767 MAINTENANCE PLANNING DATA

767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-7 JUNE 2000 Revised Airworthiness Limitations (AWL) section to include limitations for 767-400ER and revised Airplane Applicability for current AWLs. Revised current AWL title to more accurately reflect inspection areas. Revised AWL for Strut to reflect reassessment of the damage tolerance ratings. Revised interval for CMRs 24-33-00-6A and 26-10-00-6A from DAILY to 48 HRS. Added CMR 27-51-00-5I applicable only to the 767-400ER airplane. Added CMR H78-34-00-5A applicable to airplanes with GE CF6-80C2 engines. Revised CMR 29-11-00-6F by adding a note to indicate the hydraulic system internal leakage limits. Revised airplane applicability for CMRs 27-51-00-5D and H77-00-00-6D. Revised effectivity for CMR 31-41-02-4A since it is not applicable to the 767-400ER. Added AWLs for Fuselage to reflect reassessment of damage tolerance rating due to recent test and fleet performance data. Submitted by: N. HENNIGS (Boeing) 7/6/00 Approved by: A. BAHRAMI (FAA) FEBRUARY 2001 Revised CMR 31-41-00-2A to limit airplane applicability to the 767-200/-300 airplanes. Added CMR 31-63-00-2A applicable only to the 767-400ER airplane. Deleted CMR H78- 00-5A for both Engine 1 and Engine 2. Revised CMR N77-41-01-4A and H77-00-00-6D by adding an airplane note applicable to the 767-200/300 airplanes only. Revised statement in preamble to airworthiness limitations that specifies roll back of any escalated baseline structural inspection intervals when reaching the AWL threshold. Revised Instruction 3 for use of FLS threshold curve to add 400ER. Submitted by: A. K. STENDER (Boeing) 4/18/01 Approved by: L. LIU-NELSON (FAA) SEPTEMBER 2002 Added CMR 52-51-07-4A applicable only to airplanes incorporating Boeing Service Bulletin 767-25-0325. This amended type certificate complies with the new 14 CFR 25.795 and the amended 14 CFR 25.772 as issued under Federal Register Docket No. FAA-2001-11032. Submitted by: LINH Q. VU (Boeing) 8/30/02 Approved by: L. LIU-NELSON (FAA) REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-8 767 MAINTENANCE PLANNING DATA OCTOBER 2002 Revised CMR 52-51-07-4A to change applicability to show airplane Line Number 895 and on and any airplane that has incorporated Service Bulletin 767-25-0325 or 767-25-0327 or 767-25-0332. Revised the Structural Safe Life Parts section to reference current Service Letter 767-SL-32- 092 in place of superseded Service Letters 767-SL-32-21 and 767-SL-32-37. Submitted by: LINH Q. VU (Boeing) 10/15/02 Approved by: L. LIU-NELSON (FAA) AUGUST 2004 Revised Airworthiness Limitations (AWL) Section 9 to add FAA Letter 120S-03-953 and 6 page enclosure as an AMOC for AD 2003-18-10 in lieu of superseded AD 2001-08-28 and FAA AMOC letter 120S-02-962. Revised Section 9 CMR 36-11-01-6C to add Rolls-Royce engine note on Page 9.1-3. Revised the Structural Safe Life Parts Section page 9.0-57 to escalate Life Limits and define additional Life Limit components for the 767-400ER. Submitted by: S. A. PIERINI (Boeing) 8/15/04 Approved by: JULY 2005 Revised CMR 31-41-02-4A Interval from 04000 HRS to 10800 HRS. Item Number H77-00- 00-6D was renamed as H77-41-00-5A to agree with corresponding Item Number in Section 6. Submitted by: B. McLoughlin (Boeing) Approved by: Dorr Anderson REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-9 MARCH 2006 Added new Fuel System Airworthiness Limitations section which includes inspections of the Auto Shutoff and Ground Fault Interrupter systems, and design limitations of the Hot Short Protector and motor operated valves. Submitted by: S. Pierini (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): OCTOBER 2006 Revised CMR Task 52-51-07-4A interval from 4 years to 6 years to reflect improved reliability data for the Flight Deck Door Strike Assembly. Submitted by: S. Pierini (Boeing) Approved by: Seattle FAA ACO: JANUARY 2007 Revised Airworthiness Limitations – Systems section introduction to include revisions recommended by the Seattle FAA Flight Standards group. Revised applicability of Fuel System Airworthiness Limitation Numbers 28-AWL-23 and 28-AWL-24 to remove ITT actuator part number reference. The part number is listed in Service Bulletin 767-28A0090. Submitted by: S. Pierini (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-10 767 MAINTENANCE PLANNING DATA OCTOBER 2007 Revised Section D. Airworthiness Limitations (AWLs) – Systems paragraph on Exceptional Short-Term Extensions for AWLs to clarify notification requirements. Revised Systems AWL Page Format paragraph to become Section E. Page Format: Fuel Systems Airworthiness Limitations, and relettered the Sections following Section E. Added AWL Number 28-AWL-27, a yearly check of the Main and Center Auxiliary Fuel Tank Boost Pump Ground Fault Interruption (GFI) Control Relay System, applicable to airplane Line Numbers 961 and on and airplanes that have incorporated Service Bulletin 767- 28A0085. Added AWL Number 28-AWL-28, a yearly check of the Center Auxiliary Fuel Tank Override/ Jettison Fuel Pump Uncommanded-On System, applicable to airplane Line Numbers 961 and on and airplanes that have incorporated Service Bulletin 767-28A0085. Revised CMR 52-51-07-4A Task Interval from 6 years to 9 years to reflect improved reliability data for the Flight Deck Security Door. Added Section I. Reporting Uncontrolled High Thrust Failure Conditions per FAR 121.703 and FAR 135.415. Submitted by: (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): MARCH 2008 Revised 28-AWL-01and 28-AWL-26 by removing the 36000FH task interval limitation based upon engineering review and operator maintenance practice. Revised 28-AWL-18 to reflect the new maximum loop resistance values associated with the lightning protection of the unpressurized FQIS wire bundle installations so as to satisfy the Airworthiness Limitation Instructions required by SFAR 88. Also removed the joint resistance values and 36000FH task interval limitation based upon engineering review and operator maintenance practice. Submitted by: John Sabolchy (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-11 APRIL 2008 Revised 28-AWL-06 to add additional Component Maintenance Manual (CMM) information. Submitted by: Jason Onorati (Boeing) Approved by: Philip Forde (Seattle FAA ACO): MAY 2008 Revised B. AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS to add restrictions on flight hours and flight cycles for 767-200SF and 76-300BCF to comply with FAA Title 14 CFR Part 26. Revised C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS to limit 767-200SF Nose Landing Gear, Main Landing Gear and Landing Gear Support Structure to 1,000 flight cycles. Revised C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS to limit 767-300BCF Nose Landing Gear, Main Landing Gear and Landing Gear Support Structure to 2,000 flight cycles. Submitted by: John Sabolchy (Boeing) Approved by: Philip Forde (Seattle FAA ACO): JUNE 2008 Revised airplane applicability table to add the 767-300BCF. Added CMRs 31-51-00-5B and 31-51-00-5C that are applicable to the 767-300BCF model. The CMRs are necessary for compliance to 14 CFR 25.703 and 14 CFR 25.1309. Submitted by: Mike Eckelberry (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-12 767 MAINTENANCE PLANNING DATA JUNE 2008 R1 Revised Airworthiness Limitations-Structural Inspection Table Tasks 53-10-I07C, 53-30-I04C, 53-60-I05C, 53-10-I07D, 53-30-I04D, 53-30-I04D, 53-60-105D, 53-30-I01, 53-50-I01, 53-60-I01 by adding airplane effectivities and intervals from Service Bulletin 767-53-0210. Submitted by: Mike Eckelberry (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): AUGUST 2008 Revised Airworthiness Limitations-Structural Inspection Table Tasks 53-10-I07C, 53-30-I04C, 53-60-I05C, 53-10-I07D, 53-30-I04D, 53-60-105D by adding an additional inspection threshold and interval for aircraft L/N 971. Revised text to refer to correct Flight Standards Handbook. Submitted by: Jason Onorati (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): SEPTEMBER 2008 Revised airplane applicability table to add the 767-200SF Revised CMRs 31-51-00-5B and 31-51-00-5C to add applicability for the 767-200SF model. The CMRs are necessary for compliance to 14 CFR 25.703 and 14 CFR 25.1309. Submitted by: Jason Onorati (Boeing) Approved by: Dorr Anderson (Seattle FAA ACO): NOVEMBER 2008 Revised Airworthiness Limitations-Structural Inspection table tasks 53-10-I07A, 53-30-I04A, 53-60-I05A, 53-10-I07B, 53-30-I04B, and 53-60-105B by adding revised inspection method and new inspection threshold of 37,500 cycles due to structural repair for L/N 973. Submitted by: John Sabolchy (Boeing) Approved by: Seattle FAA ACO REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-13 JANUARY 2009 Revised Section B. AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS by removing the 900 flight cycle or 2,700 flight hour restrictions for the 767-300BCF, to comply with FAA Title 14 CFR Part 26. Submitted by: John Sabolchy (Boeing) Approved by: Jeffrey Duven, Seattle FAA ACO MARCH 2009 Revised Section B. AIRWORTHINESS LIMITATIONS for compliance with 14 CFR 26.45 (c) by adding VN194 (Serial Number 25616) to the list of 767 airplanes. Submitted by: John Sabolchy (Boeing) Approved by: Jeffrey Duven, Seattle FAA ACO MAY 2009 Revised B. AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS to clarify effectivity on passenger to freighter conversion in accordance with FAA Title 14 CFR Part 26. Revised Airworthiness Limitations-Structural Inspection Table by adding airplane effectivities and intervals from Service Bulletins 767-53-0103, 767-53-0190, 767-53-0191, 767-53-0208, 767-53-0210, and 767-53-0212. Revised text to refer to correct Flight Standards Handbook. Added Flag Note to the Airworthiness Limitations-Structural Inspection Table to highlight operational limits for certain applicable SSIs. Revised SSI 53-50-I11 by updating applicability column from "200" to "ALL" to reflect requirements called out in the DTR forms. Revised 53-80-I01A, B, C, D, E and 53-80-I15, 16 and 17 to add line number reference to applicability and a note to refer to the DTR forms. Revised SSIs 54-50-I01 and 54-50-I04 by dividing them into their own separate task requirements. (Continued on next page) Submitted by: John Sabolchy (Boeing) Approved by: Jeffrey Duven, Seattle FAA ACO SIGNATURE ON FILE 07/09/2009 REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-14 767 MAINTENANCE PLANNING DATA MAY 2009, Continued Revised SSI 54-50-I13 by adding additional rows to clarify engine effectivity and to reflect the DTR document (D622T001-DTR). Revised 57-20-I16A to change applicability from “400E” to “ALL” to reflect the correct airplane model. Revised text to refer to Document D622T001-DTR rather than Appendix B. Revised Airworthiness Limitations to include new cargo door limitations. One new cargo door limitation is applicable to passenger airplanes, eight are applicable to freighter airplanes, and three are applicable to all airplanes. Revised and added new Trailing Edge Flap limitations (Flap Loss Mitigation Program) and added wording regarding the tracking of removable parts. Forty revised Trailing Edge Flap limitations are applicable to 767-200, -300 passenger and -300 freighter airplanes, Line Numbers 922 and later, except as noted, and are applicable to all 767-400ER airplanes. Forty-nine new Trailing Edge Flap limitations are applicable to the 767-200, -300 passenger and -300 freighter airplanes, Line Numbers 1 to 921, except as noted. Added airplane effectivity note to the AIRPLANE ENGINE APPLICABILITY column of both entries for Airworthiness Limitation 53-10-I21A. Revised CMR section by correcting typographical errors by changing CMR D77-41-01-4A to CMR D77-41-00-5A and CMR P77-00-00-6B to CMR P77-41-00-5A. (Continued from previous page) (Continued from previous page) DECEMBER 2009 Revised the Airworthiness Limitations section to reflect the assessment of the 767-300 Boeing Converted Freighter's (BCF) Supplemental Structural Inspection Program. Revised 767-400 ER Landing Gear Safe Life Inner and Outer Cylinder landings by updating text from "16,6000" to "16,600". Revised the 767 Passenger- to-Freighter Conversion Airplane paragraph by removing the flight cycle and flight hour limitations for the 767-300BCF. Submitted by: John Sabolchy (Boeing) Approved by: Jeffrey Duven, Seattle FAA ACO SIGNATURE ON FILE 01/04/2010 REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-15 MAY 2010 Revised the Airworthiness Limitations – System information in Section D, Fuel Systems Airworthiness Limitations as requested by FAA Letter 140S-09-396 dated November 23, 2009. Revised the Use of Alternate Tools paragraph as requested by FAA Letter 140S-09-396 dated November 23, 2009 and as discussed in the FAA meeting on February 11, 2010. Revised the Fuel Systems Airworthiness Limitations Table by replacing the word “per” with the words “Refer to”, where the reference is to a non-FAA approved manual (such as the Standard Wiring Practices Manual or the Airplane Maintenance Manual) and where there are specific procedures in the AWL. Revised 28-AWL-10 by adding “all 767 airplanes” to AMM 28-21-02 to clarify applicability. Revised 28-AWL-22 by adding the word “two” to Step 1 to clarify the number of bonding straps. Added 28-AWL-29 and 28-AWL-30 as Critical Design Configuration Control Items for the fuel boost pump conduit liner to preclude arcing development as a result of the wire insulation chafing inside the fuel tank wire conduits. Submitted by: John Sabolchy (Boeing) Approved by: Robert Breneman for Jeffrey Duven, Seattle FAA ACO SIGNATURE ON FILE 05/27/2010 REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-16 767 MAINTENANCE PLANNING DATA JUNE 2010 This revision includes changes to support certain 767 passenger aircraft. For L/N 969, Tasks 53-30-I01, 53-50-I01, 53-60-I01, 53-10-I07C, 53-30-I04C, 53-60-I05C, 53-10-I07D, 53-30-I04D, 53-60-I05D were revised by updating the additional inspections with reference to SB 767-53-0210. For L/N 971, Tasks 53-10-I07C, 53-30-I04C, 53-60-I05C, 53-10-I07D, 53-30-I04D, 53-60-I05D were revised by updating the additional inspections with reference to SB 767-53-0211. For both L/Ns 969 and 971, the 37,500 cycle reduced threshold for the tasks noted above was revised to 50,000 cycles due to the inclusion of SB inspections. Revised the 767 Passenger-to-Freighter Conversion Airplane paragraph by removing the 3,750 flight cycle and 11,250 flight hour limitations for the 767-200 Boeing Special Freighter (767-200SF). Revised the Airworthiness Limitations Section to reflect the assessment of the 767-200SF Supplemental Structural Inspection Program. Certain Structural Significant Items (SSIs) include a flag note to indicate an operational limitation – no 767-300BCF and 767-200SF airplane may be operated beyond the SSI threshold until the applicable inspection procedures are validated, published in the appropriate manual and accepted by the FAA. Revised Structural Safe Life Parts by removing the operational Life Limit of 1,000 Landings for the “767-200SF Nose Landing Gear, Main Landing Gear and Gear Support Structure” and replacing it with the calculated Safe-Life Limit. Revised Structural Safe Life Parts by adding the following text “WING MAIN LANDING GEAR BEAM” to provide clarity for the Life Limit requirements for the 767-400E. Revised SSIs 57-20-I12C, 57-20-I15J, 57-20-I16K, and 57-10-I20A by changing the thresholds from FLS Curve to 50,000 FC or 70,000 FC, as applicable. Added SSI 57-10-I20B. Added SSIs 55-10-I09A, 55-10-I13D, 55-10-I13E, 55-10-I14C, 55-10-I14D, 55-10-I31A, and 55-10-I31B. Submitted by: John Sabolchy (Boeing) Approved by: Robert Breneman for Jeffrey Duven, Seattle FAA ACO SIGNATURE ON FILE 07/09/2010 JULY 2010 Added new Section F., Airworthiness Limitations – Nitrogen Generation System Tasks. Submitted by: John Sabolchy (Boeing) Approved by: Ron Landes for Robert Breneman, Seattle FAA ACO SIGNATURE ON FILE 07/26/2010 REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-17 AUGUST 2010 Revised 47-AWL-04 by updating the interval from 6,600 Flight Hours (FH) to 3,000 FH based on updated analysis. Revised 47-AWL-05 by updating the interval from 5,000 FH to 3,000 FH based upon updated analysis. Revised the Task Description by replacing “Functionally” with “Operationally” to accurately reflect the inspection intent. Submitted by: John Sabolchy (Boeing) Approved by: Robert D. Breneman, Seattle FAA ACO SIGNATURE ON FILE 08/13/2010 AUGUST 2010 R1 Revised 47-AWL-04 and 47-AWL-05 by updating the interval from 3,000 Flight Hours (FH) to 2,600 FH based upon a change to the certification analysis for fuel tank flammability exposure for the 767 Nitrogen Generation System. Submitted by: John Sabolchy (Boeing) Approved by: Philip Forde for Robert Breneman Seattle FAA ACO SIGNATURE ON FILE 08/24/2010 AUGUST 2010 R2 Revised SSIs 53-10-I07C/53-30-I04C/53-60-I05C and 53-10-I07D/53-30-I04D/53-60-I05D by adding the following text to provide better clarification regarding the applicability of DTR Check Forms: “L/N 994, Lap S-26R: BS 1406 to BS 1428 and S-25R to S-27R centerlines must be inspected with external detailed inspection every 600 flight cycles (after reaching threshold).” Submitted by: John Sabolchy (Boeing) Approved by: Donald Eiford for Robert D. Breneman, Seattle FAA ACO SIGNATURE ON FILE 09/21/2010 APRIL 2011 Revised Airworthiness Limitations-Structural Inspection table tasks 53-10-I07A, 53-30-I04A, 53-60-I05A, 53-10-I07B, 53-30-I04B, and 53-60-I05B by adding revised inspection method due to structural repair for L/N 1004. Submitted by: John Sabolchy (Boeing) Approved by: Steven Fox for Robert D. Breneman, Seattle FAA ACO SIGNATURE ON FILE 05/19/2011 JUNE 2011 Revised Airworthiness Limitations - Structural Inspections table task 53-10-I07C/53-30-I04C /53-60-I05C by adding revised inspection method and threshold due to structural repair for L/N 1008. Submitted by: Bill Lindholm (Boeing) Approved by: Steven Fox for Robert D. Breneman, Seattle FAA ACO SIGNATURE ON FILE 07/26/2011 REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-18 767 MAINTENANCE PLANNING DATA JULY 2011 Revised 47-AWL-03 to incorporate NGS performance features to show compliance with 14 CFR 26.33. Submitted by: Mark Arnold (Boeing) Approved by: Robert D. Breneman (Seattle FAA ACO) SIGNATURE ON FILE 08/05/2011 NOVEMBER 2011 Revised Airworthiness Limitations - Structural Inspections table tasks 53-10-I07C/ 53-30-I04C/53-60-I05C and 53-10-I07D/53-30-I04D/53-60-I05D to provide the applicability and inspection methods due to the structural repair of L/N 1018 and L/N 1019. Submitted by: Bill Lindholm (Boeing) Approved by: Julie Alger (Seattle FAA ACO) SIGNATURE ON FILE 12/21/2011 DECEMBER 2011 Revised Airworthiness Limitations - Structural Inspections table task SSI 53-10-I07D/ 53-30-I04D/53-60-I05D to provide the applicability and inspection method due to the structural repair of L/N 1020. Submitted by: Bill Lindholm (Boeing) Approved by: Ivan Li (Seattle FAA BASOO) SIGNATURE ON FILE 1/27/2012 FEBRUARY 2012 Revised Airworthiness Limitations - Structural Inspections Table Task SSI 53-10-I07A/53-30- I04A/53-60-I05A and 53-10-I07B/53-30-I04B/53-60-I05B inspection in accordance with SB 767-53-0231 for L/N 973, and inspection in accordance with SB 767-53-0238 for L/N 1004. Revised Airworthiness Limitations - Structural Inspections Table Task SSI 53-10-I07C/53- 30-I04C/53-60-I05C and 53-10-I07D/53-30-I04D/53-60-I05D inspection in accordance with SB 767-53-0230 for L/N 994. Revised Airworthiness Limitations - Structural Inspections Table Task SSI 53-10-I07C/53- 30-I04C/53-60-I05C and 53-10-I07D/53-30-I04D/53-60-I05D by deleting alternate inspection for L/N 1018 at Lap S-26L: BS 467 to BS 489 and S-25L to S-27L. Alternate inspections specified in revision dated NOV 2011 for structural repair are not valid due to skin replacement and return to drawing configuration. Submitted by: Mike Eckelberry (Boeing) Approved by: Kanji Patel (Seattle FAA ACO) SIGNATURE ON FILE 3/7/2012 REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-19 OCTOBER 2012 Revised the Airworthiness Limitations - Structural Inspections, Introduction Section by adding references to MPD Appendix K (Structures Baseline Requirements). Revised Airworthiness Limitations - Structural Inspections Table Task 53-10-I07C/53-30- I04C/53-60-I05C by adding Inspection Method and Repeat Interval due to structural repair of L/N 1040. Revised Airworthiness Limitations - Structural Inspections Table Task 53-10-I07C/53-30- I04C/53-60-I05C by referencing the SB 767-53-0240 for L/N 1008 and SB 767-53-0244 for L/N 1019. Revised Airworthiness Limitations - Structural Inspections Table Task 53-10-I07D/53-30- I04D/53-60-I05D by referencing the SB 767-53-0244 for L/N 1019. Revised Section D by replacing the “FUEL SYSTEMS AIRWORTHINESS LIMITATIONS” subheading with “INTRODUCTION" to be consistent with other Section 9 documents. Revised Section E lettering to be a subheading of Section D, to be consistent with other Section 9 documents. Revised the subheading of Section E from “FUEL SYSTEM AIRWORTHINESS LIMITATIONS” to “D.1 AWLs – FUEL SYSTEM IGNITION PREVENTION” to be consistent with other Section 9 documents. Added Section D.2 – Engine Fuel Suction Feed System, and ALI 28-AWL-101 – Engine Fuel Suction Feed Operational Test, that is required to protect against engine flameout during suction feed operations. Revised Section F, making it Section D.3 to be consistent with other Section 9 documents. Added “AWLs – Nitrogen Generation System” subheading to be consistent with other Section 9 documents. Added Section D.4 – Impact-Resistant Fuel Tank Access Doors, and CDCCL 57-AWL-01 – Impact-Resistant Fuel Tank Access Doors, to verify the fuel tank access door is impact- resistant during installation of the Fuel Tank Access Doors. Revised Section G lettering, making it Section E to be sequential in order to the heading changes made above. (Continued on next page) Submitted by: Sheila Reilley (Boeing) SIGNATURE ON FILE FAA BASOO 11/02/2012 REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-20 767 MAINTENANCE PLANNING DATA OCTOBER 2012, Continued Revised Section H, making it a subheading of Section E to be consistent in format with other Section 9 documents. Revised Section I, making it a subheading of Section E and revised the subheading title from "CERTIFICATION MAINTENANCE REQUIREMENTS TASKS" to "CMR TASKS" to be consistent with other Section 9 documents. Revised CMR tasks by changing CMR D77-41-01-4A to CMR D77-41-00-5A and CMR P77- 00-00-6B to CMR P77-41-00-5A to match the MPD Task Numbers. Revised Section J, making it Section F to be sequential in order to the heading changes previously incorporated. (Continued from previous page) (Continued from previous page) REVISIONS REVISION AND REVISION DESCRIPTION APPROVAL OCT 2012 Section Page Date Section Page Date Section Page Date Section Page Date Section Page Date D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-21 LIST OF EFFECTIVE PAGES 767 MAINTENANCE PLANNING DATA 9.0 1 OCT 2012 9.0 2 BLANK 9.0 3 OCT 2012 9.0 4 BLANK 9.0 5 OCT 2012 9.0 6 OCT 2012 9.0 7 OCT 2012 9.0 8 OCT 2012 9.0 9 OCT 2012 9.0 10 OCT 2012 9.0 11 OCT 2012 9.0 12 OCT 2012 9.0 13 OCT 2012 9.0 14 OCT 2012 9.0 15 OCT 2012 9.0 16 OCT 2012 9.0 17 OCT 2012 9.0 18 OCT 2012 9.0 19 OCT 2012 9.0 20 OCT 2012 9.0 21 OCT 2012 9.0 22 BLANK 9.0 23 OCT 2012 9.0 24 JUN 2010 9.0 25 JUN 2010 9.0 26 JUN 2010 9.0 27 OCT 2012 9.0 28 DEC 2009 9.0 29 NOV 2009 9.0 30 DEC 2009 9.0 31 DEC 2009 9.0 32 JUN 2010 9.0 33 OCT 2012 9.0 34 OCT 2012 9.0 35 OCT 2012 9.0 36 OCT 2012 9.0 37 OCT 2012 9.0 38 OCT 2012 9.0 39 OCT 2012 9.0 40 OCT 2012 9.0 41 OCT 2012 9.0 42 OCT 2012 9.0 43 OCT 2012 9.0 44 OCT 2012 9.0 45 OCT 2012 9.0 46 OCT 2012 9.0 47 OCT 2012 9.0 48 OCT 2012 9.0 49 OCT 2012 9.0 50 OCT 2012 9.0 51 OCT 2012 9.0 52 OCT 2012 9.0 53 OCT 2012 9.0 54 OCT 2012 9.0 55 OCT 2012 9.0 56 OCT 2012 9.0 57 OCT 2012 9.0 58 OCT 2012 9.0 59 OCT 2012 9.0 60 OCT 2012 9.0 61 OCT 2012 9.0 62 OCT 2012 9.0 63 OCT 2012 9.0 64 OCT 2012 9.0 65 OCT 2012 9.0 66 OCT 2012 9.0 67 OCT 2012 9.0 68 OCT 2012 9.0 69 OCT 2012 9.0 70 OCT 2012 9.0 71 OCT 2012 9.0 72 OCT 2012 9.0 73 OCT 2012 9.0 74 OCT 2012 9.0 75 OCT 2012 9.0 76 OCT 2012 9.0 77 OCT 2012 9.0 78 OCT 2012 9.0 79 OCT 2012 9.0 80 OCT 2012 9.0 81 OCT 2012 9.0 82 OCT 2012 9.0 83 OCT 2012 9.0 84 OCT 2012 9.0 85 OCT 2012 9.0 86 OCT 2012 9.0 87 OCT 2012 9.0 88 OCT 2012 9.0 89 JUN 2010 9.0 90 JUN 2010 9.0 91 OCT 2012 9.0 92 MAY 2010 9.0 93 OCT 2012 9.0 94 OCT 2012 9.0 95 MAY 2010 9.0 96 MAY 2010 9.0 97 MAY 2010 9.0 98 MAY 2010 9.0 99 MAY 2010 9.0 100 MAY 2010 9.0 101 MAY 2010 9.0 102 MAY 2010 9.0 103 MAY 2010 9.0 104 MAY 2010 9.0 105 MAY 2010 9.0 106 MAY 2010 9.0 107 MAY 2010 9.0 108 MAY 2010 9.0 109 MAY 2010 9.0 110 MAY 2010 9.0 111 MAY 2010 9.0 112 OCT 2012 9.0 113 OCT 2012 9.0 114 OCT 2012 9.0 115 OCT 2012 9.0 116 JUL 2011 9.0 117 JUL 2011 9.0 118 OCT 2012 9.0 119 OCT 2012 9.0 120 OCT 2012 9.0 121 SEP 2008 9.0 122 OCT 2012 9.0 123 SEP 2008 9.0 124 OCT 2012 9.0 125 OCT 2012 9.0 126 OCT 2012 9.0 127 OCT 2012 9.0 128 OCT 2012 9.0 129 OCT 2012 9.0 130 OCT 2012 9.0 131 OCT 2007 9.0 132 BLANK OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-22 767 MAINTENANCE PLANNING DATA THIS PAGE INTENTIONALLY LEFT BLANK BLANK 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-23 A. SCOPE The scheduled maintenance requirements described in this section result from Model 767 airplane certification activities with the U.S. Federal Aviation Administration (FAA). Accordingly, this FAA approved Airworthiness Limitations and Certification Maintenance Requirements document is cross- referenced in the Model 767 Type Certificate Data Sheet. These maintenance actions are mandatory. This Airworthiness Limitations Section is FAA approved and specifies maintenance required under Federal Aviation Regulation (FAR) 43.16 and 91.403 unless an alternative program has been FAA approved. AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS The Airworthiness Limitations may only be revised with the approval of the Seattle FAA Aircraft Certification Office (ACO). If the inspections cannot be accomplished due to repairs and/or modifications, an alternate inspection approved by the Seattle FAA ACO must be used. CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs) These scheduled maintenance tasks may only be revised by the Seattle FAA ACO (appropriate regulatory authority). Principal Airworthiness Inspectors (local regulatory authority) may not change these requirements or the intervals associated with these requirements. B. AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS The Structural Inspection Program approved in Section 3 of the 767 Maintenance Review Board (MRB) Report and contained in Section 2 of this MPD describes an initial baseline structural maintenance program for all Structural Significant Items (SSIs). This program was developed in accordance with the guidelines of MSG-3 and partially satisfies the requirements of FAR 25.571 by providing accidental and environmental damage detection opportunity for all SSIs, and in some cases, fatigue damage detection opportunity until the supplemental inspection threshold is reached. The supplemental structural inspections listed in this Section 9 “Airworthiness Limitations” are for those SSIs that do not receive adequate fatigue damage detection opportunity from the initial baseline structural program that is listed in Section 2 and in Appendix K. The inspections shown in this section and Appendix K are to be accomplished in conjunction with and not as a substitute for the existing structural maintenance program found in Section 2. OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-24 767 MAINTENANCE PLANNING DATA The supplemental structural inspection program uses the Damage Tolerance Rating (DTR) system to determine the inspections (and repeat intervals) necessary to provide adequate fatigue damage detection. The DTR system defines a required DTR (a numerical value) that must be achieved for each SSI. DTR Check Forms which define the inspection options and the required DTR are contained in Document D622T001-DTR. THRESHOLD The certifying authority (Seattle FAA ACO) requires designation of all SSIs into two categories. These two categories are referred to as Type 1 and Type 2. Type 1 structure requires the implementation threshold to be established by crack growth analysis. Type 2 structure is allowed to have the implementation threshold established by fatigue analysis (supported by test evidence) and allows for the future escalation of the inspection threshold when sufficient data from the initial inspections statistically support an increased threshold. See Document D622T001-DTR for a detailed definition of Type 1 and Type 2 categories. The inspections are to be done on the basis of the threshold specified in the AWL – Structural Inspections table and repeat inspections determined from DTR Check Forms contained in Document D622T001-DTR. A formal control system must be established for removable structural parts (repairable/rotable/expendables) which are subject to supplemental inspections, such as the flap support members. If part usage history data is available for all parts, the supplemental inspection program would follow the actual part usage history data. If part usage history data is not available, but records indicate that no part changes have occurred between airplanes, airplane usage history data can be used to start a tracking program for the supplemental inspections. If parts usage data is not available and the parts could have been switched between airplanes in the same maintenance program, it should be assumed that the time on any part is equal to the oldest airplane in the maintenance program. If a maintenance program includes airplanes from several operators, the oldest airplane in that group of airplanes would be used as the oldest airplane in the maintenance program. After overhaul or upon replacement of a part, as appropriate, a tracking program should be established to control the removable parts. This system must also apply to used structural parts which are purchased for installation on an airplane. Where no cumulative cycles history is available for any removed/interchangeable SSI, then calculate the accumulated flight cycles by using previous installation history. If previous installation history, too, is not available then assume that the limiting cycles (threshold) has already been reached and then inspection is to be done before installation of the removed SSI on the applicable airplane series. JUN 2010 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-25 The Airworthiness Limitations – Structural Inspections table defines the inspection implementation threshold. Some items are sensitive to flight length and identified by “FLS” (Flight Length Sensitive) in the Threshold column of the table. FLS Items require both flight hours and flight cycles to determine the implementation threshold. Refer to Figure 1, shown on the next page, to determine the threshold for FLS Items. JUN 2010 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-26 767 MAINTENANCE PLANNING DATA FIGURE 1. FLIGHT LENGTH SENSITIVE (FLS) THRESHOLD CURVE Instructions for the use of the Flight Length Sensitive (FLS) Threshold Curve: 1. Determine, for each airplane, the accumulated flight cycles and flight hours. 2. Enter the FLS Threshold Curve at the appropriate flight cycles and flight hours and plot point. 3. The initial supplemental inspection must be accomplished before crossing into the shaded area on the FLS Threshold Curve. Note that the shaded area for the -200, -200SF, -300 Passenger, and -300BCF aircraft is different from that for the -300F Freighter and -400ER Passenger aircraft. JUN 2010 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-27 In addition to the thresholds described above, a calendar threshold of 20 years applies unless an initial inspection of an FAA approved Corrosion Prevention and Control Program (CPCP) has occurred, constituting CPCP implementation. The information contained in Appendix K has been added to comply with the AD 2003-18-10 requirements when an airplane reaches the flight cycle or flight hour supplemental inspection threshold (whichever comes first). Appendix K contains the 1995-1999 versions of MPD Section 8, Structural Inspection Program, and is the baseline structural inspection program associated with the October 2002 MPD Section 9, Airworthiness Limitations and CMRs. AD 2003-18-10 paragraph (c) requires the incorporation of the October 2002 MPD Section 9 or an appropriately approved AMOC to the AD. When reaching the threshold of 50,000 flight cycles (-200, -200SF1 and -300 Passenger or -300 Passenger converted to -300BCF aircraft after 10,000 cycles or more as a -300 Passenger) or 40,000 flight cycles (-300F Freighter or -400ER Passenger or -300 Passenger converted to -300BCF aircraft before 10,000 cycles as a -300 Passenger), all C-check (or higher) structural inspection repeat intervals must be no greater than those shown in Appendix K. Structures “S 1C” check interval is defined as 3,000 flight cycles or 18 months (whichever comes first). This means that any operator, who has escalated the structures program by changing either task intervals (flight cycles) or the C-check interval (flight cycles), must reduce the repeat frequencies back to the MPD baseline structures program intervals before accumulating 50,000 flight cycles or 40,000 flight cycles respectively or the FLS cycles and hours (whichever comes first). The reason for this is that the FAR 25.571 damage tolerance evaluation takes credit for the baseline structures program defined in Appendix K. The airworthiness limitations listed in Section 9 are supplemental structural inspections of the SSIs for which the required DTR is not satisfied by the baseline structural inspections defined in Appendix K. Any continued escalation beyond the MPD baseline structures program may result in additional structure not meeting the required DTR which was the basis of certification. The inspections shown in Section 9 Airworthiness Limitations are to be accomplished in conjunction with and not as a substitute for the existing structures maintenance program found in Appendix K. 767 PASSENGER-TO-FREIGHTER CONVERSION AIRPLANES Certain 767 airplanes are modified from passenger model airplanes to a freighter configuration via Boeing service bulletin. After incorporation of the Boeing passenger-to-freighter service bulletin, these 767-200 and 767-300 airplanes are designated as 767-200SF and 767-300BCF. Refer to Section C of this chapter for additional data related to 767-200SF and 767-300BCF structural safe life parts. 1 Only one -200SF exists, and it was modified after 14,900 cycles as a Passenger aircraft. OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-28 767 MAINTENANCE PLANNING DATA Certain 767-300BCF supplemental inspection thresholds are calculated based on the summation of fatigue damage accrued as a passenger and then a freighter. These are identified by “Combined Threshold” in the Threshold column. Refer to Figure 2 to determine the threshold for these items. Certain 767-300BCF supplemental inspection thresholds are calculated from the date of modification. These are identified by “Mod Date Sensitive” in the Threshold column. Refer to Figure 3 to determine the threshold for these items. Instructions for the use of the Combined Life Threshold curve: 1. Determine, for each airplane, the accumulated flight cycles prior to BCF modification. 2. Enter the threshold curve at the appropriate flight cycles as 300ER. 3. The initial supplemental inspection must be accomplished before crossing the 300BCF Combined Threshold curve. Instructions for the use of the Mod Date Sensitive curve: 1. Determine, for each airplane, the accumulated flight cycles prior to BCF modification. 2. Enter the threshold curve at the appropriate flight cycles as 300ER. 3. The initial supplemental inspection must be accomplished before crossing the 300BCF Mod Date Sensitive curve. DEC 2009 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-29 FIGURE 2. Combined Passenger and Freighter Life Threshold Combined Threshold 25000 30000 35000 40000 45000 50000 55000 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 Flights as 300ER (Cycle s) Combined Threshold (Cycles) 53-30-I01 BCF2 Section 43 Crown SK/STR at Aft Edge External Doubler 53-30-I01 BCF10 Crown Stringer STA 654+110 to STA 786 53-30-I04D BCF1 Inner Skin at Lower Fastener Row S-26L Lap 53-30-I04A BCF2 Outer Skin at Upper Fastener row S-8L Lap (L2 Panel) 53-30-I04B STR 8R Lap BS 434 - 654+22 Inner Skin at Lower Fastner Row NOV 2009 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-30 767 MAINTENANCE PLANNING DATA FIGURE 3. Mod Date Sensitive Structure DEC 2009 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-31 REPEAT INSPECTION INTERVAL A repeat inspection interval for the fatigue inspection of an SSI is established from its DTR Check Form. Airplanes with an average flight length (flight hours per landing) equal to or more than 8 hours must use the DTR Check Form labeled "767 > 8 hours" at the top of the form (see Document D622T001- DTR for DTR Check Forms). Revision to the required DTR or the DTR curve is not allowed without approval from the Seattle FAA ACO. REPORTING RESULTS OF STRUCTURAL INSPECTIONS All cracks found during these inspections shall be reported within ten (10) days directly to the Manager of the Seattle FAA ACO, Transport Airplane Directorate, FAA and to Boeing Commercial Airplanes using the Discrepant Structure Report Form. Refer to Document D622T001-DTR for the required report form (any suitable alternative which contains the same information may be used). DEC 2009 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-32 767 MAINTENANCE PLANNING DATA The following pages, included in the Airworthiness Limitations – Structural Inspections table, list the Airworthiness Limitation supplemental inspection requirements. Each item is listed by SSI Number, DTR Check Form Title, Inspection Zone, Airplane/Engine Applicability, Type and Threshold. NOTE: There are 767-200SF Fuselage ALIs that do not have corresponding DTR Check Forms. The inspection type and repeat inspection interval are given in the DTR document. There are 767-200SF and 767-300BCF Wing ALIs that do not have corresponding DTR Check Forms. The inspection type and repeat inspection interval are given in the DTR document. There are corresponding DTR Check Forms (in Document D622T001-DTR) for each item listed in the table. Where there is more than one listing for a given SSI Number, the DTR Check Form Title is the unique identifier along with the Airplane/Engine Applicability. Airplane/engine applicability is listed as follows: ALL = All Airplanes PASS (-ER ONLY) = Passenger Airplanes, Extended Range Only. PASS = Passenger Airplanes < 8 HOURS = Airplanes with cumulative stage length (Flight Hours per Landing) 200 = 767-200, -200ER less than 8 hours. 200SF = 767-200 Special Freighter 300 = 767-300, -300ER > 8 HOURS = Airplanes with cumulative stage length (Flight Hours per Landing) 300BCF = 767-300 Boeing Converted Freighter equal to or more than 8 hours. 400E = 767-400ER 300F = All 767-300 Freighters 4000 = P&W PW4052, PW4056, PW4060, PW4062 7R4 = P&W JT9D-7R4D and -7R4E 80A = GE CF6-80A 80C = GE CF6-80C 524 = RR RB211-524H JUN 2010 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-33 AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE INSPECTION ZONE AIRPLANE/ ENGINE APPLICABILITY TYPE AND THRESHOLD 27-40-I01A Stabilizer Trim Actuator – Lower Gimbal Lug Assy BS 1708.5, WL 239.9 311, 312 ALL Type 1 50,000 Cycles (200, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 27-40-I01B Stabilizer Trim Actuator – Lower Gimbal Plate Assy BS 1708.5, WL 239.9, BL 0.0 311, 312 400E Type 1 40,000 Cycles 52-30-I02A Standard Cargo Door forward and aft – Applicable to 767-200, 200SF, -300, -300BCF (aft) and -400 passenger airplanes – Beam #2 @ STA 210.15, section between upper access and Vent Door Cutouts 821, 822 200, 200SF 300BCF, 300 PASS 400E <2> Type 1 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (400E) 52-30-I05A Latch Cam Support Frame Fitting – Forward large Cargo Door – Fitting Lug Bore 821 ALL <2> Type 2 50,000 Cycles (200, 300 PASS) 40,000 Cycles (300BCF, 300F, 400E) 52-30-I05B Latch frame inner chord – Forward large Cargo Door – Latch Frame Inner Chord at Splice to Latch Frame Support Fitting 821 ALL Type 1 37,500 Cycles (200, 300 PASS) 30,000 Cycles (300BCF, 300F, 400E) 52-30-I05C Outer Skin – Forward large Cargo Door – Outer Skin at attachment to main hinge segments at forward and aft ends of the door 821 ALL Type 1 37,500 Cycles (200, 300 PASS) 30,000 Cycles (300BCF, 300F, 400E) 52-30-I07A Latch Cam Support Fitting – Main Deck Cargo Door – Fitting Lug Bore 838 200SF 300BCF, 300F <2> Type 2 40,000 Cycles (300F) 50,000 Cycles (200SF) Mod Date Sensitive (300BCF) 52-30-I07B Latch Frame Inner Chord – Main Deck Cargo Door – Latch Frame Inner Chord at Splice to Latch Frame Support Fitting 838 200SF 300BCF, 300F <2> Type 1 30,000 Cycles 44,900 Cycles (200SF) Mod Date Sensitive (300BCF) OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-34 767 MAINTENANCE PLANNING DATA 52-30-I07C Outer Skin – Main Deck Cargo Door – Outer Skin at attachment to main hinge segments at forward and aft ends of the door 838 200SF 300BCF, 300F <2> Type 1 44,900 Cycles (200SF) Mod Date Sensitive (300BCF) 30,000 Cycles (300F) 52-30-I07E MDCD Outer Skin Lap Splice – Upper row (upper skin) – Intercostal #5 838 200SF 300BCF, 300F <2> Type 2 50,000 Cycles (200SF) Mod Date Sensitive (300BCF) 40,000 Cycles (300F) 52-30-I07F MDCD Outer Skin Lap Splice – Lower row (lower skin) – Intercostal #5 838 200SF 300BCF, 300F <2> Type 1 44,900 Cycles (200SF) Mod Date Sensitive (300BCF) 30,000 Cycles (300F) 52-30-I09A Latch Cam Support Fitting – Aft large Cargo Door – Fitting Lug Bore 822 300F <2> Type 2 40,000 Cycles 52-30-I09B Latch Frame Inner Chord – Aft large Cargo Door – Latch Frame Inner Chord at Splice to Latch Frame Support Fitting 822 300F Type 1 30,000 Cycles 52-30-I09C Outer Skin – Aft large Cargo Door – Outer Skin at attachment to main hinge segments at forward and aft ends of the door 822 300F Type 1 30,000 Cycles 53-10-I07A 53-30-I04A 53-60-I05A Skin Longitudinal Lap Splices – Upper Row – Crown and Upper Lobe, Sections 41, 43 and 46. DTR Check Form not applicable to: 1) L/N 945: STA 617 S-8R. Must inspect per SB 767-53-0190. 2) L/N 963: STA 1465 - 1476, STR 8L. Must inspect per SB 767-53-0208. 3) 300BCF: S-8L STA 654+22 to 654+110; S-8R, STA 434 to 654+22 (not applicable) and S-2R 654+22 to 654+110 (no inspection). 4) 200SF: S-8R, STA 434 to 676. 5) L/N 1004: BS 1464 to BS 1478, S-8R: Must inspect per SB 767-53-0238. 6) L/N 973: Lap S-8R, STA 1555: Must inspect per SB 767-53-0231. 220, 230, 250 ALL Except where noted for L/N 945, L/N 963, L/N 973 and L/N 1004 200SF and 300BCF Type 2 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 37,500 Cycles (L/N 945, L/N 963) AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE INSPECTION ZONE AIRPLANE/ ENGINE APPLICABILITY TYPE AND THRESHOLD OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-35 53-10-I07B 53-30-I04B 53-60-I05B Skin Longitudinal Lap Splices – Lower Row – Crown and Upper Lobe, Sections 41, 43 and 46. DTR Check Form not applicable to: 1) L/N 945: STA 617 S-8R. Must inspect per SB 767-53-0190. 2) L/N 963: STA 1465 - 1476, STR 8L. Must inspect per SB 767-53-0208. 3) 300BCF: S-8R, STA 434 to 654+22; S-8L, STA 654+22 to 654+110 (not applicable); S-2R, STA 654+22 to 654+110 (No inspection). 4) 200SF: S-8R, STA 434 to 676 (not applicable). 5) L/N 1004: BS 1464 to BS 1478, S-8R: Must inspect per SB 767-53-0238. 6) L/N 973: Lap S-8R: STA 1555: Must inspect per SB 767-53-0231. 220, 230, 250 ALL Except where noted for L/N 945, L/N 963, L/N 973, L/N 1004, 200SF and 300BCF Type 2 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 37,500 Cycles (L/N 945, L/N 963) 53-10-I07C 53-30-I04C 53-60-I05C Skin Longitudinal Lap Splices – Upper Row – Bilge and Lower Lobe, Sections 41, 43 and 46. DTR Check Form not applicable to: 1) L/N 946, STA 1175-1197, S-26R. Must inspect per SB 767-53-0191. 2) L/N 873: STA 1197+82 and 1197+121, S-36R. Must inspect per SB 767-53-0103. 3) L/N 969 from STA 1408 to 1417 S-26R: Must inspect per SB 767-53-0210. 4) L/N 971: Lap S-26L: BS 654 + 22 to BS 654 + 44 and S-26L. Must inspect per SB 767-53-0211. 5) L/N 967: STA 1564 - 1582, STR 26R. Must inspect per SB 767-53-0212. 6) 300BCF: S-37R STA 368 to 434 (No inspection). 7) 200SF: S-37R, STA 368 to 434 (No inspection). 8) L/N 994: Lap S-26R: STA 1417. Must inspect per SB 767-53-0230. 9) L/N 1008: Lap S-26L: BS 303, 325, 347, and 368. Must inspect per SB 767-53- 0240. 10) L/N 1019: Lap S-26L: BS 292 to BS 314. Must inspect per SB 767-53-0244. 11) L/N 1040: Lap S-26R: Between BS 1560 to BS 1565 and S-25R to S-27R must be inspected with external detailed visual inspection every 900 flight cycles, upon reaching threshold. 100 ALL Except where noted for L/N 873, L/N 946, L/N 967, L/N 969, L/N 971, L/N 994, L/N 1008, L/N 1019, and L/N 1040 200SF and 300BCF Type 2 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 37,500 Cycles (L/N 946, L/N 967) 30,000 Cycles (L/N 873) AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE INSPECTION ZONE AIRPLANE/ ENGINE APPLICABILITY TYPE AND THRESHOLD OCT 2012 D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-36 767 MAINTENANCE PLANNING DATA 53-10-I07D 53-30-I04D 53-60-I05D Skin Longitudinal Lap Splices – Lower Row – Bilge and Lower Lobe, Sections 41, 43 and 46. DTR Check Form not applicable to: 1) L/N 946, STA 1175-1197, S-26R. Must inspect per SB 767-53-0191. 2) L/N 873: STA 1197+82 and 1197+121, S-36R. Must inspect per SB 767-53-0103. 3) L/N 969 from STA 1408 to 1417 S-26R: Must inspect per SB 767-53-0210. 4) L/N 971, Lap S-26L: BS 654 + 22 to BS 654 + 44 and S-26L. Must inspect per SB 767-53-0211. 5) L/N 967: STA 1564 - 1582, STR 26R. Must inspect per SB 767-53-0212. 6) 300BCF: STA 434 to 654+110, S-26L. 7) 200SF: STA 434 to 676, S-26L. Must inspect per 53-30-I04D BCF1 at a threshold of 27,900 cycles. 8) L/N 994, Lap S-26R: STA 1417. Must inspect per SB 767-53-0230. 9) L/N 1019: Lap S-26L: BS 292 to BS 314 Must inspect per SB 767-53-0244. 10) L/N 1020: Lap S-36L: BS 770 to BS 784 and S-35 to S-37L centerlines must be inspected with internal detailed inspection every 900 flight cycles (after reaching threshold). 100 ALL Except where noted for L/N 873, L/N 946, L/N 967, L/N 969, L/N 971, L/N 994, L/N 1019, and L/N 1020 200SF and 300BCF Type 2 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 37,500 Cycles (L/N 946, L/N 967) 30,000 Cycles (L/N 873) 53-10-I08B 53-30-I24B Frames above S-20 220, 230 ALL Except 200SF, 300BCF Type 2 50,000 Cycles (200, 300 PASS) 40,000 Cycles (300F, 400E) 53-10-I08B 53-30-I24B Frames above S-20, Frame (Fully visible) 220, 230 200SF Type 2 50,000 Cycles 53-10-I08B 53-30-I24B BCF 3 – Frames above S-20, Not Applicable to Areas of Hidden Frame Structure 220, 230 300BCF Type 2 50,000 Cycles 53-10-I08C 53-30-I24C 53-60-I08C Frames, Below S-20, Frame (Fully visible) 100 200SF Type 2 50,000 Cycles 53-10-I08C 53-30-I24C 53-60-I08C Frames, S-20 and below. BS 246 to BS 786 and BS 1065 to BS 1582 100 ALL Except 200SF, 300BCF Type 2 50,000 Cycles (200, 300 PASS) 40,000 Cycles (300F, 400E) 53-10-I08C 53-30-I24C 53-60-I08C BCF 5 – Frames below S-20, All Frames Except the Areas of Hidden Frame Structure 100 300BCF Type 2 50,000 Cycles AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE INSPECTION ZONE AIRPLANE/ ENGINE APPLICABILITY TYPE AND THRESHOLD OCT 2012 767 MAINTENANCE PLANNING DATA D622T001-9 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-37 53-10-I10A Forward Passenger Entry/Service Door Cutout- Edge Frame – Inner Chord Door STA 76.3, S-7 to S-12 and S-19 to S-23, Door STA 123.7, S-8 to S-12 and S-19 to S-23 119, 221, 222, 223, 224 ALL Type 2 50,000 Cycles (200, 300 PASS) 40,000 Cycles (200SF, 300BCF, 300F, 400E) 53-10-I10B Forward Passenger Entry/Service Door Cutout- Upper Main Sill – Inner Chord Door STA 100 to Door STA 129.9 221, 222 ALL Type 2 50,000 Cycles (200, 300 PASS) 40,000 Cycles (200SF, 300BCF, 300F, 400E) 53-10-I12 Main Equipment Center Access Door Cutout BS 303 – BS 325, LBL 13.1 – RBL 13.1 119 ALL Type 2 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 53-10-I13 Forward Equipment Bay Access Door Cutout – BS 144.5 – BS 163.2. LBL 9 – RBL 9 113, 114 ALL Type 2 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 53-10-I14A Window #1 Cutout Structure – AB POST 211, 212 ALL Type 1 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) 53-10-I14B Window #1 Cutout Structure – BD SILL 211, 212 ALL Type 1 50,000 Cycles (200, 200SF, 300BCF, 300 PASS) 40,000 Cycles (300F, 400E) AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE INSPECTION ZONE AIRPLANE/ ENGINE APPLICABILITY TYPE AND THRESHOLD OCT 2012