 12000 FC6 YR54-520-00 Pylon Forward & Aft Torque Box - Right Nacelle Pylon (GEnx) INT - DET ENG CNG54-522-00 Pylon Forward & Aft Torque Box - Right Nacelle Pylon (Trent 1000) INT - DET ENG CNG54-524-00 Aft Pylon FairingINT - DET 12000 FC6 YR54-526-00 Aft Pylon FairingINT - DET 24000 FC12 YR54-815-01 Forward Torque Box - Left Nacelle StrutEXT - ZON (GV) 3 YR54-820-01 Forward Torque Box - Left Nacelle StrutINT - ZON (GV) 3 YR54-825-01 Aft Torque Box - Left Nacelle StrutEXT - ZON (GV) 3 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-124787 AIRWORTHINESS LIMITATIONS54-830-01 Aft Torque Box - Left Nacelle StrutINT - ZON (GV) 3 YR54-855-02 Forward Torque Box - Right Nacelle Strut EXT - ZON (GV) 3 YR54-860-02 Forward Torque Box - Right Nacelle StrutINT - ZON (GV) 3 YR54-865-02 Aft Torque Box - Right Nacelle StrutEXT - ZON (GV) 3 YR54-870-02 Aft Torque Box - Right Nacelle StrutINT - ZON (GV) 3 YR54-890-01 Forward Nacelle Strut Fairing - Left Nacelle Strut INT - ZON (GV) 3 YR54-895-01 Forward Torque Box - Left Nacelle StrutEXT - ZON (GV) 3 YR54-900-01 Forward Torque Box - Left Nacelle StrutINT - ZON (GV) 3 YR54-905-01 Aft Torque Box - Left Nacelle StrutEXT - ZON (GV) 3 YR54-910-01 Aft Torque Box - Left Nacelle StrutINT - ZON (GV) 3 YR54-935-02 Forward Nacelle Strut Fairing - Right Nacelle Strut INT - ZON (GV) 3 YR54-940-02 Forward Torque Box - Right Nacelle Strut EXT - ZON (GV) 3 YR54-945-02 Forward Torque Box - Right Nacelle StrutINT - ZON (GV) 3 YR54-950-02 Aft Torque Box - Right Nacelle StrutEXT - ZON (GV) 3 YR54-955-02 Aft Torque Box - Right Nacelle StrutINT - ZON (GV) 3 YR55-500-00 Fuselage Body Section 48INT - DET 24000 FC12 YR55-502-00 Fuselage Body Section 48EXT - DET 24000 FC12 YR55-504-00 Fuselage Body Section 48EXT - DET 12000 FC6 YR55-506-00 Vertical Stabilizer, Front Spar to Rear SparINT - SDET 24000 FC12 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-12555-508-00 Vertical Stabilizer, Front Spar to Rear SparEXT - SDET 6000 FC3 YR55-510-00 Vertical Stabilizer, Rear Spar to Trailing Edge INT - DET 12000 FC6 YR55-512-00 RudderINT - DET 12000 FC6 YR55-514-00 RudderINT - SDET 24000 FC12 YR55-516-00 Horizontal Stabilizer Center Section, Left & Right INT - SDET 24000 FC12 YR55-516-01 Horizontal Stabilizer Center Section, Left & Right INT - SDET 24000 FC12 YR55-518-00 Horizontal Center Section, Left & RightEXT - DET 12000 FC6 YR55-520-00 Horizontal Center Section, Left & RightEXT - DET 24000 FC12 YR55-522-00 Left Horizontal Stabilizer, Front Spar to Rear Spar INT - DET 12000 FC6 YR55-524-00 Left Horizontal Stabilizer, Front Spar to Rear Spar INT - SDET 24000 FC12 YR55-526-00 Left Horizontal Stabilizer, Rear Spar to Trailing Edge INT - DET 12000 FC6 YR55-528-00 Left Horizontal Stabilizer, Rear Spar to Trailing Edge INT - DET 24000 FC12 YR55-530-00 Left ElevatorINT - DET 12000 FC6 YR55-532-00 Left ElevatorINT - SDET 24000 FC12 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-126787 AIRWORTHINESS LIMITATIONS55-534-00 Right Horizontal Stabilizer, Front Spar to Rear Spar INT - DET 12000 FC6 YR55-536-00 Right Horizontal Stabilizer, Front Spar to Rear Spar INT - SDET 24000 FC12 YR55-538-00 Right Horizontal Stabilizer, Rear Spar to Trailing Edge INT - DET 12000 FC6 YR55-540-00 Right Horizontal Stabilizer, Rear Spar to Trailing Edge INT - DET 24000 FC12 YR55-542-00 Right ElevatorINT - DET 12000 FC6 YR55-544-00 Right ElevatorINT - SDET 24000 FC12 YR55-809-00 Vertical Stabilizer Auxiliary Spar to Rear Spar EXT - ZON (GV) 6 YR55-812-00 Vertical Stabilizer Auxiliary Spar to Front Spar INT - ZON (GV) 12 YR55-821-00 Vertical Stabilizer Rear Spar to Trailing Edge EXT - ZON (GV) 6 YR55-824-00 Vertical Stabilizer Rear Spar to Trailing Edge INT - ZON (GV) 12 YR57-500-00 Wing Center Section, Left and RightINT - DET 24000 FC12 YR57-502-00 Leading Edge to Front Spar -Inboard of Canted Rib INT - DET 24000 FC12 YR57-504-00 Leading Edge to Front Spar - Outboard of Canted Rib INT - DET 24000 FC12 YR57-506-00 Center Fuel TankINT - DET 24000 FC12 YR57-508-00 Center Fuel Tank, Dry Bay, Main TankINT - DET 24000 FC12 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalSEP 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-12757-510-00 Main TankINT - DET 24000 FC12 YR57-512-00 Main TankINT - DET 24000 FC12 YR57-514-00 Surge Tank, Inspar AreaINT - DET 24000 FC12 YR57-515-00 Surge Tank, Inspar AreaINT - DET 12000 FC6 YR57-516-00 Wing Tip - Rib 40 to Closure RibINT - SDET 24000 FC12 YR57-517-00 Inboard and Outboard Wing Trailing EdgeINT - DET 24000 FC12 YR57-518-00 Rear Spar to Landing Gear SupportBeam to Trailing Edge INT - DET 12000 FC6 YR57-520-00 Rear Spar to Landing Gear Support BeamEXT - DET 12000 FC6 YR57-522-00 Rear Spar to Landing Gear Support BeamINT - DET 24000 FC12 YR57-526-00 Landing Gear Support Beam to Trailing Edge INT - DET 24000 FC12 YR57-528-00 Inboard Flap, Left WingINT - SDET 24000 FC12 YR57-532-00 Outboard Flap, Left WingINT - SDET 24000 FC12 YR57-534-00 Aileron, Left WingINT - SDET 24000 FC12 YR57-536-00 Leading Edge to Front SparINT - DET 24000 FC12 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-128787 AIRWORTHINESS LIMITATIONS57-538-00 Leading Edge to Front SparINT - DET 24000 FC12 YR57-540-00 Center Fuel TankINT - DET 24000 FC12 YR57-542-00 Center Fuel Tank, Dry Bay, Main TankINT - DET 24000 FC12 YR57-544-00 Main TankINT - DET 24000 FC12 YR57-546-00 Main TankINT - DET 24000 FC12 YR57-548-00 Surge Tank, Inspar AreaINT - DET 24000 FC12 YR57-549-00 Surge Tank, Inspar AreaINT - DET 12000 FC6 YR57-550-00 Wing TipINT - SDET 24000 FC12 YR57-551-00 Inboard and Outboard Wing Trailing EdgeINT - DET 24000 FC12 YR57-552-00 Rear Spar to Landing Gear SupportBeam to Trailing Edge INT - DET 12000 FC6 YR57-554-00 Rear Spar to Landing Gear Support BeamEXT - DET 12000 FC6 YR57-556-00 Rear Spar to Landing Gear Support BeamINT - DET 24000 FC12 YR57-560-00 Landing Gear Support Beam to Trailing Edge INT - DET 24000 FC12 YR57-562-00 Inboard Flap, Right WingINT - SDET 24000 FC12 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalFEB 2013787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-12957-566-00 Outboard Flap, Right WingINT - SDET 24000 FC12 YR57-568-00 Aileron, Right WingINT - SDET 24000 FC12 YR57-826-01 Left Wing Inspar Area (Fuel Tanks), Upper and LowerWing – Inboard of Wing BL 860 (Rib 32) to Wing to BodyFairingsEXT - ZON (GV) 6 YR57-830-01 Dry Bay - Left WingINT - ZON (GV) 12 YR57-834-01 Wing Inspar Area Outboard of Rib 32 to Rib40 – Upper and Lower Wing – Left Wing EXT - ZON (GV) 6 YR57-854-01 Inboard Trailing Edge Flap – Left WingEXT - ZON (GV) 3 YR57-866-01 Outboard Trailing Edge Flap – Left WingEXT - ZON (GV) 6 YR57-870-01 Outboard Aileron – Left WingEXT - ZON (GV) 6 YR57-920-02 Right Wing Inspar Area (Fuel Tanks), Upper and Lower Surfaces – Inboard of Wing BL 860 (Rib 32) to Wing toBody FairingsEXT - ZON (GV) 6 YR57-924-02 Right Wing Dry BayINT - ZON (GV) 12 YR57-928-02 Wing Inspar Area Outboard of Rib 32 to Rib 40– Upper and Lower Surfaces – Right Wing EXT - ZON (GV) 6 YR57-948-02 Inboard Trailing Edge Flap – Right WingEXT - ZON (GV) 3 YR57-960-02 Outboard Trailing Edge Flap – Right Wing EXT - ZON (GV) 6 YR57-964-02 Outboard Aileron – Right WingEXT - ZON (GV) 6 YRMRB / MPDItem Number Task Description Inspection LevelPost-ThresholdRepeat IntervalFEB 2013D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-130787 AIRWORTHINESS LIMITATIONSAPPENDIX B. DISCREPANTSTRUCTURE REPORT FORMDiscrepant Structure Report Forms are required for the reporting ofall significant structural discrepancies found on all inspection tasks identified by a “F” ofthe fatigue program in D011Z009-03, Section 2. Should any operator or Boeing desire a change in the reporting procedure, they may request a meeting ofall 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 2011787 AIRWORTHINESS LIMITATIONSD011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-131SEP 2011D011Z009-03-01BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-132787 AIRWORTHINESS LIMITATIONS 

# DISCREPANT STRUCTURE REPORT SIDE 2

7. DISCREPANCY DISCRIPTION: _____________________________________________________________________________________________

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________

_________________________________________________________________________________________________________________________ Attach sketch, photos, and text as required to describe defect and specific location. When applicable give details of

associated discrepancies on the same aircraft, related experience with this discrepancy on any aircraft, and previous

modification(s) to the discrepant structure.



# 7 A

. T Y P E O F D I S C R E P A N C Y :

B E N T

B R O K E N

B U C K L E D

B U R N E D

C L O G G E D



# 7B. SIZE OF DISCREPANCY: INCHES, OR CENTIMETERS

AREA ___________________ X _____________________________________ DEPTH_____________________

CRACK LENGTH INITIALLY DETECTED ____________________________________ DATE________________

FINAL MEASUREMENT (IF DIFFERENT) ____________________________________ DATE________________

7C. DISCREPANT PART:

FRAME/BULKHEAD

PRESSURE BULKHEAD

FRAME AROUND OPENING

WINDOW FORGING

KEEL BEAM

FLOOR

WING CENTER SECTION

WING DRY-BAY AREA/COMPT.

SPAR

RIB

LANDING GEAR BEAM

FLAP TRACK

FAIRING

________________________ CONTAMINATED

CORRODED

CRACKED

DEFORMED

DELAMINATED DENTED

DETACHED

IMPROPERLY

ADJUSTED

LEAK LOOSE

MISSING

OUT-OF-TOLERANCE

STUCK

WORN WRINKLED

___________

___________

___________

S K I N

P L A T E / P A N E L

CHO RD

S T RI NG E R NO

. B E A M

S T RUT / B RA CE

L I NK / RO D

L O NG E RO N

F I T T I NG

B RA CK E T / CL I P

S T O P

F A S T E NE R

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J O I NT / S P L I CE

L UG

W E L D

B O ND

O P E N HO L E

F A S T E NE R HO L E

CUT

- O UT

A CCE S S / L I G HT NI NG HO L E

NO T CH/ G RO O V E

DI S CO NT I NI T Y

B A S I C M A T E RI A L

B US HI NG

P I N

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _



# 7C. DISCREPANT PART:

BODY STA. NO.__________

WING STA. NO.__________

VERT. STAD. STA.________

HORIZ. STAB. STA.________

NACELLE/PYLON

COMPARTMENT___________

NOSE LANDING GEAR

MAIN LANDING GEAR

WING LANDING GEAR

BODY LANDING GEAR D O O R

R U D D E R

E L E V A TO R

A I L E R O N

FL A P

S L A T

S P O I L E R

TA B ( A L S O C H E C K A B O V E )

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ I N TE R I O R

I N B O A R D

L E FT

FO R W A R D

U P P E R

L A N D I N G E D G E

M I D D L E

S P E C I FI C L O C A TI O N

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ E X TE R I O R

O U TB O A R D

R I G H T

A FT

L O W E R

TR A I L E R E D G E

S I D E

INSPECTED BY R E P A I R E D B Y



# ORIGINATED BY DATESEP 2011