767-200/300/300F/400ER AIRWORTHINESS LIMITATIONS 767-200/300/300F/400ER AIRWORTHINESS LIMITATIONS (AWLs) D622T001-9-01 JUNE 2019 This 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 for development, 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 this document on to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by the Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. 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COMPILED AND PUBLISHED BY: MAINTENANCE PROGRAMS ENGINEERING BOEING COMMERCIAL AIRPLANE GROUP SEATTLE, WASHINGTON D622T001-9-01 JUN 2019 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-1 EXPORT CONTROLLED - EAR ECCN: 9E991 767-200/300/300F/400ER AIRWORTHINESS LIMITATIONS THIS PAGE INTENTIONALLY LEFT BLANK D622T001-9-01 BLANK BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-2 EXPORT CONTROLLED - EAR ECCN: 9E991 767-200/300/300F/400ER AIRWORTHINESS LIMITATIONS TABLE OF CONTENTS REVISIONS .................................................................................................................................................................................................................................. 1.0-5 LIST OF EFFECTIVE PAGES .................................................................................................................................................................................................... 1.0-18 A. SCOPE................................................................................................................................................................................................................................... 1.0-19 B. AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONS...................................................................................................................................... 1.0-20 C. AIRWORTHINESS LIMITATIONS - STRUCTURAL SAFE LIFE PARTS ............................................................................................................................... 1.0-93 D. AWLS - STRUCTURAL LIMIT OF VALIDITY (LOV)............................................................................................................................................................... 1.0-95 APPENDIX A – STRUCTURES BASELINE REQUIREMENTS.................................................................................................................................................... A.0-1 A. SCOPE................................................................................................................................................................................................................................. A.0-1 B. STRUCTURES BASELINE INSPECTION REQUIREMENTS ............................................................................................................................................. A.1-1 D622T001-9-01 JUN 2019 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-3 EXPORT CONTROLLED - EAR ECCN: 9E991 767-200/300/300F/400ER AIRWORTHINESS LIMITATIONS THIS PAGE INTENTIONALLY LEFT BLANK D622T001-9-01 BLANK BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-4 EXPORT CONTROLLED - EAR ECCN: 9E991 767-200/300/300F/400ER AIRWORTHINESS LIMITATIONS REVISIONS JULY 2014 Original Release This revision contains no technical changes. Please see the 767 MPD Section 9, D622T001-9 for historical Revision Log information. NOVEMBER 2014 Revised Subsection B. Airworthiness Limitations - Structural Inspections to add a paragraph which addresses special inspection requirements for operators that have incorporated Service Bulletin 767-23-0228. DECEMBER 2014 Added a new Section D. AWLs - Structural Limit of Validity (LOV) as required by Title 14 Code of Federal Regulations (CFR) Section 26.21 (Amendment 26-6). FEBRUARY 2015 Revised Structural Safe Life Parts section by reformatting for clarification and updating the 767-400ER life limits based on completion of the main landing gear full-scale fatigue tests and analysis. OCTOBER 2015 Revised SSI 52-30-I02A to reflect changes made to the DTR Check Form requirements. Added SSI 57-10-I03B - Rear Spar Lower Chord and Skin - Wing Center Section - Hidden Locations - BBL 49.5, 62.05 and 73.0 for the -200SF and -300BCF to the table of Airworthiness Limitations - Structural Inspections in Section B. Added Item 5 to the Table Notes for the Airworthiness Limitations - Structural Inspections Table and added a footnote to the following SSI Items affected by this new note: 57-10- I01A, 57-10-I02C, 57-10-I03A, 57-10-I03B, 57-10-I03C, 57-10-I20A, 57-10-I24A, 57-20-I12C, 57-20-I15J, and 57-20-I16K. DECEMBER 2015 Revised Section D. AWLs - Structural Limit of Validity (LOV) to add applicability for the 767-300BCF. D622T001-9-01 JUN 2019 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-5 EXPORT CONTROLLED - EAR ECCN: 9E991 767-200/300/300F/400ER AIRWORTHINESS LIMITATIONS JULY 2016 Deleted the FAA Approval signature column from the Revision Log to improve the layout and provide consistency across all Section 9/AWL/CMR/SCI documents. Submittal signatures will no longer be included in the Revision Log. Revised front matter under “REMOVAL OF EXCESS SEALANT WHEN INSPECTING” to update the reference to sealant of fuel tank fasteners to point to the 767 Special Compliance Items/Airworthiness Limitations document, D622T001-9-04. Revised the Airworthiness Limitations - Structural Inspections Table in Section B by adding SSI 53-30-I08A - Fuselage Circumferential Skin and Stringer Splice - BS 434 for the 767-300F, L/N 1108 and on. Revised SSI 57-53-I03I.2 to combine SSI/DTR Forms and their requirements into one SSI/DTR Form to cover all aircraft and added #5 Inboard Flap Support to the title for clarification. Revised SSI 57-53-I03J.1 to combine with SSI 57-53-I03J.2 DTR Form and their requirements into one SSI/DTR Form to cover all aircraft and added #5 Inboard Flap Support to the title for clarification and removed Flag Note <2>. Revised SSI 57-53-I03J.2 to combine SSI/DTR Forms and their requirements into one SSI/DTR Form to cover all airplane models and added #5 Inboard Flap Support to the title for clarification. Revised SSI 57-53-I03K to combine SSI/DTR Forms and their requirements into one SSI/DTR Form to cover all aircraft and added #5 Inboard Flap Support to the title for clarification. Deleted SSI 57-53-I03L.1 and 57-53-I03L.2 as those requirements are now covered in SSI 57-53-I03L. Revised SSI 57-53-I03L to combine SSI/DTR Forms and their requirements into one SSI/DTR Form to cover all aircraft and added #5 Inboard Flap Support to the title for clarification. JULY 2018 Revised document header from 767 to 767-200/300/300F/400ER to list all derivatives. Revised Section A. Scope to add requirement for document to be used in its entirety. Added guidelines that provides a 24 month grace period of change incorporation. Revised Section B reference document names for consistency within this document. Revised to address the inclusion of Appendix A being added to the document to define the baseline inspection program. Revised Threshold section to clarify A-Check and C-check inspection interval, after reaching threshold, to be 3,000 flight cycles, 24 months or 9,000 flight hours for the C-check, and 300 flight cycles or 900 flight hours for the A-check. Revised structural inspection results reporting instructions. The manager of the FAA Oversight Office, the Transport Airplane Directorate, and the FAA have been removed from the list of required recipients. Revised Removal of Excess Sealant When Inspecting to add excess sealant removal instructions and added a table with detailed descriptions table for Excess Sealant. Added the word “Fuselage” to the beginning of phrase “Structural Inspections “ regarding the Airworthiness Limitations document for the 767-300BCF. Revised definition of 767-300, 767-300ER from “300” to “300 PASS”, for clarity. Removed the two notes stating that some ALIs for the 767-200SF and 767-300BCF do not have corresponding DTR check forms. This is to clarify that all 200SF and 300BCF ALIs are included in the DTR Check Form Document. Removed "No DTR Check Form" notes from ALIs table to clarify that all ALIs are included in the DTR Check Form Document. (Continued on next page D622T001-9-01 JUN 2019 BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 1.0-6 EXPORT CONTROLLED - EAR ECCN: 9E991 767-200/300/300F/400ER