MAINTENANCE PLANNING DOCUMENT SUPPLEMENT FOR B757 … · MAINTENANCE PLANNING DOCUMENT SUPPLEMENT...

MAINTENANCE PLANNING DOCUMENT SUPPLEMENT

FOR B757-200 PCF/PCC CONVERSION PC-0118-05

ORIGINAL ISSUE DATE: MAY 28, 2004

REVISION LEVEL: OCTOBER 25, 2017

COMPILED AND PUBLISHED BY: PRECISION CONVERSIONS

4900 SW GRIFFITH DRIVE, SUITE 133 BEAVERTON, OREGON 97005

PRECISION CONVERSIONS CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 Precision Conversions Unpublished Work – All Rights Reserved

THIS INFORMATION CONTAINED HEREIN IS PROPRIETARY TO PRECISION CONVERSIONS, LLC, AND SHALL NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED FOR ANY DESIGN OR MANUFACTURE EXCEPT WHEN SUCH USER POSSESSES DIRECT, WRITTEN AUTHORIZATION FROM PRECISION CONVERSIONS, LLC.

MAINTENANCE PLANNING DOCUMENT SUPPLEMENT FOR B757-200PCF/PCC CONVERSION

PC-0118-05 Oct 25/2017 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page 1

HIGHLIGHTS

The October 2017 revision of this manual brings it up to date through the September 2017 revision of OEM MPD D622N001. A listing of general updates is included in this section. Changes to task format or task numbering are not indicated by right margin.

General Changes:

1. Updated document title, and references to the title throughout. Was “Maintenance Planning Data Document Supplement for B757 Cargo/Combi Conversion.”

Section 1, System and Power Plant:

1. Added Changed Tasks PC-21-004-00, PC-21-005-00, PC-26-010-00 (PCF & PCC).

2. Page 1.1-1: Task PC-21-003-00 – Clarified Task Description.

3. Page 1.1-9: Task PC-26-2020-00 – Clarified Note.

Section 2, Structure:

1. Added 52-436-00, 52-440-00 to list of Deleted Inspections (PCF).

2. Added 53-246-00, 53-248-00, 53-250-00, 53-262-00, 53-264-00 to list of Deleted Inspections (PCF & PCC).

3. .1-5: Task PC-53-118-00 - Added Zone 117.

Section 3, Zonal:

No changes.

Section 9, Airworthiness Limitations and Certification Maintenance Requirements:

No changes.

Appendix M – Task Number Conversion Cross-Reference Index:

1. Removed obsolete Precision task reference tables.

Appendix N – ICA Documents:

1. Page N.0-1: Updated ICA Manuals with latest revision levels and dates.



REVISIONS REV LEVEL DESCRIPTION REV DATE APPROVAL

IR Initial Release May 28, 2004 Bill Barclift, May 28, 2004

A General updates prior to STC issuance. August 12, 2004 Bill Barclift, August 12, 2004

B General updates prior to STC issuance. September 02, 2004 Bill Barclift, September 02, 2004

C General updates prior to STC issuance. October 01, 2004 Bill Barclift, October 01, 2004

D Updated text on FTR Forms in Section B.1 and B.4 January 10, 2005 Mike Violetto, January 10, 2005

E General update prior to STC issuance. March 22, 2005 Mike Violetto, March 22, 2005

F Updated Section 5 and 6. July 28, 2005 Mike Violetto, July 28, 2005

G AMM reference clarification December 23, 2005 Mike Violetto, December 23, 2005

H Revised Item Number PCF-52-30-00-4H July 28, 2006 Mike Violetto, July 28, 2006

SEPT 2006 Deleted lubrication tasks no longer necessary. Modified operational check of PA system. September 08, 2006 Mike Violetto, September 08, 2006

NOV 2006 Revised section 8, 10, Appendix B, Appendix E, and Appendix G to correlate with Boeing MPD task restructuring. November 10, 2006 Mike Violetto

APR 2007 General release to incorporate D622N001 Jan 07 update. Reinstated inadvertently deleted system inspections. Reference Appendix I for specific changes.

April 30, 2007 Mike Violetto

NOV 2007 General release to incorporate D622N001 Sep 07 update. Reference Appendix I for specific changes. November 21, 2007 Tracy Leonardi


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RECORD OF TEMPORARY REVISIONS

REVISION INSERTED REMOVED REVISION INSERTED REMOVED TR NO. DATE BY DATE TR NO. DATE TR NO. DATED BY DATE TR NO. DATE

1 06/20/08 TL Nov 08 2 07/17/09 TF Jun 11 3 CANCELLED 4 CANCELLED 5 04/18/14 DH Dec 14 6 06/06/16 RG Nov16 7 01/03/17 RG Feb 17


LIST OF EFFECTIVE PAGES

Page Date Page Date Page Date


TITLE PAGE 1 Oct 25/2017 HIGHLIGHTS 1 Oct 25/2017 REVISIONS 1 Oct 25/2017 2 Oct 25/2017 RECORD OF TEMPORARY REVISIONS 1 Feb 23/2017 LIST OF EFFECTIVE PAGES 1 Oct 25/2017 2 Oct 25/2017 TABLE OF CONTENTS 1 Oct 25/2017 2 Oct 25/2017 3 Oct 25/2017 INTRODUCTION INTRO-1 Oct 25/2017 INTRO-2 Feb 15/2016 INTRO-3 Feb 15/2016 INTRO-4 Oct 25/2017 SECTION 1 1.0-1 Feb 23/2017 1.0-2 Feb 27/2015 1.0-3 Feb 27/2015 1.0-4 Feb 27/2015 1.0-5 Oct 25/2017 1.0-6 Feb 23/2017 1.0-7 Nov 23/2016 1.0-8 Oct 25/2017 1.0-9 Feb 15/2016 1.1-1 Oct 25/2017 1.1-2 Feb 27/2015 1.1-3 Feb 27/2015 1.1-4 Feb 27/2015 1.1-5 Feb 27/2015 1.1-6 Nov 23/2016

1.1-7 Oct 25/2017 1.1-8 Feb 27/2015 1.1-9 Oct 25/2017 1.1-10 Feb 27/2015 1.1-11 Feb 23/2017 1.1-12 Feb 15/2016 1.1-13 Feb 27/2015 1.1-14 Feb 27/2015 1.1-15 Feb 27/2015 1.1-16 Feb 27/2015 1.1-17 Feb 15/2016 1.1-18 Feb 27/2015 1.1-19 Feb 27/2015 1.1-20 Feb 27/2015 1.1-21 Feb 27/2015 1.1-22 Feb 27/2015 1.1-23 Feb 27/2015 1.1-24 Feb 27/2015 1.1-25 Feb 27/2015 1.1-26 Feb 27/2015 1.1-27 Feb 27/2015 SECTION 2 2.0-1 Feb 27/2015 2.0-2 Feb 27/2015 2.0-3 Feb 27/2015 2.0-4 Feb 27/2015 2.0-5 Feb 27/2015 2.0-6 Feb 27/2015 2.0-7 Oct 25/2017 2.0-8 Feb 23/2017 2.1-1 Feb 27/2015 2.1-2 Feb 27/2015 2.1-3 Feb 27/2015 2.1-4 Feb 23/2017 2.1-5 Oct 25/2017 2.1-6 Feb 27/2015 2.1-7 Feb 27/2015 2.1-8 Feb 27/2015 2.1-9 Feb 27/2015 2.1-10 Feb 27/2015 2.1-11 Feb 27/2015 2.1-12 Feb 27/2015 2.1-13 Feb 27/2015

2.1-14 Feb 27/2015 2.1-15 Feb 27/2015 2.1-16 Feb 27/2015 2.1-17 Feb 27/2015 2.1-18 Feb 27/2015 2.1-19 Feb 27/2015 2.1-20 Feb 27/2015 2.1-21 Feb 27/2015 2.1-22 Feb 27/2015 2.1-23 Feb 27/2015 2.1-24 Feb 27/2015 2.1-25 Feb 27/2015 2.2-1 Feb 27/2015 SECTION 3 3.0-1 Dec 08/2014 3.0-2 Dec 08/2014 3.0-3 Dec 08/2014 3.0-4 Dec 08/2014 3.1-1 Dec 08/2014 3.1-2 Dec 08/2014 3.1-3 Dec 08/2014 3.1-4 Dec 08/2014 3.1-5 Dec 08/2014 SECTION 4 4.0-1 May 03/2013 SECTION 5 5.0-1 May 03/2013 SECTION 6 6.0-1 May 03/2013 SECTION 7 7.0-1 May 03/2013 SECTION 8 8.0-1 May 03/2013 SECTION 9

SEE SECTION 9 FOR Feb 23/2017 LIST OF EFFECTIVE PAGES


LIST OF EFFECTIVE PAGES

Page Date Page Date Page Date


SECTION 10 10.0-1 May 03/2013 APPENDIX A A.0-1 May 03/2013 APPENDIX B B.0-1 May 03/2013 APPENDIX C C.0-1 May 03/2013 APPENDIX D D.0-1 May 03/2013 D.1-1 May 03/2013 D.2-1 May 03/2013 D.3-1 May 03/2013 APPENDIX E E.0-1 May 03/2013 APPENDIX F F.0-1 May 03/2013 APPENDIX G G.0-1 May 03/2013 APPENDIX H H.0-1 May 03/2013 APPENDIX I I.0-1 May 03/2013 APPENDIX J J.0-1 May 03/2013 APPENDIX K K.0-1 May 03/2013 APPENDIX L L.0-1 May 03/2013 L.1-1 May 03/2013 L.1-2 May 03/2013

L.1-3 May 03/2013 L.1-4 May 03/2013 L.1-5 May 03/2013 L.1-6 May 03/2013 L.1-7 May 03/2013 L.1-8 May 03/2013 APPENDIX M M.0-1 Oct 25/2017 APPENDIX N N.0-1 Oct 25/2017



TABLE OF CONTENTS SECTION PAGE HIGHLIGHTS ............................................................................................................................................................................................................. 1 REVISIONS ................................................................................................................................................................................................................ 1 RECORD OF TEMPORARY REVISIONS ................................................................................................................................................................. 1 LIST OF EFFECTIVE PAGES ................................................................................................................................................................................... 1 TABLE OF CONTENTS ............................................................................................................................................................................................ 1 INTRODUCTION

A PURPOSE ................................................................................................................................................................................. INTRO-1 B SCHEDULED MAINTENANCE PROGRAM DEVELOPMENT ................................................................................................. INTRO-2 C APPLICABILITY OF ZONAL AND STRUCTURES INSPECTION PROGRAMS ..................................................................... INTRO-2 D MAINTENANCE CHECKS ........................................................................................................................................................ INTRO-2 E MAINTENANCE CHECK INTERVAL ESCALATION ................................................................................................................ INTRO-2 F WARRANTY (VENDOR ITEMS) ............................................................................................................................................... INTRO-2 G AUTOMATED CUSTOMIZED (AC) TASK CARDS .................................................................................................................. INTRO-2 H REVISIONS ............................................................................................................................................................................... INTRO-2 I PERIODIC AIRPLANE WEIGHING .......................................................................................................................................... INTRO-3 J ACRONYMS AND ABBREVIATIONS ....................................................................................................................................... INTRO-4

1 SYSTEMS AND POWERPLANT MAINTENANCE REQUIREMENTS

A SCOPE ............................................................................................................................................................................................ 1.0-1 B GENERAL NOTES .......................................................................................................................................................................... 1.0-1 C PAGE FORMAT: SYSTEM MAINTENANCE REQUIREMENTS .................................................................................................... 1.0-3 SYSTEMS AND POWERPLANT MAINTENANCE TASKS ........................................................................................................................ 1.0-5

2 STRUCTURAL MAINTENANCE REQUIREMENTS

A SCOPE ............................................................................................................................................................................................ 2.0-1 B NOTES ............................................................................................................................................................................................ 2.0-1 C OPERATING RULES ...................................................................................................................................................................... 2.0-1 D AGE EXPLORATION PROGRAM .................................................................................................................................................. 2.0-2 E SUPPLEMENTAL STRUCTURAL INSPECTION PROGRAM ....................................................................................................... 2.0-2 F CORROSION PREVENTION.......................................................................................................................................................... 2.0-3 G REPORTING RESULTS OF STRUCTURAL INSPECTIONS ........................................................................................................ 2.0-3 H PAGE FORMAT .............................................................................................................................................................................. 2.0-5 STRUCTURAL MAINTENANCE TASKS .................................................................................................................................................... 2.0-7 STRUCTURAL ILLUSTRATIONS .............................................................................................................................................................. 2.2-1



TABLE OF CONTENTS – CONTINUED SECTION PAGE

3 ZONAL INSPECTION REQUIREMENTS A SCOPE ............................................................................................................................................................................................ 3.0-1 B NOTES ............................................................................................................................................................................................ 3.0-1 C PAGE FORMAT: ZONAL INSPECTION REQUIREMENTS ........................................................................................................... 3.0-3 ZONAL INSPECTION TASKS .................................................................................................................................................................... 3.1-1

4 SOURCE DOCUMENTS FOR TASKS

A SCOPE ............................................................................................................................................................................................ 4.0-1

5 RESERVED

6 RESERVED

7 RESERVED

8 RESERVED

9 AIRWORTHINESS LIMITATIONS AND CERTIFICATION MAINTENANCE REQUIREMENTS A SCOPE ............................................................................................................................................................................................ 9.0-6 B AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS ............................................................................................ 9.0-7 C AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS ................................................................................... 9.0-15 D AIRWORTHINESS LIMITATIONS – SYSTEMS ........................................................................................................................... 9.0-15 E CERTIFICATION MAINTENANCE REQUIREMENTS (CMR) ..................................................................................................... 9.0-15 F PAGE FORMAT: CERTIFICATION MAINTENANCE REQUIREMENTS ..................................................................................... 9.0-17 G CERTIFICATION MAINTENANCE REQUIREMENT TASKS ......................................................................................................... 9.1-1 H JAA UNIQUE REQUIREMENTS..................................................................................................................................................... 9.2-1

10 RESERVED

APPENDIX A ACCESS DATA AND ZONE DIAGRAMS

A GENERAL ....................................................................................................................................................................................... A.0-1 B IDENTIFICATION OF ACCESS DOORS AND PANELS ............................................................................................................... A.0-1 C ACCESS DOORS AND PANEL INFORMATION ........................................................................................................................... A.0-1

APPENDIX B RESERVED



TABLE OF CONTENTS – CONTINUED

SECTION PAGE APPENDIX C TASKS SORTED BY INTERVAL

A SCOPE ............................................................................................................................................................................................ C.0-1 APPENDIX D CROSS-REFERENCE INDEXES

A SCOPE ............................................................................................................................................................................................ D.0-1 B NOTES ............................................................................................................................................................................................ D.0-1 C APPLICABILITY .............................................................................................................................................................................. D.0-1 D PAGE FORMAT .............................................................................................................................................................................. D.0-1

APPENDIX E AIRPLANE DIMENSIONS AND STATION DIAGRAMS

A GENERAL DIMENSIONS ............................................................................................................................................................... E.0-1 B MAJOR AIRPLANE DIMENSIONS ................................................................................................................................................. E.0-1

APPENDIX F SUPPLEMENTAL STRUCTURAL INSPECTION PROGRAM

A STRUCTURAL DTRs AND REPORT FORMS ............................................................................................................................... F.0-1 APPENDIX G PRECLUDED SYSTEMS TASKS .............................................................................................................................................................. G.0-1 APPENDIX H RESERVED APPENDIX I CRITICAL SYSTEMS .................................................................................................................................................................................. I.0-1

A CRITICAL SYSTEMS LIST .............................................................................................................................................................. I.0-1 APPENDIX J RESERVED APPENDIX K RESERVED APPENDIX L STRUCTURES AND FATIGUE CROSS-REFERENCE

A GENERAL ....................................................................................................................................................................................... L.0-1 APPENDIX M TASK NUMBER CONVERSION CROSS-REFERENCE INDEX .............................................................................................................. M.0-1 APPENDIX N ICA DOCUMENTS

ICA FOR FREIGHTER AND COMBI CONVERSIONS .............................................................................................................................. N.0-1


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INTRODUCTION – B757-200PCF/PCC MAINTENANCE PLANNING DATA A. Purpose

1. This “Maintenance Planning Document Supplement for B757-200 PCF/PCC Conversion” is a supplement to the Boeing “757 Maintenance Planning Document,” and is applicable to certain Boeing 757-200 airplanes converted from a passenger to a Freighter/Combi configuration in accordance with FAA STC ST02278SE (Combi) and STC ST01529SE (Freighter). The information contained in this document only applies to items, components and/or systems that have been modified or added, and is not intended to duplicate data that is presented in the Boeing document.

This document is to be used in conjunction with Boeing “757 Maintenance Planning Document,” D622N001, September 2017.

2. The “Maintenance Planning Document Supplement for B757-200 PCF/PCC Conversion,” Doc. No. PC-0118-05, is the “Principal Manual” as

defined by CFR H25.4(b). Appendix N of this document describes the remaining ICA (Instructions for Continued Airworthiness) documents.

3. There are no special tools, special inspections, or special inspection techniques that are required by this supplemental maintenance program.

4. Send communications about this document to:

Precision Conversions Attn: Technical Publications 4900 SW Griffith Drive, Suite 133 Beaverton, OR 97005

5. This document provides instructions for continued airworthiness, and is in compliance with CFR 25.1529.

6. The data contained herein is applicable to all Boeing 757-200 aircraft converted from the passenger configuration by Precision Conversions and

designated B757-200PCF (Freighter) or B757-200PCC (Combi).

7. The scheduled maintenance tasks in this document should not be considered as all-inclusive. Each individual airline has final responsibility to decide what to do and when to do it, except for those maintenance requirements identified as “Airworthiness Limitations” or “Certification Maintenance Requirements (CMR).” Temporary requirements in the form of Service Letters, Service Bulletins and Airworthiness Directives are the responsibility of the individual airline to incorporate. Maintenance tasks recommended in engine, APU, and vendor manuals should also be considered.

8. In addition to the maintenance tasks described herein, for the freighter configuration, the Supplemental Maintenance Manual (SMM), PC-0118-

06, is the reference document for maintenance procedures, whether required, suggested, or other. For the Combi, the reference document is Supplemental Maintenance Manual (SMM), PC-0118-229. See the “Introduction” sections of these documents for additional information on their usage and limitations.


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B. Scheduled Maintenance Program Development

1. This section is unchanged from the OEM Maintenance Planning Data document, except for the following:

a. Section 9 is approved separately by the FAA Aircraft Certification Office. C. Applicability of Zonal and Structures Inspection Program

1. No changes to this section. See OEM Maintenance Planning Data document. D. Maintenance Checks

1. No changes to this section. See OEM Maintenance Planning Data document. E. Maintenance Check Interval Escalation

1. No changes to this section. See OEM Maintenance Planning Data document. F. Warranty (Vendor Items)

1. The accomplishment, at specific intervals, of maintenance tasks as recommended in this document, does not imply a warranty by Precision Conversions for service life of vendor components. If an operator is concerned with a specific warranty for a vendor item, the vendor should be contacted regarding warranty policy, overhaul times, and service information.

G. Maintenance Task Cards

1. Maintenance task cards can be purchased from Precision Conversions. Email [email protected] for additional information.

H. Revisions

1. This Maintenance Planning Document Supplement will be kept current by revision service. A list of effective pages will be provided with each revision. Two revision services will be used to keep the manual current; they are normal and temporary, and are described below. This manual is available both digitally and hardcopy.

(a) Normal Revision Service

1 Aircraft operators who have contracted continuing normal revision service for this manual receive revisions annually, as indicated in the Precision Conversions Customer Support Reference Guide.

mailto:[email protected]


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2 On each individual page the revised area is indicated by a revision bar on the right margin. Those pages which have not been technically revised, but have been reprinted due to recomposition, will not appear with a revision bar. Those pages which have changed due to formatting may or may not be indicated by a revision bar. The List of Effective Pages will not be updated to show recomposition or formatting changes.

3 Each page is positively identified by a date in the lower left corner. The List of Effective Pages (LEP) carries this information and is to

be used as the authority for the manual content.

4 The date of a revised page will be the same as or later than the date of the replaced page.

(b) Temporary Revisions

1 Temporary revisions to this manual will be issued as necessary to alert customers of configuration differences and to provide temporary instructions prior to the next scheduled revision.

2 Each temporary revision will be incorporated into the manual supplement at the next normal revision schedule. I. Periodic Airplane Weighing

1. This section is unchanged from the OEM Maintenance Planning Data document, except for the following:

a. The following document is a supplement to the Boeing Weight and Balance Control and Loading Manual:

OL0182, “Airplane Weight and Balance Control and Loading Manual Supplement to Boeing Weight and Balance Manual, Model B757-200.”


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J. ACRONYMS AND ABBREVIATIONS AC Aircraft

FTR Flaw Tolerance Rating System

SB Service Bulletin

AD Airworthiness Directive

GVI General Visual Inspection

SDI Special Detailed Inspection AMM Aircraft Maintenance Manual

HFEC High Frequency Eddy Current

SRM Structural Repair Manual

APL Applicability

ICA Instructions for Continued Airworthiness

SSI Structural Significant Item

ATA Air Transport Association

LBL Left Buttock Line

SSIP Supplemental Structural Inspection Program

AWL Airworthiness Limitations

LEP List of Effective Pages

STA Body Station

BS Body Station

LFEC Low Frequency Eddy Current

STC Supplemental Type Certificate CDSS Cockpit Door Surveillance System

LIF LIM Life Limited

SVC Servicing

CFMU Cargo Fire Maintenance Unit

LUB Lubrication

TR Temporary Revision CFR Code of Federal Regulation

MO Month

ULB Underwater Locator Beacon

CMR Certification Maintenance Requirement

MPD Maintenance Planning Document

UT Ultra Sonic

CPCP Corrosion Prevention and Control Program

MRB Maintenance Review Board

VCK Visual Check

DET Detailed Inspection

NDI Non-Destructive Inspection

WL Water Line DIS Discard

NDT Non-Destructive Testing

YR Year

DTR Damage Tolerance Rating System

OEM Original Equipment Manufacturer ENG Engine

OPC Operational Check

F Fatigue Item

PCC Precision Conversions Combi FAA Federal Aviation Administration

PCC/PCF Precision Conversions Combi/Freighter

FC Flight Cycle

PCF Precision Conversions Freighter

FH Flight Hours

PGM Indicated program, i.e., S = Structural and F = Fatigue Item

FiDS Fire Detection and Suppression System

RBL Right Buttock Line FLS Flight Length Sensitive

RST Restoration

FNC Functional Check

S Structural Item


SYSTEMS AND POWER PLANT MAINTENANCE PROGRAM

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SECTION 1 – SYSTEMS AND POWER PLANT MAINTENANCE REQUIREMENTS

A. Scope

Section 1.0 of the MPD Supplement outlines the Scheduled Maintenance Tasks for the Systems Maintenance Requirements. This section is arranged in ATA order. It covers some, or all of, the following aircraft systems.

12 Servicing 33 Lights 70 Standard Practices – Engine 20 Standard Practices 34 Navigation 71 Power Plant 21 Air Conditioning & Pressurization 35 Oxygen 72 Engine 22 Auto Flight 36 Pneumatic 73 Engine Fuel & Control 23 Communications 38 Water Waste 74 Ignition 24 Electrical Power 49 Airborne Auxiliary Power Unit (APU) 75 Air 25 Equipment & Furnishings 51 Structures & Standard Practices 76 Engine Controls 26 Fire Protection 52 Doors (Mechanical) 77 Engine Indicating 27 Flight Controls 53 Fuselage 78 Exhaust 28 Fuel 54 Nacelles/Pylons 79 Oil 29 Hydraulic Power 55 Stabilizers 80 Starting 30 Ice & Rain Protection 56 Windows 31 Indicating & Recording Systems 57 Wings 32 Landing Gear (Mechanical)

General Notes, applicable to all systems, are followed by note specific to ATA Chapters 49 and 71-80. Following the notes, the format of the pages that list the Scheduled Maintenance Requirements Tasks is illustrated and explained. All systems maintenance program tasks in ATA 12 through 57 are followed by Pratt & Whitney and Rolls-Royce powerplant tasks (ATA 71-80).

B. General Notes

No changes to this section except as follows. See OEM Maintenance Planning Document.

Threshold Determination

1. For System/Powerplant OEM task that is contained in this Section 1 of the PC-0118-05 MPD Supplement, threshold is determined from the lifetime of the aircraft.

2. For System/Powerplant Precision task that is contained in this Section 1 of the PC-0118-05 MPD Supplement, threshold is determined from the modification of the aircraft.

3. For any System task that is new to this revision of the PC-0118-05 MPD Supplement, note the following for threshold determination:

If the indicated threshold has been exceeded, inspect at next 1C inspection.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY

MAN HOURS TASK DESCRIPTION THRES. REPEAT APL ENG

PC-XX-XXX-XX AIRPLANE MAINTENANCE MANUAL PROCEDURE (CHAPTER,

SECTION, SUBJECT) WHICH SUPPORTS THE MPD REQUIREMENT

MPD SEQUENCE NUMBER 000-999 = SEQUENCE NUMBER OF OEM SYSTEM AFFECTED BY

CONVERSION

2000-2999 = SEQUENCE NUMBER OF CONVERSION-ADDED/MODIFIED SYSTEM

FIRST TWO DIGITS = ATA CHAPTER “PC” IDENTIFIES PRECISION CONVERSIONS ADDED TASKS EXAMPLE ILLUSTRATING FORMAT:

PC-35-005-00 6 VCK 4500 FH 4500 FH 211

212 PCF/PCC ALL 0.50 Visually check crew/supernumerary oxygen mask/regulator assembly

for condition and verify operation of crew mask microphone.

FIG 1-1 SYSTEMS MAINTENANCE REQUIREMENTS EXAMPLE PAGE




C. Page Format: Systems Maintenance Requirements

1. MPD NUMBER

No changes to this explanation. See OEM 757 Maintenance Planning Data document. 2. AMM REFERENCE

No changes to this explanation. See OEM 757 Maintenance Planning Data document.

3. CAT FAILURE-EFFECT CATEGORIES (CAT) & REGULATORY REQUIREMENTS

No changes to this explanation. See OEM 757 Maintenance Planning Data document. 4. TASK MSG-3 TASK CATEGORIES


5. INTERVAL


6. ZONE


7. ACCESS





8. APPLICABILITY

APL ENG Applicable Airplane Model and Engine. “Note” refers to an explanation under the task description.

APL PCF= B757-200PCF (Precision Conversions Freighter) PCC = B757-200PCC (Precision Conversions Combi) PCF/PCC = Precision Conversions Freighter and Combi NOTE = Airplane Applicability Note ENGINE ALL = All 757 Engines NOTE = Engine Applicability Note

9. MANHOURS


10. TASK DESCRIPTION




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SYSTEMS AND POWERPLANT MAINTENANCE TASKS – FREIGHTER

The following table lists OEM MPD item numbers that have been deleted or changed due to the conversion to the Freighter configuration. Items that have been changed have been assigned a new Precision Conversions MPD item number. Additionally, new inspections due to the Freighter conversion are listed. As noted, some of these have been renumbered as compared with previous versions of this document.

FREIGHTER DELETED OEM INSPECTIONS

CHANGED OEM INSPECTIONS

NEW INSPECTIONS

OEM MPD ITEM NUMBER

OEM MPD ITEM NUMBER PC MPD ITEM NUMBER

PC MPD ITEM NUMBER

21-002-00 21-003-00 PC-21-003-00 PC-21-2000-00 21-006-00 21-004-00 PC-21-004-00 PC-21-2004-00 25-003-00 21-005-00 PC-21-005-00 PC-21-2006-00 25-004-00 21-025-00 PC-21-025-00 PC-21-2008-00 25-005-00 21-026-00 PC-21-026-00 PC-21-2012-00 25-010-00 21-030-01 PC-21-030-01 PC-25-2000-00 25-014-00 23-001-00 PC-23-001-00 PC-25-2004-00 25-014-01 23-005-01 PC-23-005-01 PC-26-2010-00 25-015-00 23-005-02 PC-23-005-02 PC-26-2014-00 25-015-01 25-034-00 PC-25-034-00 PC-26-2016-00 25-016-01 26-010-00 PC-26-010-00 PC-26-2018-00 25-016-02 27-001-05 PC-27-001-05 PC-26-2020-00 25-017-01 31-001-01 PC-31-001-01 PC-52-2000-00 25-018-00 31-001-02 PC-31-001-02 PC-52-2002-00 25-019-00 31-002-00 PC-31-002-00 PC-52-2004-00 25-020-00 31-007-01 PC-31-007-01 PC-52-2006-00 25-021-00 32-001-05 PC-32-001-05 PC-52-2008-00 25-022-00 33-007-01 PC-33-007-01 PC-52-2010-00 25-024-00 35-005-00 PC-35-005-00 PC-52-2012-00 25-026-00 35-015-01 PC-35-015-01 PC-52-2014-00 25-031-01 38-001-00 PC-38-001-00 PC-52-2016-00 25-032-01 52-005-00 PC-52-005-00 PC-52-2018-00 25-034-01 52-005-01 PC-52-005-01 PC-52-2020-00 25-035-01 52-005-03 PC-52-005-03 PC-52-2022-00




FREIGHTER DELETED OEM INSPECTIONS,

cont’d

CHANGED OEM INSPECTIONS, cont’d

NEW INSPECTIONS,

cont’d

26-014-00 76-101-05 PC-76-101-05 PC-52-2024-00 26-014-01 PC-52-2026-00 26-016-00 PC-52-2028-00 33-001-00 PC-52-2030-00 33-004-01 PC-52-2032-00 33-006-00 PC-52-2034-00 33-007-00 PC-52-2036-00 35-006-00 PC-52-2068-00 35-007-00 PC-52-2070-00 35-008-00 PC-56-2000-00 35-009-00 35-010-00 35-017-00 35-018-00 38-002-00 38-003-00 38-004-01 38-005-01 38-006-01 52-003-00 52-004-00 52-005-05 52-005-06 52-005-09 52-005-10



PC-0118-05 Nov 23/2016 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page 1.0-7

FREIGHTER DELETED OEM INSPECTIONS,

cont’d


NEW INSPECTIONS,

cont’d

52-005-11 52-011-00 52-019-00 52-019-01 52-019-02 52-031-01 52-031-02 52-032-01 52-033-00 52-033-01 52-034-00 52-035-00 52-036-00 52-036-02 52-037-00 52-038-00




SYSTEMS AND POWERPLANT MAINTENANCE TASKS – COMBI The following table lists OEM MPD item numbers that have been deleted or changed due to the conversion to the Combi configuration. Items that have been changed have been assigned a new Precision Conversions MPD item number. Additionally, new inspections due to the Combi conversion are listed. As noted, some of these have been renumbered as compared with previous versions of this document.

COMBI DELETED OEM INSPECTIONS

CHANGED OEM INSPECTIONS

NEW INSPECTIONS

OEM MPD ITEM NUMBER

OEM MPD ITEM NUMBER PC MPD ITEM NUMBER

PC MPD ITEM NUMBER

33-006-00 21-002-00 PC-21-002-00 PC-21-2000-00 52-033-00 21-003-00 PC-21-003-00 PC-21-2002-00 52-034-00 21-004-00 PC-21-004-00 PC-21-2004-00 52-035-00 21-005-00 PC-21-005-00 PC-21-2006-00 52-036-00 21-006-00 PC-21-006-00 PC-21-2008-00 52-037-00 21-025-00 PC-21-025-00 PC-21-2010-00 52-038-00 21-026-00 PC-21-026-00 PC-23-2000-00

23-001-00 PC-23-001-00 PC-23-2002-00 25-014-00 PC-25-014-00 PC-23-2004-00 25-015-00 PC-25-015-00 PC-23-2006-00 25-016-01 PC-25-016-01 PC-25-2002-00 25-032-01 PC-25-032-01 PC-26-2006-00 25-034-00 PC-25-034-00 PC-26-2008-00 26-010-00 PC-26-010-00 PC-26-2010-00 26-016-00 PC-26-016-00 PC-26-2012-00 27-001-05 PC-27-001-05 PC-26-2014-00 31-007-01 PC-31-007-01 PC-26-2016-00 32-001-05 PC-32-001-05 PC-26-2018-00 33-001-00 PC-33-001-00 PC-26-2020-00 33-004-01 PC-33-004-01 PC-26-2022-00 33-007-00 PC-33-007-00 PC-33-2002-00 35-010-00 PC-35-010-00 PC-33-2004-00 38-001-00 PC-38-001-00 PC-33-2006-00 52-003-00 PC-52-003-00 PC-33-2008-00




COMBI DELETED OEM INSPECTIONS,

cont’d


NEW INSPECTIONS,

cont’d

52-004-00 PC-52-004-00 PC-33-2010-00 52-005-00 PC-52-005-00 PC-52-2000-00 52-005-01 PC-52-005-01 PC-52-2002-00 52-005-03 PC-52-005-03 PC-52-2004-00 52-005-05 PC-52-005-05 PC-52-2006-00 52-005-06 PC-52-005-06 PC-52-2008-00 52-005-09 PC-52-005-09 PC-52-2010-00 52-005-10 PC-52-005-10 PC-52-2012-00 52-005-11 PC-52-005-11 PC-52-2014-00 52-031-01 PC-52-031-01 PC-52-2016-00 52-031-02 PC-52-031-02 PC-52-2018-00 52-032-01 PC-52-032-01 PC-52-2020-00 52-033-01 PC-52-033-01 PC-52-2022-00 52-036-02 PC-52-036-02 PC-52-2024-00 76-101-05 PC-76-101-05 PC-52-2026-00 PC-52-2028-00 PC-52-2030-00 PC-52-2032-00 PC-52-2034-00 PC-52-2036-00 PC-52-2060-00 PC-52-2062-00 PC-52-2064-00 PC-52-2066-00 PC-52-2068-00 PC-52-2070-00 PC-56-2000-00




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 21: AIR CONDITIONING PC-21-002-00 7 RST 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

200 NOTE PCC ALL 4.00 Clean return air grilles in the passenger compartment. INTERVAL NOTE: Whichever comes first. ACCESS NOTE: Remove return air grilles.

PC-21-003-00 6 DIS 3000 FH 3000 FH NOTE NOTE PCF/PCC

NOTE ALL 0.60 Change recirculation air prefilter (left side only).

ZONE/ACCESS NOTE: Task is the same as OEM MPD Task 21-003-00, except right recirculation filter is deleted. AIRPLANE NOTE: If installed.

PC-21-004-00 6 DIS 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF/PCC ALL 3.00 Change recirculation air high efficiency filter (left side only). ZONE/ACCESS NOTE: Task is the same as OEM MPD Task 21-004-00, except right recirculation filter is deleted. INTERVAL NOTE: Whichever comes first

PC-21-005-00 9 DET 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

NOTE NOTE PCF/PCC ALL 0.75 Visually check condition of recirculation air check valve flapper and hinge pin for wear and security (removal from duct required). ZONE/ACCESS NOTE: Task is the same as OEM MPD Task 21-005-00, except right recirculation valve is deleted. INTERVAL NOTE: Whichever comes first.

PC-21-006-00 9 DIS 3000 FH 3000 FH 250 PCC

NOTE ALL 0.10 Change aft galley ventilation filters (in passenger compartment).

AIRPLANE NOTE: Galley ventilation filters are not installed on airplanes line number 916 and subsequent that have not incorporated the new generation interior (PRR 54787).

PC-21-025-00 6 DIS 1500 FH 1500 FH NOTE NOTE PCF/PCC ALL 0.40 Change cabin zone temperature sensor filters.

ZONE/ACCESS NOTE: Component has been relocated, but procedure is the same as passenger aircraft. See PC AMM 21-61-11/401 for new location depending on PCF or PCC configuration. See OEM maintenance manual 21-61-11/401 for procedure.

PC-21-026-00 9 FNC 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

NOTE NOTE PCF/PCC ALL 0.40 Check (off-aircraft) switch setting of zone duct overheat switches and circuit verification. INTERVAL NOTE: Whichever comes first. ZONE/ACCESS NOTE: Component has been relocated, but procedure is the same as passenger aircraft. See PC AMM 21-61-01/1 for new location. See OEM maintenance manual 21-61-01/501 for procedure.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG PC-21-030-01 OPC 750 FH 750 FH 212 PCF ALL 0.30 Check operation of E/E cooling smoke/low flow detection system

with test switch. AIRPLANE NOTE: Right side recirculation system is deactivated. This task does not require pushing R RECIRC FAN switch-light.

PC-21-2000-00 7 RST 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

200 NOTE PCF/PCC ALL 3.00 Clean return air grilles in the cargo compartment.

INTERVAL NOTE: Whichever comes first. ACCESS NOTE: Remove return air grilles.

PC-21-2002-00 GVI 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

200 NOTE PCC ALL Visually inspect blowout panels in the cargo compartment for condition.

ZONE/ACCESS NOTE: See PC AMM for component locations. PC-21-2004-00 VCK 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF/PCC ALL 0.50 Visually check flight deck lavatory vent duct for condition

ZONE/ACCESS NOTE: see PC AMM 21-58-00 for component location.

PC-21-2006-00 VCK 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF/PCC ALL 0.50 Visually check alternate forward equipment cooling duct for condition.


PC-21-2008-00 VCK 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF/PCC ALL 0.50 Visually check main deck riser duct restrictor plate for condition.


PC-21-2010-00 VCK 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCC ALL 0.50 Check condition and operation of flight deck main supply line.


PC-21-2012-00 VCK 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF ALL 0.50 Visually check mix manifold riser duct caps (2) for condition.





MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 23: COMMUNICATIONS PC-23-001-00 9 OPC 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

NOTE NOTE PCF/PCC ALL 0.50 Operationally check lavatory address speaker.

INTERVAL NOTE: Whichever comes first.

ZONE/ACCESS NOTE: Component has been relocated, but procedure is the same as passenger aircraft. See PC AMM 23-31-00/1 for new location. See OEM maintenance manual 23-31-00/501 for procedure.

PC-23-005-01 9 DIS LIF LIM LIF LIM NOTE NOTE PCF ALL 0.50 Replace the voice recorder Underwater Locator Beacon (ULB)

battery at the manufacturer’s recommended ULB life limit.


PC-23-005-02 9 OPC 2 YR 2 YR NOTE NOTE PCF ALL 0.50 Operationally check the voice recorder Underwater Locator Beacon

(ULB).


PC-23-2000-00 VCK 24 MO 24 MO NOTE NOTE PCC ALL Inspect the main harnesses running to individual components and

equipment for CDSS (cockpit door surveillance system).

NOTE: for security purposes the smoke barrier door functions as the cockpit door.

ZONE/ACCESS NOTE: Refer to PC AMM 31-00-00 for component locations.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG PC-23-2002-00 RST 6 MO 6 MO 250

PCC ALL Clean video camera housing viewing window for CDSS (cockpit

door surveillance system).


ZONE/ACCESS NOTE: Refer to PC AMM 31-00-00 for component locations.

PC-23-2004-00 DET 24 MO 24 MO NOTE NOTE PCC ALL Inspect installation of the following CDSS (cockpit door surveillance

system) components: monitors, cameras, system control unit, on/off switch, circuit breaker, cabin ready switch.


ZONE/ACCESS NOTE: See Global Airworks AMM 23-81-00 for component locations and procedure.

PC-23-2006-00 FNC 12 MO 12 MO NOTE NOTE PCC ALL Conduct CDSS (cockpit door surveillance system) operational check

in accordance with Global Airworks AMM 23-81-00 procedure.


ZONE/ACCESS NOTE: See Global Airworks AMM 23-81-00 for component locations and procedure.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 25: EQUIPMENT AND FURNISHINGS PC-25-014-00 8 GVI 750 FH 750 FH 836

846 PCC ALL 0.10 Check No. 4 passenger door-mounted escape slide inflation bottles

for proper pressure. PC-25-015-00 8 RST 3 YR

NOTE 3 YR

NOTE 836 846

PCC ALL 4.20 Restore No. 4 passenger door mounted escape slides. NOTE: Restoration includes functional (inflation) and component checks as recommended by vendor and replacement of age-dated items (batteries, survival kit) as required.

INTERVAL NOTE: For Evacuation Systems, perform the following every 3 years up to and including 15 years. After system has been in service for more than 15 years, the following should be done each year (annually), if the inflatable and hose are not replaced at 15 years.

PC-25-016-01 OPC 3 YR 3 YR 836

846 PCC ALL 2.00 Operationally check, on a sampling basis, the No. 4 passenger door

mounted escape slides per the following schedule.

Operators with four (4) or fewer airplanes in their fleet should perform the operational check on one (1) passenger door escape slide in their fleet within each three (3) year period.

Operators with five (5) or more airplanes in their fleet should perform the operational check on three (3) passenger door escape slides in their fleet within each three (3) year period.

Each sample may be taken from the left or right side. A different exit should be selected at each check. Inadvertent deployments may not be used to satisfy this requirement.

PC-25-032-01 GVI 12 MO 12 MO 836

846 836 846

PCC ALL 0.20 Visually check the No. 4 door-mounted escape slide assembly latch cables for condition.

AIRPLANE NOTE: Service Bulletin 757-25A0108 provides the procedure to accomplish the check. Applicable to passenger and PCC airplanes line numbers 1 through 344 that have not accomplished the termination action per this service bulletin or equivalent. This check is required per FAA AD 90-12-11.



PC-0118-05 Nov 23/2016 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page 1.1-6

MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG PC-25-034-00 8 RST 5 YR

NOTE 5 YR

NOTE NOTE NOTE PCF/PCC ALL 2.00 Restore the emergency escape descent devices.

INTERVAL NOTE: Manufacturer currently recommends overhaul at five (5) years or after each use, whichever occurs first.

ZONE/ACCESS NOTE: Inertia reels are located in flight compartment. See PC AMM 25-61-00/1 for location.

PC-25-2000-00 8 OPC 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF ALL 0.10 Check supernumerary seat restraint attachment (and inertia reel if installed).


ZONE/ACCESS NOTE: Double attendant seat has been relocated to flight compartment and is referred to as supernumerary seat. See PC AMM 25-11-00/1 for new location. See OEM maintenance manual 25-25-02/401 for procedure.

PC-25-2002-00 GVI 3000 FH 3000 FH 250

NOTE PCC ALL Perform general visual inspection of smoke barrier for condition.

NOTE: Barrier is located between cargo and passenger compartment.

PC-25-2004-00 VCK 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

210 NOTE

NOTE PCF NOTE

ALL 0.10 Visually check Flight Deck Cabinet Check surfaces for cracks, cuts, stains, loose bonding and any other obvious defects. Check doors, hinges, and latches for damage and deformation. Check placards for legibility, damage, and for secure attachment to mating parts. Check sealant for deterioration. NOTE: Defective components must be repaired or replaced. Refer to PC AMM 25-10-01


ZONE/ACCESS NOTE: Cabinet has been installed forward of STA 297.00 partition in lieu of left observer seat.

AIRPLANE NOTE: If installed.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 26: FIRE PROTECTION PC-26-010-00 8 OPC 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

NOTE NOTE PCF/PCC ALL 1.30 Operationally check cargo fire extinguishing armed switches and verify firing circuit integrity and cargo compartment isolation. ZONE/ACCESS NOTE: Task is the same as OEM MPD Task 26-010-00, except right recirculation system is deactivated. INTERVAL NOTE: Whichever comes first.

PC-26-016-00 OPC 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCC ALL 0.48 Operationally check the lavatory smoke detectors. ZONE/ACCESS NOTE: Combi (PCC) passenger lavatories only. Note that crew lavatories in Freighter (PCF) and Combi (PCC) do not have smoke detectors. INTERVAL NOTE: Whichever comes first.

PC-26-2006-00 SVC 10 YRS 10 YRS 250

PCC ALL Remove the halon bottles and perform hydrostatic check as per

supplier requirements. Note: bottles may be returned to supplier for this test.

PC-26-2008-00 SVC 4000 FH

18 MO 4000 FH 18 MO

250

PCC ALL Check due date for squib replacement and replace if expired. INTERVAL NOTE: whichever comes first.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG PC-26-2010-00 GVI 600 FH 600 FH NOTE PCF/PCC ALL Perform a GVI inspection of detectors for cleanliness. If cleaning

required, remove detectors from airplane as per PC AMM 26-10-00. Service detectors as per component maintenance manual. Reinstall detectors. ZONE/ACCESS NOTE: See PC AMM 26-10-00 for component locations.

PC-26-2012-00 RST NOTE NOTE 250

PCC ALL Replace halon bottles with integral pressure switches and squibs.

Replace pressure regulator and filter assembly. INTERVAL NOTE: following any suppression system discharge event.

PC-26-2014-00 FNC 1000 FH 1000 FH NOTE NOTE PCF/PCC ALL Perform a functional check of the smoke detectors using the CFMU

test switch as per PC AMM 26-10-00. ZONE/ACCESS NOTE: CFMU panel located in E/E bay

PC-26-2016-00 GVI 18,500 FH 18,500 FH NOTE NOTE PCF/PCC ALL Perform a general visual inspection of the FiDS system identification

placards. ZONE/ACCESS NOTE: placards are located in the E/E bay for the CFMU and at each smoke detector. INTERVAL NOTE: task satisfied by E/E zonal and cabin zonal inspections.

PC-26-2018-00 DET 18,500 FH 18,500 FH NOTE NOTE PCF/PCC ALL Perform a detailed inspection of the smoke detector units, visible

wiring, pans and attachment hardware for damage. NOTE: with detector pan removed. ZONE/ACCESS NOTE: see PC AMM 26-10-00 for component location




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG PC-26-2020-00 GVI 24,000 FH 24,000FH NOTE NOTE PCF/PCC ALL Perform a general visual inspection of the FiDS system wiring.

ZONE/ACCESS NOTE: main deck cargo compartment and E/E compartment. NOTE: Task satisfied by OEM Internal E/E Zonal and Cabin Zonal inspections.

PC-26-2022-00 GVI 6000 FH 6000 FH 250

PCC ALL Perform a general visual inspection of the halon bottles, tubing, and

racks.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 27: FLIGHT CONTROLS PC-27-001-05 9 DET 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

118 119BL PCF ALL 1.00 Detailed visual inspection of flight control cables under galleys and lavatories for wear, broken strands, corrosion, kinks and bird caging. Check end fittings, turnbuckles, pulleys, brackets, fairleads and quadrants for wear, corrosion, cracks and security.

INTERVAL NOTE: Whichever comes first. PC-27-001-05 9 DET 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

118 153 154 161 162 165 166

119BL 1532 1612 1652

NOTE

PCC ALL 3.65 Detailed visual inspection of flight control cables under galleys and lavatories for wear, broken strands, corrosion, kinks and bird caging. Check end fittings, turnbuckles, pulleys, brackets, fairleads and quadrants for wear, corrosion, cracks, and security.


ACCESS NOTE: Aft cargo compartment ceiling panels Body Station (BS) 1240 to BS 1320.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 31: INDICATING/RECORDING SYSTEMS PC-31-001-01 9 RST LIF LIM LIF LIM NOTE NOTE PCF ALL 0.50 Replace the digital flight data recorder Underwater Locator Beacon

(ULB) at the manufacturer’s ULB life limit.


PC-31-001-02 9 OPC 2 YR 2 YR NOTE NOTE PCF ALL 0.50 Operationally check the digital flight data recorder Underwater

Locator Beacon (ULB).


PC-31-002-00 9 OPC 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF ALL 0.50 Verify all required aircraft parameters are recorded properly on the flight data recorder.



PC-31-007-01 OPC 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

211 212

311AL PCF/PCC ALL 2.00 Check take-off configuration warning system.

NOTE: Task is the same as in OEM Maintenance Manual EXCEPT: Prior to procedure, ensure main deck cargo door (MDCD) is closed.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 32: LANDING GEAR PC-32-001-05 9 DET 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

118 119BL PCF/PCC ALL 0.25 Detailed visual inspection of landing gear cables under galleys and lavatories for wear, broken strands, corrosion, kinks and bird caging. Check end fittings, turnbuckles, pulleys, brackets, fairleads and quadrants for wear, corrosion, cracks, and security. AIRPLANE NOTE: 10% of operators fleet. INTERVAL NOTE: Whichever comes first.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 33: LIGHTS PC-33-001-00 8 OPC 750 FH 750 FH 200 PCC ALL 0.20 Operationally check emergency lights using test switches.

NOTE: Attendant panel is relocated in the Combi. Refer to PC-AMM-33-22-00 for panel location. Procedure is the same as in the Boeing OEM MPD.

PC-33-004-01 OPC 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

200 PCC ALL 0.50 Operationally check emergency lights using control switches.

NOTE: Attendant panel is relocated in the Combi. Refer to PC AMM 33-22-00 for panel location. Procedure is the same as in Boeing OEM MPD. INTERVAL NOTE: Whichever comes first.

PC-33-007-00 8 FNC 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

250 NOTE

PCC ALL 3.00 Functionally check the ceiling light illumination levels at passenger cabin aisle and cross-aisle locations (if photo luminescent floor proximity lights installed.) ZONE NOTE: Task applicable to Combi’s remaining passenger cabin only. INTERVAL NOTE: Whichever comes first.

PC-33-007-01 OPC 750 FH 750 FH 200 PCF ALL 0.50 Operationally check emergency lights using pilot’s control switch.

INTERVAL NOTE: Whichever comes first. PC-33-2002-00 RST 6000 FH

18 MO 6000 FH 18 MO

250 NOTE

PCC ALL Photoluminescent emergency escape path marking lighting: Inspection. Inspect and clean and/or replace damaged or missing top cover/casing, bottom track, photoluminescent elements, lateral segments, and end caps or ramps (if installed). ZONE NOTE: Escape path marking lighting is installed in passenger cabin only. INTERVAL NOTE: Whichever comes first.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG PC-33-2004-00 RST 6000 FH

18 MO 6000 FH 18 MO

250 NOTE

PCC ALL Photoluminescent emergency escape path marking lighting: Servicing/Cleaning.

Clean and/or replace top cover and photoluminescent insert.

ZONE NOTE: Escape path marking lighting is installed in passenger cabin only.

INTERVAL NOTE: Whichever comes first. PC-33-2006-00 FNC 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

250 NOTE

PCC ALL Photoluminescent emergency escape path marking lighting: Functional check.

Functionally check illumination levels in passenger cabin. Replace or repair inoperative ceiling lamps at life raft area. Replace inoperative or missing exit markers.


INTERVAL NOTE: Whichever comes first. PC-33-2008-00 FNC 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

250 NOTE

PCC ALL Photoluminescent emergency escape path marking lighting: Inspection and functional check.

Return test segment of initial installation to STG Aerospace for examination to ensure coating performance acceptability. Reference STG Manual L21-10, ICAW Photoluminescent Aisle Path Marking System, for the shipping address.


INTERVAL NOTE: Whichever comes first. PC-33-2010-00 8 FNC 10 YR

10 YR

250

NOTE PCC ALL 3.00 Photoluminescent emergency escape path marking lighting:

Manufacturer inspection and functional check.

Return test segment of initial installation to STG Aerospace for examination to ensure coating performance acceptability.

Reference STG Manual L21-10, ICAW Photoluminescent Aisle Path Marking System, for the shipping address.





MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 35: OXYGEN PC-35-005-00 6 DET 4500 FH 4500 FH 211

212 PCF ALL 0.50 Visually check crew/supernumerary oxygen mask/regulator

assembly for condition and verify operation of crew mask microphone, if present.

PC-35-010-00 8 DET 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

200 PCC ALL 2.00 Visually check oxygen module sets of passenger oxygen masks evenly spaced throughout the passenger cabin for condition. INTERVAL NOTE: Whichever comes first.

PC-35-015-01 OPC 2250 FH 2250 FH 211

212 PCF ALL 0.6 Operationally check the crew/supernumerary oxygen

mask/regulator.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 38: WATER/ WASTE PC-38-001-00 8 RST NOTE NOTE NOTE NOTE PCF/PCC ALL 2.00 Disinfect potable water system.

INTERVAL NOTE: As required per applicable regulatory authority.

ZONE/ACCESS NOTE: See PC AMM 38-10-00/201 for location and procedure.

NOTE TO OPERATORS

PCF/PCC ALL Crew lavatory module periodic maintenance.

NOTE: The crew lavatory module is covered under a separate Supplemental Type Certificate (STC) held by AIM Aviation, Inc. Refer to Maintenance Manual for Module Assembly, Lavatory, No. AA14485-1, AIM Aviation, Inc. for more information.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 52: DOORS

PC-52-003-00 6 DET 24000

FH 72 MO NOTE

24000 FH

72 MO NOTE

836 846

231AL 252AR

PCC ALL 0.40 Visual check for proper extension of the rotary snubber dampening fluid level indicator for the No. 4 left and right passenger doors.


PC-52-004-00 9 GVI 750 FH 750 FH 253

254

2535 2541

NOTE

PCC ALL 0.20 Check emergency power reservoir pressure gauge for required pressure for the No. 4 left and right passenger doors. ACCESS NOTE: Remove Special Access 2241 door panel to access emergency pressure gauge.

PC-52-005-00 6 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

832 842

231AL 232AR

PCF ALL 0.20 Lubricate the No. 2 left and right passenger doors hinge mechanism. Some airplanes may not have lube points on lower hinge(s).

NOTE: No. 2 doors are deactivated.

INTERVAL NOTE: Whichever comes first. MRB frequency is 2C.

PC-52-005-00 6 LUB 6000 FH 18 MO NOTE

6000 FH 18 MO NOTE

832 836 842 846

231AL 232AR 251AL 252AR

PCC ALL 0.20 Lubricate the passenger doors No. 2 and 4 hinge mechanism. Some airplanes may not have lube points on lower hinge(s).


INTERVAL NOTE: Whichever comes first. MRB frequency is 2C

PC-52-005-01 6 LUB 6000 FH 18 MO NOTE

6000 FH 18 MO NOTE

832 842

231AL 232AR 8321 8421

PCF ALL 0.40 Lubricate the No. 2 left and right passenger doors hinge torque tubes (Door and Body).






MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG

PC-52-005-01 6 LUB 6000 FH 18 MO NOTE

6000 FH 18 MO NOTE

832 836 842 846

231AL 232AR 251AL 252AR 8321 8361 8421 8461

PCC ALL 0.40 Lubricate the left and right passenger doors No. 2 and 4 hinge torque tubes (door and body). INTERVAL NOTE: Whichever comes first.

PC-52-005-03 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

832 842

231AL 232AR

PCF ALL 0.30 Lubricate the No. 2 left and right passenger door rollers and latch crank bearings.


PC-52-005-03 LUB 6000 FH 18 MO NOTE

6000 FH 18 MO NOTE

832 836 842 846

8321 8361 8421 8461

PCC ALL 0.30 Lubricate the No. 2 and 4 left and right passenger door rollers and latch crank bearings.


PC-52-005-05 LUB 500 FH

NOTE 500 FH NOTE

836 846

8361 8461

PCC ALL 0.20 Lubricate the left and right passenger doors No. 4 girt bar sliding mechanism.

INTERVAL NOTE: More frequent lubrication (daily) may be required to prevent icing during cold weather operations depending on the operator’s experience.

PC-52-005-06 LUB 6000 FH 18 MO

6000 FH 18 MO

836 846

8361 8461

PCC ALL 0.50 Lubricate the left and right passenger doors No. 4 activate/deactivate and girt bar handling mechanisms.

PC-52-005-09 LUB 12000 FH

36 MO 12000 FH

36 MO 836 846

836 846

PCC ALL 0.10 Lubricate the left and right passenger door No.4 lower harness slide release latch.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN


PC-52-005-10 LUB 12000 FH 36 MO

12000 FH 36 MO

836 846

251AL 252AR

PCC NOTE

ALL 0.20 Lubricate left and right passenger doors No. 4 emergency power assist support assembly bearing and cam actuation support bearing.

AIRPLANE NOTE: SB 757-52-0055. Applicable to passenger and Combi airplanes, line numbers 455 and on, and passenger and Combi airplanes, line numbers 1 through 454, which have had the terminating action per this service bulletin or equivalent accomplished.

PC-52-005-11 LUB 4000 FH 4000 FH 836

846 251AL 252AR

PCC NOTE

ALL 0.20 Lubricate left and right passenger doors No. 4 emergency power assist support assembly bearing and cam actuation support bearing.

AIRPLANE NOTE: SB 757-52-0055. Applicable to passenger and Combi airplanes, line numbers 1 through 454, which have not had the service bulletin incorporated.

PC-52-031-01 FNC 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

836 846

PCC NOTE

ALL 1.20 Functionally check the travel of the No. 4 left and right passenger door emergency power actuation cable.

AIRPLANE NOTE: SB 757-52-0055. Applicable to passenger and Combi airplanes, line numbers 455 and on, and passenger and Combi airplanes, line numbers 1 through 454, which have had the terminating action per this service bulletin, or equivalent. INTERVAL NOTE: Whichever comes first.

PC-52-031-02 FNC 4000 FH 4000 FH 836

846 836 846

PCC NOTE

ALL 1.20 Functionally check the travel of the No. 4 left and right passenger door emergency power actuator cable.

AIRPLANE NOTE: SB 757-52-0055. Applicable to passenger and Combi airplanes, line numbers 1 through 454, which have not had the terminating action accomplished per this service bulletin, or equivalent




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN


PC-52-032-01 OPC 12000 FH 36 MO NOTE

12000 FH 36 MO NOTE

836 846

PCC ALL 0.40 Operationally check the adjustment of the No. 4 left and right passenger door emergency mechanism including the disarm cable, trigger pin mechanism, and mode select lockout mechanism.


PC-52-033-01 OPC 12000 FH 36 MO NOTE

12000 FH 36 MO NOTE

836 846

2535 2541

PCC ALL 2.00 Operationally check the adjustment of the No. 4 left and right passenger door girt bar mechanism.


PC-52-036-02 GVI 6 MO 6 MO 836 846

PCC ALL 0.50 Inspect the No. 4 right and left passenger door power assist for unusual wear marks, damage, and/or cracks per service bulletin 757-52A0023 and FAA AD 95-25-01.

AIRPLANE NOTE: SB 757-52A0023 is applicable as follows: Group 1: All 757 Passenger Airplanes line positions 1-151. Group 2: All 757 Passenger Airplanes line positions 152-578.

PC-52-2000-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

837 837 PCF/PCC ALL 0.20 Lubricate crew entry door latch rods.


PC-52-2002-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

837 837 PCF/PCC ALL 0.20 Lubricate crew entry door handle connecting rod.


PC-52-2004-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

837 837 PCF/PCC ALL 0.20 Lubricate crew entry door outer latch yoke bearing.


PC-52-2006-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

837 837 PCF/PCC ALL 0.20 Lubricate crew entry door hinge.





MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG PC-52-2008-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door hinges.


PC-52-2010-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door lift actuator.


PC-52-2012-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door link assemblies.


PC-52-2014-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door micro switches.


PC-52-2016-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door latch assemblies.


PC-52-2018-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door latch spools.


PC-52-2020-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door locking mechanism gang bar.


PC-52-2022-00 LUB 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

838 838 PCF/PCC ALL 0.20 Lubricate main cargo door vent door.





MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN


PC-52-2024-00 VCK 00048 HRS

NOTE

00048 HRS

NOTE

NOTE NOTE PCF/PCC ALL Visually check the condition of the main cargo door seals and depressors.

INTERVAL NOTE: 48 elapsed clock hours.

ZONE/ACCESS NOTE: See PC AMM 52-30-00/1 to locate component.

PC-52-2026-00 DIS 1000 FH 1000 FH NOTE NOTE PCF/PCC ALL Visually check hydraulic panel filters. Replace filters if indicator is

red.

ZONE/ACCESS NOTE: See PC AMM 52-30-00/401 to locate component and for removal and installation instructions.

PC-52-2028-00 VCK 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

NOTE NOTE PCF/PCC ALL Visually check the main cargo door pressure relief doors (vent doors) including mechanisms and striker plate for wear and security.



PC-52-2030-00 OPC 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

NOTE NOTE PCF/PCC ALL Operational check hydraulic pump.

INTERVAL NOTE: Service/replacement pump as recommended by vendor.


PC-52-2032-00 VCK 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF/PCC ALL Inspect hydraulic fluid level using fuel level sight gauge on hydraulic tank. Fill as required.


ZONE/ACCESS NOTE: See PC AMM 52-30-00/401 to locate component.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN


PC-52-2034-00 VCK 6000 FH 18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF/PCC ALL Inspect all main cargo door hydraulic lines/connections for any fluid leakage.


ZONE/ACCESS NOTE: See PC AMM 52-30-00/401 to locate cargo door/hydraulic panel hydraulic lines.

PC-52-2036-00 VCK 1000 FH 1000 FH NOTE NOTE PCF/PCC ALL Inspect the following main cargo door external hydraulic lines for

damage, wear or leakage: -Main cargo door upper sill to main cargo door -At the FWD main cargo door actuator cover -At the AFT main cargo door actuator cover

ZONE/ACCESS NOTE: See PC AMM 52-30-00/401 to locate cargo door, actuator covers.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN


PC-52-2060-00 FNC 6000 FH 6000 FH 250 250 PCC ALL 0.25 Functionally check the smoke barrier door lock deny time delay and verification of the deny function.

PC-52-2062-00 FNC 6000 FH 6000 FH 250 250 PCC ALL 0.25 Functionally check the smoke barrier door lock deny time delay and

verification of reversion to default mode.)

PC-52-2064-00 FNC 750 FH 750 FH 250 250 PCC ALL 0.50 Functionally check the smoke barrier door hinges, latches, and handle.

PC-52-2066-00 GVI 6000 FH 6000 FH 250 250 PCC ALL 0.25 General visual inspection of the smoke barrier door seals for condition

and security.

PC-52-2068-00 OPC 5000 FC 5000 FC 830 830 PCF/PCC ALL 0.10 Operationally test latch/lock system of crew entry door.

PC-52-2070-00 OPC 5000 FC 5000 FC 830 830 PCF/PCC ALL 0.10 Operationally test crew entry door.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 56: WINDOWS PC-56-2000-00 OPC 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

NOTE NOTE PCF/PCC ALL Operationally check the No. 2 right-hand flight deck window external opening mechanism.


ZONE/ACCESS NOTE: See PC AMM 56-11-04/1 to locate external opening mechanism.




ATA 71-80 (PW2000)

No changes to these sections. See OEM 757 Maintenance Planning Data document. ATA 71-80 (RR RB211-535)

No changes to these sections except task PC-76-101-05 below. See OEM 757 Maintenance Planning Data document.




MPD ITEM NUMBER

AMM REFERENCE

C A T

T A S K

INTERVAL

ZONE ACCESS

APPLICABILITY MAN

HOURS TASK DESCRIPTION THRES. REPEAT APL ENG ATA 76: ENGINE CONTROLS: ROLLS ROYCE PC-76-101-05 6 DET 12000 FH

36 MO NOTE

12000 FH 36 MO NOTE

118 119BL PCF/PCC 0.65 Detailed inspection of the thrust control cables under galleys and lavatories for condition.

INTERVAL NOTE: Whichever comes first. 10% of operator’s fleet.


STRUCTURAL MAINTENANCE REQUIREMENTS


SECTION 2 – STRUCTURAL MAINTENANCE REQUIREMENTS

A. Scope

This section of the MPD Supplement outlines the scheduled tasks for the Structural Maintenance Requirements. The supplement provided in this section shows the inspections that have been affected or created due to the Precision Conversions Freighter/Combi conversion. This program is designed to provide timely detection and repair of structural damage which may occur in the fleet during Freighter/Combi operations. Detection of corrosion, stress corrosion, minor accidental damage and fatigue cracking by visual and/or Non-Destructive Test (NDT) procedures is considered. Major accidental damage such as that caused by bird strike or large ground handling equipment is considered readily detectable and visible signs such as fuel leaks, loose fasteners, loss of cabin pressure, etc., continue to be an essential part of the Structural Maintenance Requirements. This program is intended to serve as a guide for airlines to develop individual maintenance programs. The structural tasks listed herein constitute minimum inspection requirements for all B757-200PCF/PCC airplanes. Notes applicable to the Structural Maintenance Requirements are followed by explanations of the operating rules, age exploration program, supplemental structural inspection program, reporting of structural inspection tasks, and the page format.

B. Notes

No changes to this section. See OEM Maintenance Planning Data document.

C. Operating Rules

All airplanes in an operator's or group of operators 757PCF/PCC fleet shall be subject to the provisions of this document. These include requirements for external and internal inspections, corrosion prevention and control requirements, and a supplemental structural inspection program. Initial check intervals for the Structural Maintenance Requirements are expressed in both calendar time and flight cycles. Any check interval change would be substantiated by service experience and handled by FAA approved program revision procedures as applicable to each operator or group of operators. Supplemental structural inspection requirements listed in the Airworthiness Limitations Section 9 should be maintained utilizing methodology provided in Precision Conversions Document PC-0118-05-DTR or alternate FAA approved routine program revision procedure. One maintenance program based on Section 9 Airworthiness Limitations has been selected and is included in this Section 2. Special Detailed inspections are to be used when specified for inspecting hidden details or may be used as alternatives to detailed visual inspections. Hidden details requiring NDT procedures are listed under appropriate zones either internally or externally.




Normal cleanup procedures are to be used prior to conducting general visual or detailed inspections. Specified cleanup procedures are to be used for Special Detailed Inspections. Sealant and corrosion protection finishes should only be removed when specified and restored in accordance with the 757 Airplane Maintenance Manual after the task is completed. Excessive dust, debris, or overspray of corrosion inhibiting compounds, found during any inspection, are considered to be an unsatisfactory condition possibly reducing the fire resistance of the airplane design. Clean-up of these materials should be a standard part of maintenance activity. (Reference 757 Service Letter 757-SL-25-064 dated March 23, 1998).

D. Age Exploration Program It is required that each aircraft in an operator’s fleet be inspected at the initial and repetitive inspections shown in this Section 2, and/or Section 9 and/or in PC-0118-05-DTR.

E. Supplemental Structural Inspection Program Where the initial scheduled inspection program does not ensure timely detection of potential fatigue damage in a structural item, supplemental fatigue related inspections will be required and are listed as Airworthiness Limitations in Section 9. Such supplemental inspections will begin at or prior to the threshold defined in this Section 2 and/or Section 9 of this document, and/or in PC-0118-05-DTR. One supplemental inspection program has been developed for all affected structure, using the Damage Tolerance Rating System (DTR) or Flaw Tolerance Rating (FTR), defined in PC-0118-05-DTR of this document. The resulting Precision Conversions inspections are identified by an MPD Item Number containing a reference to FTR Check Form in the Task Description of this Section 2 and designated as Fatigue Items (F under column PGM). These inspections must be accomplished at or prior to the specified threshold for the task. For OEM inspections which are Fatigue Items, utilize Boeing DTR forms (D622N001-DTR), adjusting for PC reduction factors for both threshold and repeat inspection interval.

When reaching the threshold of 50,000 flight cycles or the Flight Length Sensitive (FLS) cycles and hours (whichever comes first), all C-Check (or higher) Structural Inspection Repeat Intervals must be no greater than those shown in this section. The Structures C-Check Interval is defined as 3,000 flight cycles or 18 months. This interval restriction applies only to an extension to the flight cycle limit and not the calendar limit. 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 the FLS cycles and hours (whichever comes first). The reason for this is that the CFR 25.571 Damage Tolerance Evaluation takes credit for the Baseline Structures Program. The airworthiness limitations listed in Section 9 cover structure for which the required DTR is not satisfied by the Baseline Structural Inspections of this section. 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. All MPD tasks with 1000 or higher MPD sequence numbers (ex. PC-53-1102-00) are structures added/modified during the conversion. These tasks have 20000 flight cycles as the threshold (unless otherwise noted) since modification.




When reaching the threshold shown in Precision Conversion Document, PC-0118-05-DTR, all C-check (or higher) structural inspection repeat intervals must be no greater than those shown in MPD Section 2 and/or MPD Section 9, and or PC-0118-05-DTR. The Structures C-Check Interval is defined as 3000 flight cycles or 18 months (whichever comes first).

F. Corrosion Prevention Inspection requirements are determined on the basis of continual maintenance to preserve or restore the inherent corrosion preventive measures and structural surface finishes. The 757 Corrosion Prevention and Control Program (CPCP) is included as part of the Structural Inspection Requirement contained in this section. The objective of the CPCP is to control corrosion found on all structure listed in the Structural Inspection Requirement to Level 1 or better. All structural inspection items with an interval of 3000 FC or 18 months (whichever comes first) or higher (unless otherwise specified) require the application of the CPCP Basic Task.

G. Reporting Results Of Structural Inspections

Reports of structural significant defects, as defined by the FAA Service Difficulty Reporting (SDR) process, shall be submitted by operators who are operating under FAA regulations.

In addition to the above, all cracks found during the supplemental structural inspections shall be reported within ten (10) days directly to Manager Seattle Certification Office, Transport Airplane Directorate FAA and Precision Conversions using the Discrepant Structure Report form. Refer to Precision Conversions Document PC-0118-05-DTR for the required report form (any suitable alternative which contains the same information may be used).




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS

INTERVAL APPLICABILITY MAN HOURS TASK DESCRIPTION THRES. REPEAT APL ENG


SECTION, SUBJECT) WHICH SUPPORTS THE MPD REQUIREMENT

00-99 = MPD SEQUENCE NUMBER 000-999 = SEQUENCE NUMBER OF OEM STRUCTURE

AFFECTED BY CONVERSION

1000-1999 = SEQUENCE NUMBER OF CONVERSION-ADDED/MODIFIED STRUCTURE

FIRST TWO DIGITS = ATA CHAPTER “PC” IDENTIFIES PRECISION CONVERSIONS ADDED TASKS EXAMPLE ILLUSTRATING FORMAT PC-52-1438-00 838 NOTE PCF ALL INTERNAL - SPECIAL DETAILED: Main deck cargo door:

External skin, BS 480 to 620, S-4L and WL 203

INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-01 for repeat inspections.

FIGURE 2-1 STRUCTURES MAINTENANCE REQUIREMENTS EXAMPLE




H. Page Format

1. MPD ITEM NUMBER

Each task in the MPD is identified with a unique number by zone and ATA. The first 2 digits correspond to ATA Chapter. The remaining digits denote the MPD Sequence Number.

2. AMM REFERENCE

Airplane Maintenance Manual procedure (Chapter, Section, Subject) which supports the MPD requirement.

3. PGM

Indicated program, i.e., S = Structural Item and F = Fatigue Item

4. ZONE

The zone identifies where the task is performed on the airplane

5. ACCESS

Access door/panel number required to gain access to item to be inspected (see Access Door/Panel illustrations, Section 4).

6. INTERVAL

Task intervals are specified in terms of flight cycles or calendar time.

7. APPLICABILITY


APL PCF= B757-200PCF (Precision Conversions Freighter) PCC = B757-200PCC (Precision Conversions Combi) PCF/PCC = Precision Conversions Freighter and Combi NOTE = Airplane Applicability Note

ENGINE ALL = All 757 Engines NOTE = Engine Applicability Note




8. MANHOURS

Estimated man hour required to perform the task. The estimates do not include man hours for performing the following functions:

• Docking the aircraft • Positioning/removing work stands • Access door/panel removal and installation • Cabin equipment, lining, floor panel and insulation removal and installation • Defueling, purging and refueling fuel tanks • Correcting discrepancies found while performing the task

The estimates are based on the use of skilled personnel and assume that inspections in the same zone with a common frequency will be performed together.

9. TASK DESCRIPTION

The level of inspection performed and a description of the task.




Structural Maintenance Tasks – OEM Structures Affected by Conversion The following table lists Boeing inspections modified due to the OEM structure being affected by the conversion.

DELETED INSPECTIONS* CHANGED INSPECTIONS CHANGED INSPECTIONS

PCF and PCC Items OEM MPD Item Number PC MPD Item Number OEM MPD Item Number PC MPD Item Number

PCF and PCC 52-414-00 PC-52-414-00 PCF Only

52-408-00 53-102-00 PC-53-102-00 53-236-00 PC-53-236-00 52-410-00 53-106-00 PC-53-106-00 52-464-00 53-118-00 PC-53-118-00 53-246-00 53-410-00 PC-53-410-00 PCC Only 53-248-00 53-412-00 PC-53-412-01 53-236-00 PC-53-236-01 53-250-00 53-412-00 PC-53-412-02 53-262-00 53-414-00 PC-53-414-00 53-264-00 53-416-00 PC-53-416-00

53-418-00 PC-53-418-00 53-420-00 PC-53-420-00 53-422-00 PC-53-422-01 53-422-00 PC-53-422-02 53-518-00 PC-53-518-00

53-522-00 PC-53-522-00 PCF Only 53-528-00 PC-53-528-00 52-436-00 52-438-00 52-440-00

* Operators must evaluate and determine applicability of OEM structural inspection tasks not listed. If the structure is no longer present due to the cargo conversion, the applicable portions of the OEM task which no longer apply need not be completed.




Structural Maintenance Tasks – Conversion-Added/Modified Structures The following table lists the new MPD inspections of the structure added during the conversion. The new inspections can be identified by the sequence number of -1000 or higher.

NEW INSPECTIONS - MPD ITEM NUMBER

PCF Only PCC and PCF PC-53-1056-00 PC-52-1204-00 PC-53-1012-00 PC-53-1078-00 PC-53-1140-00 PC-53-1058-00 PC-52-1252-00 PC-53-1014-00 PC-53-1080-00 PC-53-1142-00 PC-53-1182-00 PC-52-1400-00 PC-53-1016-00 PC-53-1082-00 PC-53-1144-00 PC-53-1184-00 PC-52-1402-00 PC-53-1018-00 PC-53-1084-00 PC-53-1146-00 PC-53-1186-00 PC-52-1404-00 PC-53-1020-00 PC-53-1086-00 PC-53-1148-00 PC-53-1188-00 PC-52-1406-00 PC-53-1022-00 PC-53-1088-00 PC-53-1150-00 PC-53-1190-00 PC-52-1408-00 PC-53-1024-00 PC-53-1090-00 PC-53-1152-00 PC-53-1192-00 PC-52-1410-00 PC-53-1026-00 PC-53-1092-00 PC-53-1154-00 PC-53-1194-00 PC-52-1412-00 PC-53-1028-00 PC-53-1094-00 PC-53-1156-00 PC-53-1196-00 PC-52-1414-00 PC-53-1030-00 PC-53-1096-00 PC-53-1158-00 PC-53-1198-00 PC-52-1416-00 PC-53-1032-00 PC-53-1098-00 PC-53-1160-00 PC-53-1200-00 PC-52-1418-00 PC-53-1034-00 PC-53-1100-00 PC-53-1162-00 PC-53-1202-00 PC-52-1420-00 PC-53-1036-00 PC-53-1102-00 PC-53-1164-00 PC-53-1204-00 PC-52-1422-00 PC-53-1038-00 PC-53-1104-00 PC-53-1166-00 PC-53-1206-00 PC-52-1424-00 PC-53-1040-00 PC-53-1106-00 PC-53-1168-00 PC-53-1208-00 PC-52-1426-00 PC-53-1042-00 PC-53-1108-00 PC-53-1170-00

PC-52-1428-00 PC-53-1044-00 PC-53-1110-00 PC-53-1172-00 PC-52-1430-00 PC-53-1046-00 PC-53-1112-00 PC-53-1174-00

PCC Only PC-52-1432-00 PC-53-1048-00 PC-53-1114-00 PC-53-1176-00 PC-53-1222-00 PC-52-1434-00 PC-53-1050-00 PC-53-1116-00 PC-53-1178-00 PC-53-1224-00 PC-52-1436-00 PC-53-1052-00 PC-53-1118-00 PC-53-1180-00 PC-53-1226-00 PC-52-1438-00 PC-53-1054-00 PC-53-1120-00 PC-53-1228-00 PC-52-1440-00 PC-53-1060-00 PC-53-1122-00

PC-52-1442-00 PC-53-1062-00 PC-53-1124-00 PC-52-1444-00 PC-53-1064-00 PC-53-1126-00 PC-53-1000-00 PC-53-1066-00 PC-53-1128-00 PC-53-1002-00 PC-53-1068-00 PC-53-1130-00 PC-53-1004-00 PC-53-1070-00 PC-53-1132-00 PC-53-1006-00 PC-53-1072-00 PC-53-1134-00 PC-53-1008-00 PC-53-1074-00 PC-53-1136-00 PC-53-1010-00 PC-53-1076-00 PC-53-1138-00




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


ATA 52: DOORS PC-52-414-00 S 832

842 NOTE 375 FC 375 FC PCF/PCC ALL 0.10 EXTERNAL – GENERAL VISUAL: Passenger Door Exterior

Passenger door external skin ACCESS NOTE: As viewed from the ground.

PC-52-1204-00 S 837 NOTE 375 FC 375 FC PCF/PCC ALL

0.20 EXTERNAL - GENERAL VISUAL: Crew entry door, external skin,

frames and stops.

ACCESS NOTE: As viewed from the airplane. PC-52-1252-00 S 838 NOTE 375 FC 375 FC PCF/PCC ALL

0.20 EXTERNAL - GENERAL VISUAL: Main deck cargo door, external

skin, frames and stops.

ACCESS NOTE: As viewed from the airplane. PC-52-1400-00 F 837 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Crew entry door, external skin.


PC-52-1402-00 F 837 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Crew entry door, frames, ribs, stop

fittings and adjacent structure.


PC-52-1404-00 F 838 20000 FC NOTE PCF/PCC ALL

EXTERNAL – DETAILED: Main deck cargo door, external skin.

BS 480 to 620, Upper Sill to Lower Sill.



INTERNAL – DETAILED: Main deck cargo door, external skin.

BS 480 to 620, Upper Sill to Lower Sill.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-52-1408-00 F 838 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED–: Main deck cargo door, inner skin.


PC-52-1410-00 F 838 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Main deck cargo door, Intercostals.

INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-04 for repeat inspections


INTERNAL - DETAILED: Main deck cargo door, frames.

BS 480 to BS 620, S-4L to S-17L.



INTERNAL - DETAILED: Main deck cargo door, lower frames.

BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610 I-7 (WL 229) to door lower sill.


PC-52-1416-00 F 838 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Main deck cargo door, lower sill

BS 480 to BS 620.


PC-52-1418-00 F 838 20000 FC NOTE PCF/PCC ALL INTERNAL -DETAILED: Main deck cargo door, support fittings on

door and surround upper sill. BS 489 to BS 500 and BS 600 to BS 611, S-4L to S-6L.


PC-52-1420-00 F 837 20000 FC NOTE PCF/PCC ALL EXTERNAL - SPECIAL DETAILED: Crew entry door, external

skin. BS 302 to BS 333.


PC-52-1422-00 F 837 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Crew entry door, frames and

ribs. BS 302 to BS 333





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS



EXTERNAL - SPECIAL DETAILED: Main deck cargo door:

External skin. BS 480 to 620, upper sill to lower sill.



INTERNAL - SPECIAL DETAILED: Main deck cargo door:

External skin and splice. BS 480 to 620, WL 203. Longitudinal splice from interior at WL203.




Frames. BS 480 to BS 620, S-4L to S-17L.




Lower frames. BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610 I-7 (WL 229) to lower sill.

INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-07 for repeat inspections..




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-52-1432-00 F 838 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Main deck cargo door:

Upper sill, BS 480 to BS 620. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-13 for repeat inspections.

PC-52-1434-00 F 838 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Main deck cargo door:

Lower sill, BS 480 to BS 620. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-13 for repeat inspections.



Latch, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, S-17L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-90 for repeat inspections.



External skin, BS 480 to 620, S-4L and WL 203 INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-01 for repeat inspections.

PC-52-1440-00

F 838 20000 FC NOTE PCF/PCC ALL


Frames. BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610 I-7 (WL 229) to lower sill. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-07 for repeat inspections.



External skin, BS 480 to 620, S-4L and WL 203 INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-01 for repeat inspections.



Latch to lower frame attachment - BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-52-30-07 for repeat inspections.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


ATA 53: FUSELAGE PC-53-102-00 S 118 119BL 6000 FC

36 MO NOTE

6000 FC 36 MO NOTE

PCF/PCC ALL 1.00 INTERNAL - DETAILED: Floor Beams and Seat Tracks Floor beams and seat tracks immediately below and adjacent to galleys and lavatories if installed.

INTERVAL NOTE: Whichever comes first. PC-53-106-00 S 100 113AL

119BL 821/822

823 832/833 834/835 842/843 844/845

3000 FC 18 MO NOTE

3000 FC 18 MO NOTE

PCF/PCC ALL

3.00 EXTERNAL - DETAILED: Door stops and adjacent visible cutout structure within aircraft contour at all body openings (passenger, cargo, emergency, including overwing escape; and Section 41 access and electronic equipment doors).


PC-53-118-00 S 117

118 6000 FC

36 MO NOTE

6000 FC 36 MO NOTE

PCF/PCC ALL

0.10 INTERNAL - DETAILED: No. 1 passenger door lower sills.


PC-53-236-00 S 837

838

NOTE 375 FC 375 FC PCF ALL 0.25 EXTERNAL – GENERAL VISUAL: Upper lobe skin body external skin including door cutouts and stops. ACCESS NOTE: As viewed from the ground.

PC-53-236-01 S 836

837 838 846

NOTE 375 FC 375 FC PCC ALL 0.25 EXTERNAL – GENERAL VISUAL: Upper lobe skin body external skin including door cutouts and stops. ACCESS NOTE: As viewed from the ground.

PC-53-410-00 F 122 NOTE

NOTE PCF/PCC ALL 5.00 EXTERNAL - SPECIAL DETAILED: No. 1 cargo door cutout:

BS 560 edge frame outer chord and bearstrap, Upper sill to lower sill. (Type 2 structure).

INTERVAL NOTE: For threshold/repeat calculation, see PC-0118-05-DTR, page 1.0-1 for formula and pages 1.0-2 and 1.0-3 for reduction factors. Utilize Boeing DTR forms (D622N001-DTR), adjusting for PC reduction factor.

NOTE: The NDI method(s) necessary to accomplish the intent of this inspection are contained in the 757 non-destructive test manual D634N301. The inspection procedures are contained in Part 6, Subject 53-30-07.

AIRPLANE NOTE: B757 -200 passenger airplanes line number 1-57 converted to B757-200PCF/PCC airplanes.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-412-01 F 122 NOTE NOTE PCF/PCC ALL 1.25 INTERNAL - SPECIAL DETAILED: No. 1 cargo door cutout:

BS 560 edge frame inner chord and web, upper sill to S-24 (Type 2 structure)

INTERVAL NOTE: For threshold/repeat calculation, see PC-0118-05-DTR, page 1.0-1 for formulas and pages 1.0-2 and 1.0-3 for reduction factors. Utilize Boeing DTR forms (D622N001-DTR), adjusting for PC reduction factor.


AIRPLANE NOTE: B757-200 passenger airplanes line number 1-57 converted to B757-200PCF/PCC airplanes.


BS 620 edge frame inner chord and web, S-20 to lower sill (Type 2 structure)




PC-53-414-00 F 122 NOTE

NOTE PCF/PCC ALL

5.00 EXTERNAL - SPECIAL DETAILED: No. 1 cargo door cutout:

BS 560 edge frame outer chord and bearstrap, Upper sill to lower sill (Type 2 structure).



AIRPLANE NOTE: All B757-200 passenger airplanes line number 58 and on converted to B757-200PCF/PCC airplanes.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-416-00 F 122 NOTE

NOTE PCF/PCC ALL 2.00 INTERNAL - DETAILED AND SPECIAL DETAILED: No. 1 cargo

door intercostal: Door stop No. 1 and 6, fwd and aft (Type 2 structure).



PC-53-418-00 F 122 NOTE


BS 620 edge frame outer chord and bearstrap, Upper sill to lower sill. (Type 2 structure).




PC-53-420-00 F 122 NOTE


BS 620 edge frame outer chord and bearstrap, upper sill to lower sill. (Type 2 structure).


NOTE: the NDI method(s) necessary to accomplish the intent of this inspection are contained in the 757 non-destructive test manual D634N301. The inspection procedures are contained in Part 6, Subject 53-30-07.

AIRPLANE NOTE: All B757-200 passenger airplanes line number 58 and on converted to B757-200PCF/PCC airplanes.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS



BS 560 edge frame inner chord and web, upper sill to S-24. (Type 2 structure). INTERVAL NOTE: For threshold/repeat calculation, see PC-0118-05-DTR, page 1.0-1 for formulas and pages 1.0-2 and 1.0-3 for reduction factors. Utilize Boeing DTR forms (D622N001-DTR), adjusting for PC reduction factor. NOTE: The NDI method(s) necessary to accomplish the intent of this inspection are contained in the 757 non-destructive test manual D634N301. The inspection procedures are contained in Part 6, Subject 53-10-11. AIRPLANE NOTE: All B757-200 passenger airplanes line number 58 and on converted to B757-200PCF/PCC airplanes.


BS 620 edge frame inner chord and web, S-20 to lower sill (Type 2 structure). INTERVAL NOTE: For threshold/repeat calculation, see PC-0118-05-DTR, page 1.0-1 for formulas and pages 1.0-2 and 1.0-3 for reduction factors. Utilize Boeing DTR forms (D622N001-DTR), adjusting for PC reduction factor. NOTE: The NDI method(s) necessary to accomplish the intent of this inspection are contained in the 757 non-destructive test manual D634N301. The inspection procedures are contained in Part 6, Subject 53-10-10. AIRPLANE NOTE: All B757-200 passenger airplanes line number 58 and on converted to B757-200PCF/PCC airplanes.

PC-53-518-00 F 241

242 NOTE

NOTE PCF/PCC ALL 1.50 INTERNAL – DETAILED AND SPECIAL DETAILED: Overwing

stub frames, left and right, at BS 1000 and 1020, inner chords in areas hidden by crease beam clips (Type 2 structure). INTERVAL NOTE: Flight length sensitive (FLS) task. See Boeing MPD Section 9 Figure 1 to determine threshold. NOTE: For repeat calculation, see PC-0118-05-DTR, page 1.0-1 for formula and page for 1.0-3 for reduction factor. Utilize Boeing DTR forms (D622N001-DTR), adjusting for PC reduction factor. NOTE: The NDI method(s) necessary to accomplish the intent of this inspection are contained in the 757 non-destructive test manual D634N301. The inspection procedures are contained in Part 6, Subject 53-10-18. AIRPLANE NOTE: All B757-200 passenger airplanes converted to B757-200PCF/PCC airplanes. Not applicable to overwing exit models.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-522-00 F 241

242 NOTE

NOTE PCF/PCC ALL 2.50 INTERNAL - DETAILED AND SPECIAL DETAILED: Rear spar

bulkhead inner chord edges, forward and aft BS 1040, S-14 to S-17, left and right. (Type 2 structure).



PC-53-528-00 F 241

242 NOTE

NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Rear spar bulkhead lower side

fitting inboard leg at WL 187.70 left and right. (Inspect inboard leg from both sides of hydraulic reservoir fitting). (Type 2 structure).



PC-53-1000-00 F 100

200 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Fuselage external skin.

BS 440 to BS 660, S-4R to S-26L.


PC-53-1002-00 F 100

200 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Fuselage external skin, longitudinal

splice BS 440 to BS 660, S-4R, S-1, S-6L, S-14L, S-19L, S-26L.


PC-53-1004-00 F 100

200 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Fuselage external skin, circumferential

splice BS 440, S-4R to S-26L. BS 660, S-4R to S-26L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1006-00 F 100

200 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Fuselage external skin, longitudinal

splice BS 440 to BS 660, S-4R, S-1, S-6L, S-14L, S-19L, S-26L. Fastener row on each side of stringer.


PC-53-1008-00 F 100

200 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Circumferential splice, tear strap and

doubler. BS 440, S-4R to S-26L. BS 660, S-4R to S-26L.


PC-53-1010-00 F 117

221 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Door L1 plug, external skin

BS 297 to BS 378, S-4L to S-20L.


PC-53-1012-00 F 117

221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Door L1 plug, bear strap.

BS 297 and BS 378, S-4L to S-20L.


PC-53-1014-00 F 119

221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Fuselage lower intercostals

BS 480 to BS 500, S-20L.


PC-53-1016-00 F 119

221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Fuselage lower frames

BS 460, BS 480, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, BS 620, BS 640, S-18L TO S-25L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1018-00 F 119

221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Fuselage lower sill

BS 440 to BS 660.


PC-53-1020-00 F 119

221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Lower fuselage, floor beam, frame,

splice BS 460, BS 480, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, BS 620, BS 640.


PC-53-1022-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Door L1 skin plug, stringers.

BS 333 to BS 376, DS-1L to DS-6L.

INTERVAL NOTE: Reference PC-0118-05-DTR FTR Check Form PC-53-10-03 for repeat inspections.

PC-53-1024-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILEDI: Door L1 plug, stringer fittings.

BS 376, DS-1L to DS-6L.


PC-53-1026-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Crew entry door surround structure, Fwd

intercostals. BS 297 to BS 302, DS-1L to DS-6L.


PC-53-1028-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Crew entry door surround structure, Aft

intercostals. BS 333 to BS 345, DS-1L to DS-6L.


PC-53-1030-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Crew entry door surround structure,

frame. BS 302, S-6L to S-17L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1032-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Door L1 plug, frame.

BS 365, upper sill to S-17L.



lower sill. BS 302 to BS 333.



upper sill. BS 302 to BS 333.


PC-53-1038-00 F 222 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Door R1 skin plug, external skin.

BS 324 to BS 365, upper sill to lower sill.


PC-53-1040-00 F 222 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Door R1 skin plug, bear strap.

BS 324 and BS 365, upper sill and lower sill.


PC-53-1042-00 F 222 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Door R1 plug, stringers. BS 324 to BS

365, DS-1R to DS-7R.


PC-53-1044-00 F 223

224 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Fuselage upper crown skin, external

skin. BS 340 to BS 375, LBL 48, LBL 30, LBL 12, RBL 12, RBL 30, RBL 45.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1046-00 F 231

233 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Fuselage, frames:

BS 480 and BS 620, upper sill to lower sill.


PC-53-1048-00 F 231

233 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Fuselage, frames:

BS 460 and BS 640, upper sill to lower sill.


PC-53-1050-00 F 233 20000 FC NOTE PCF/PCC ALL EXTERNAL - DETAILED: Upper fuselage, hinge:

BS 480 to BS 620, S-4L.


PC-53-1052-00 F 233

234 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED: Upper fuselage, frames:

BS 460 to BS 640, upper sill to S-4R.


PC-53-1054-00 F 233 20000 FC NOTE PCF/PCC ALL INTERNAL - DETAILED –: Upper fuselage, inner skin.

BS 460 to BS 640, S-3L to S-4L.


PC-53-1056-00 F 251

252 20000 FC NOTE PCF ALL EXTERNAL - DETAILED: Door 4 skin plug, external skin:

BS 1640 to BS 1682, upper sill to lower sill.


PC-53-1058-00 F 251

252 20000 FC NOTE PCF ALL INTERNAL - DETAILED: Door 4 skin plug:

Bear strap. BS 1640 and BS 1682, upper sill and lower sill.


PC-53-1060-00 F 100

200 20000 FC NOTE PCF/PCC ALL EXTERNAL - SPECIAL DETAILED: Fuselage external skin:

Skin. BS 440 to BS 660, S-4R to S-26L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1062-00 F 100


Longitudinal splice: BS 440 to BS 660, S-4R, S-1, S-6L, S-14L, S-19L, S-26L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-01 for repeat inspections.

PC-53-1064-00 F 100


Circumferential splice: BS 440, S-4R to S-26L. BS 660, S-4R to S-26L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-01 for repeat inspections.

PC-53-1066-00 F 100

200 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Fuselage external skin:

Middle fastener row of inner skin concealed by stringer. BS 440 to BS 660, S-4R, S-1, S-6L, S-14L, S-19L, and S-26L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-01 for repeat inspections.

PC-53-1068-00 F 100


Longitudinal splice: Fastener row on each side of stringer. BS 440 to BS 660, S-4R, S-1, S-6L, S-14L, S-19L, S-26L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-01 for repeat inspections.

PC-53-1070-00 F 100


Circumferential splice: Tear strap and doubler. BS 440, S-4R to S-26L. BS 660, S-4R to S-26L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-01 for repeat inspections.

PC-53-1072-00 F 100

200 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Fuselage stringers, BS 440 to

BS 660, S-3R to S-24L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-03 for repeat inspections.

PC-53-1074-00 F 100

200 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Fuselage Stringer Splice:

BS 440, S-3R TO S-24L. BS 660, S-3R TO S-24L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-03 repeat inspections.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1076-00 F 100


Circumferential splice: tear strap. BS 440, S-4R to S-26L. BS 660, S-4R to S-26L. Fastener rows concealed by frames.


PC-53-1078-00 F 100

200 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Fuselage, stringer splice:

Stringer. BS 440, S-3R To S-24L. BS 660, S-3R To S-24L. Fastener rows concealed by stringer splice.

INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-03 for repeat inspections

PC-53-1080-00 F 117

221 20000 FC NOTE PCF/PCC ALL EXTERNAL - SPECIAL DETAILED: Door L1 plug:

External skin. BS 297 to BS 378, S-4L to S-20L.


PC-53-1082-00 F 117

221 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door L1 plug:

Bear strap. BS 297 to BS 378, S-4L to S-20L.


PC-53-1084-00 F 117 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door L1 plug:

Lower frame and lower frame splice. BS 345, S-17L.



Lower frame and lower frame splice. BS 365, S-17L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1088-00 F 117

221 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door L1 plug:

Bear strap where concealed by frame. BS 297 to BS 378, S-4L to S-20L.


PC-53-1090-00 F 118 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door R1 plug:

Lower frame and lower frame splice. BS 345, S-17R.


PC-53-1092-00 F 119

221 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILEDI: Lower fuselage:

Intercostals. BS 480 to BS 500, S-20L.


PC-53-1094-00 F 119

221 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Lower fuselage:

Frames and failsafe chord. BS 460, BS 480, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, BS 620, BS 640, S-18L to S-25L.


PC-53-1096-00 F 119


Frame inner flange and strap. BS 480, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, S-20L to S-22L.


PC-53-1098-00 F 119


Frame, splice, failsafe chord. BS 460, BS 480, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 620, BS 640, S-25L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1100-00 F 119


Lower sill. BS 440 to BS 660.


PC-53-1102-00 F 119


Latch fitting. BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, lower sill.


PC-53-1104-00 F 119


Floor beam, splice, frame. BS 460, BS 480, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, BS 620, BS 640, lower sill.


PC-53-1106-00 F 119


Frame where concealed by stringer clip and failsafe. BS 460, BS 480, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, BS 620, BS 640, S-18L to S-25L.


PC-53-1108-00 F 119


Frame. BS 460, BS 480, BS 490, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 610, BS 620, BS 640, S-25L.


PC-53-1110-00 F 119


Fitting where concealed by frame and stringer clip. BS 460 to BS 640, S-17L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1112-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door L1 plug, stringers. BS

333 to BS 376, DS-1L to DS-6L.


PC-53-1114-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL -SPECIAL DETAILED: Door L1 plug, stringer fittings.

BS 376, DS-1L to DS-6L.


PC-53-1116-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Crew entry door surround

structure, Fwd intercostals. BS 297 to BS 302, DS-1L to DS-6L.



structure, Aft intercostals. BS 333 to BS 345, DS-1L to DS-6L.



structure: Frame. BS 302, S-6L to S-17L.



structure: Frame.BS 333, S-6L to S-17L.



Frame. BS 345, upper sill to S-17L.



Frame. BS 365, upper sill to S-17L.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS



structure, Lower sill. BS 302 to BS 333.



structure: Upper sill. BS 302 to BS 333.



structure: Frame splice. BS 333, upper sill.



Frame splice. BS 333, Lower sill.


PC-53-1136-00 F 221 20000 FC NOTE PCF/PCC ALL INTERNAL -SPECIAL DETAILED –: Door L1 plug, intercostal

where concealed by stringer and clip. BS 333 to 345, DS-1L to DS-6L.


PC-53-1138-00 F 222 20000 FC NOTE PCF/PCC ALL EXTERNAL - SPECIAL DETAILED: Door R1 plug:

External skin. BS 324 to BS 365, upper sill to lower sill.


PC-53-1140-00 F 222 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door R1 plug:



PC-53-1142-00 F 222 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door R1 plug, stringers. BS

324 to BS 365, DS-1R to DS-7R.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1144-00 F 222 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door R1 skin plug: Stringer

fittings. BS 324 and BS 365, DS-1R to DS-7R. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-10-03 for repeat inspections.

PC-53-1146-00 F 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door R1 skin plug:

Frame. BS 345, upper sill to S-17L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-10-07 for repeat inspections.

PC-53-1148-00 F 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Door R1 skin plug:

Bear strap where concealed by frame. BS 324 and BS 365, upper sill and lower sill. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-10-01 for repeat inspections.

PC-53-1150-00 F 223

224 20000 FC NOTE PCF/PCC ALL EXTERNAL - SPECIAL DETAILED: Fuselage upper crown skin:

External skin. BS 340 to BS 375, LBL 48, LBL 30, LBL 12, RBL 12, RBL 30, RBL 45. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-10-01 for repeat inspections.

PC-53-1152-00 F 231

233 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Fuselage:

Frame. BS 480 and BS 620, upper sill to lower sill. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-07 for repeat inspections.

PC-53-1154-00 F 231


Frame. BS 460 and BS 640, upper sill to lower sill. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-07 for repeat inspections.

PC-53-1156-00 F 231


Frame fitting. BS 460, BS 480, BS 620, and BS 640, upper sill and lower sill. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-07 for repeat inspections.

PC-53-1158-00 F 233 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Fuselage external skin:

BS 479 to BS 495 and BS 604 to BS 620, S-4R. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-01 for repeat inspections.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1160-00 F 233 20000 FC NOTE PCF/PCC ALL EXTERNAL - SPECIAL DETAILED: Upper fuselage:

Hinge. BS 480 to BS 620, S-4L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-17 for repeat inspections.

PC-53-1162-00 F 233

234 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Upper fuselage:

Frames and Failsafe Chord. BS 460, BS 480, BS 500, BS 520, BS 540, BS 560, BS 580, BS 600, BS 620, BS 640, upper sill to S-4R. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-07 for repeat inspections.

PC-53-1164-00 F 233 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Upper fuselage: Intercostals.

BS 460 to BS 640, S-3L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR CheckFform PC-53-30-04 for repeat inspections.

PC-53-1166-00 F 233 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Upper fuselage:

Beam. BS 440 to BS 660, upper sill. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-13 for repeat inspections.


Fitting splice. BS 440 and BS 660, S-4L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-90 for repeat inspections.

PC-53-1170-00 F 233 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Upper fuselage: Inner skin.

BS 460 to 640, S-3L to S-4L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-01 for repeat inspections.


Frame where concealed by stringer clips and failsafe. BS 460 and BS 640, S-4R to S-4L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-07 for repeat inspections.


Upper sill and stringer where concealed by splice and skin. BS 435 to BS 450 and BS 650 to BS 670, S-4L. INTERVAL NOTE: Reference PC-0118-05-DTR, FTR Check Form PC-53-30-90 for repeat inspections.




MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1176-00 F 234 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Upper fuselage splice:

Splice, frame, and failsafe chord. BS 460 to BS 640, S-4R.



Frame when concealed by stringer clips and failsafe chord. BS 460 to BS 640, S-4R to S-4L.


PC-53-1180-00 F 234 20000 FC NOTE PCF/PCC ALL INTERNAL - SPECIAL DETAILED: Upper fuselage splice:

Frame when concealed by splice and failsafe chord. BS 460 to BS 640, S-4R.


PC-53-1182-00 F 251

252 20000 FC NOTE PCF ALL EXTERNAL - SPECIAL DETAILED: Door 4 plug:

External skin. BS 1640 to BS 1682, upper sill to lower sill.


PC-53-1184-00 F 251

252 20000 FC NOTE PCF ALL INTERNAL - SPECIAL DETAILED: Door 4 plug:






MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1186-00 F 251


Stringers. BS 1640 to BS 1682, DS-1 to DS-6.


PC-53-1188-00 F 251

252 20000 FC NOTE PCF ALL INTERNAL - SPECIAL DETAILED: Door 4 plug: Stringer fitting.

BS 1640 and BS 1682, DS-1 to DS-6.


PC-53-1190-00 F 251

252 20000 FC NOTE PCF ALL INTERNAL - SPECIAL DETAILED: Door 4 area:

Frame, failsafe chord, fitting. BS 1620, S-17.


PC-53-1192-00 F 251

252 20000 FC NOTE PCF ALL INTERNAL - SPECIAL DETAILED: Door 4 area:

Frame, fitting, outer chord. BS 1640, S-16 to S-19.


PC-53-1194-00 F 251


Frame. BS 1661, upper sill to lower sill.


PC-53-1196-00 F 251


Frame, splice, and failsafe chord. BS 1661, upper sill.


PC-53-1198-00 F 251


Frame, strap, and failsafe chord. BS 1661, S-17.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1200-00 F 251




PC-53-1202-00 F 251


Fitting. BS 1620, S-17.


PC-53-1204-00 F 251


Splice and frame. BS 1661, upper sill.


PC-53-1206-00 F 251

252

20000 FC NOTE PCF ALL INTERNAL - SPECIAL DETAILED: Door 4 plug: Middle splice and frame. BS 1661, between S-14 and S-15.


PC-53-1208-00 F 251

252

20000 FC NOTE PCF ALL INTERNAL - SPECIAL DETAILED: Door 4 plug: Frame, outer flange.


PC-53-1222-00 S 253

254 3000 FC

18 MO NOTE

3000 FC 18 MO NOTE

PCC ALL INTERNAL – GENERAL VISUAL: Stringers S-5L/5R and S-8L/8R between BS 1240 and BS 1260.


PC-53-1224-00 S 253 254

3000 FC 18 MO

3000 FC 18 MO

PCC ALL INTERNAL – DETAILED VISUAL: Frame at BS 1260 at S-5L/5R and S-8L/8R.





MPD ITEM NUMBER

AMM REFERENCE

P G M ZONE ACCESS


PC-53-1226-00 F 841 20000 FC NOTE PCC ALL EXTERNAL - SPECIAL DETAILED: Skin and Vent Cutout, Door

R1, Combi. External skin. BS 345, WL 238


PC-53-1228-00 F 841 20000 FC NOTE PCC ALL EXTERNAL - SPECIAL DETAILED: Skin and Vent Cutout, Door

R1, Combi. Vent cutout. BS 345, WL 238





STRUCTURAL ILLUSTRATIONS

For illustrations to assist in general identification of structure, see Precision Conversions Document PC-0118-05-DTR.

MAINTENANCE PLANNING DOCUMENT SUPPLEMENT FOR B757-200PCF/PCC CONVERSION ZONAL INSPECTION REQUIREMENTS

PC-0118-05 Dec 08/2014 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page 3.0-1

SECTION 3 – ZONAL INSPECTION REQUIREMENTS

A. Scope

Section 3.0 of the MPD Supplement outlines the scheduled maintenance tasks for the Zonal Inspection Requirements.

B. Notes

No changes to this section. See OEM Maintenance Planning Data document.



MPD ITEM NUMBER

AMM REFERENCE ZONE ACCESS



SECTION, SUBJECT) WHICH SUPPORTS THE MPD REQUIREMENT MPD SEQUENCE NUMBER MPD SEQUENCE NUMBER 0-999 CHANGED OEM TASK

1000+ NEW TASKS DUE TO CONVERSION

FIRST TWO DIGITS = ATA CHAPTER “PC” IDENTIFIES PRECISION CONVERSIONS ADDED TASKS

EXAMPLE ILLUSTRATING FORMAT PC-52-830-00 05-41-08-212 837 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 0.70 INTERNAL - ZONAL (GV): Crew Entry Door Perform Internal General Visual Inspection of the zone with the door open.


FIG 3-1 ZONAL INSPECTION REQUIREMENTS EXAMPLE PAGE



C. Page Format: Zonal Inspection Requirements

1. MPD ITEM NUMBER

No changes to this explanation. See OEM 757 Maintenance Planning Data document. 2. AMM REFERENCE

No changes to this explanation. See OEM 757 Maintenance Planning Data document. 3. ZONE


4. ACCESS


5. INTERVAL


6. APPLICABILITY


APL PCF = B757-200PCF (Precision Conversions Freighter) PCC = B757-200PCC (Precision Conversions Combi) PCF/PCC = Precision Conversions Freighter and Combi NOTE = Airplane Applicability Note ENGINE ALL = All 757 Engines NOTE = Engine Applicability Note



7. MANHOURS


8. TASK DESCRIPTION




ZONAL INSPECTION TASKS The following table lists OEM MPD item numbers that have been deleted and/or changed due to the conversion. Items that have been changed have been assigned a new Precision Conversions MPD item number.

DELETED INSPECTIONS CHANGED INSPECTIONS CHANGED INSPECTIONS

Deleted for Freighter Only: Changed for Both Freighter and Combi Changed for Freighter Only:

OEM MPD ITEM NUMBER OEM MPD ITEM NUMBER

NEW MPD ITEM NUMBER

OEM MPD TASK NUMBER

NEW MPD ITEM NUMBER

52-824-00 52-816-00 PC-52-816-00 52-822-00 PC-52-822-00 52-826-00 52-818-00 PC-52-818-00 52-846-00 PC-52-846-00 52-848-00 52-828-00 PC-52-828-00 52-850-00 52-830-00 PC-52-830-00 53-872-10 52-832-00 PC-52-832-00 53-874-00 52-834-00 PC-52-834-00

52-840-00 PC-52-840-00

Deleted for Both Freighter and Combi

52-842-00 PC-52-842-00

53-858-20 PC-53-858-20

53-860-10 PC-53-860-10

53-862-10 PC-53-862-10

52-812-00 53-864-00 PC-53-864-00 52-814-00 53-866-00 PC-53-866-00 52-836-00 53-870-00 PC-53-870-00 52-838-00 53-874-10 PC-53-874-10 53-858-10 53-860-00 53-862-20



MPD ITEM NUMBER



ATA 52: DOORS PC-52-816-00 832 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

PCF/PCC ALL 0.40 EXTERNAL - ZONAL (GV): No. 2 Door - Entry Perform External General Visual Inspection of the zone with the door closed.

CPC NOTE: Corrosion Prevention and Control Basic Task Required.

TASK NOTE: On PCF and PCC converted aircraft, the No. 2 door is deactivated.

INTERVAL NOTE: Whichever comes first. PC-52-818-00 832 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 0.50 INTERNAL - ZONAL (GV): No. 2 Door - Entry Perform Internal General Visual Inspection of the zone with the door closed. .



PC-52-822-00 835 24000 FH 72 MO NOTE

24000 FH 72 MO NOTE

PCF ALL 0.50 INTERNAL - ZONAL (GV): No. 3 Doors – Emergency Exit

Perform an Internal General Visual Inspection of the zone with the door closed.

TASK NOTE: On PCF converted aircraft, the No. 3 doors are deactivated.




MPD ITEM NUMBER



PC-52-828-00 837 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

PCF/PCC ALL 0.40 EXTERNAL - ZONAL (GV): Crew Entry Door Perform an External General Visual Inspection of the zone with the door closed.

CPC NOTE: Corrosion Prevention and Control Basic Task Required


72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 0.70 INTERNAL - ZONAL (GV): Crew Entry Door Perform Internal General Visual Inspection of the zone with the door closed.


PC-52-832-00 838 6000 FH 18 MO NOTE

6000 FH 18 MO NOTE

PCF/PCC ALL 0.80 EXTERNAL - ZONAL (GV): Main Deck Cargo Door Perform an External General Visual Inspection of the zone with the door closed.



72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 1.40 INTERNAL - ZONAL (GV): Main Deck Cargo Door Perform Internal General Visual Inspection of the zone with the door open.




MPD ITEM NUMBER



PC-52-840-00 842 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

PCF/PCC ALL 0.40 EXTERNAL - ZONAL (GV): No. 2 Door - Service Perform an External General Visual Inspection of the zone with the door closed.




72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 0.50 INTERNAL - ZONAL (GV): No. 2 Door - Service Perform Internal General Visual Inspection of the zone with the door closed.



72 MO NOTE

24000 FH 72 MO NOTE

PCF ALL 0.50 INTERNAL - ZONAL (GV): No. 3 Doors – Emergency Exit Perform Internal General Visual Inspection of the zone with the door closed.

TASK NOTE: On PCF converted aircraft, the No. 3 doors are deactivated.




MPD ITEM NUMBER



ATA 53: FUSELAGE PC-53-858-20 221 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 0.40 INTERNAL - ZONAL (GV): Crew Entry Door - Section 41 Perform Internal General Visual Inspection of the crew entry door (Zone 837) operating mechanism in fuselage.

INTERVAL NOTE: Whichever comes first. PC-53-860-10 223

224 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 1.00 INTERNAL - ZONAL (GV): Areas Above Ceiling – Section 41 Perform Internal General Visual Inspection of the zones. (EZAP)


ACCESS NOTE: Between Body Station (BS) 297 and BS 440. PC-53-862-10 231

232 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 0.70 INTERNAL - ZONAL (GV): Main Deck - Section 43 Perform Internal General Visual Inspection of No. 2 door (Zones 832/842) operating mechanism in fuselage area.



233 6000 FH

18 MO NOTE

6000 FH 18 MO NOTE

PCF/PCC ALL 0.70 INTERNAL - ZONAL (GV): Main Deck - Section 43 Perform Internal General Visual Inspection of main deck cargo door (Zone 838) operating mechanism in fuselage area.


234 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE

PCF/PCC ALL 2.00 INTERNAL - ZONAL (GV): Areas Above Ceiling - Section 43 Perform Internal General Visual Inspection of the zones. (EZAP)



244 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE




254 24000 FH

72 MO NOTE

24000 FH 72 MO NOTE



ACCESS NOTE: Between Body Station (BS) 1180 and BS 1720.


PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page 4.0-1

SECTION 4 – SOURCE DOCUMENTS FOR TASKS

A. SCOPE

1. No changes to this section. See OEM 757 Maintenance Planning Data document.



SECTION 5 – RESERVED

B757-200PCF/PCC MAINTENANCE PLANNING DATA DOCUMENT SUPPLEMENT

PC-0118-05-9 Feb 23/2017 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT PAGE 9.0-1

SECTION 9

AIRWORTHINESS LIMITATIONS AND CERTIFICATION MAINTENANCE

Maintenance Planning Data (MPD) Document Supplement Section 9 Airworthiness Limitations and Certification Maintenance Requirements

PC-0118-05-9

ORIGINAL ISSUE DATE: MAY 28, 2004 REVISION DATE: FEBRUARY 23, 2017

COMPILED AND PUBLISHED BY:

PRECISION CONVERSIONS 4900 SW GRIFFITH DRIVE, SUITE 133

BEAVERTON, OREGON 97005

PRECISION CONVERSIONS CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 Precision Conversions Unpublished Work – All Rights Reserved

THIS INFORMATION CONTAINED HEREIN IS PROPRIETARY TO PRECISION CONVERSIONS LLC AND SHALL

NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED FOR ANY DESIGN OR MANUFACTURE EXCEPT WHEN SUCH USER POSSESSES DIRECT, WRITTEN AUTHORIZATION FROM

PRECISION CONVERSIONS LLC.



REVISIONS

REVISION & REVISION DESCRIPTION APPROVAL

Submitted By: Approved By:

Initial Release (IR)

Rev. A – General updates prior to STC issuance. Bill Barclift, August 12, 2004 Signature on file

Rev. B – General updates prior to STC issuance. Bill Barclift, Sept. 02, 2004 Signature on file

Rev. C – General updates prior to STC issuance. Bill Barclift, October 01, 2004 Signature on file

Rev. D – Added structural inspections for modified structure Revised OEM affected structure.

Mike Violetto, January 10, 2005 Signature on file

Rev. E – General update prior to STC issuance. Mike Violetto, March 22, 2005 Signature on file

Rev. F – Added certification maintenance inspection PCF-26-10-00-5 and changed the CMR inspection intervals for inspections PCF-52-30-00-5L and PCF-52-30-00-5M.

Lynn Duffy, May 18, 2005 Signature on file

Rev. G – Revised airplane applicability of MPD Item Number PCF-52-30-00-5L. Only applicable to airplanes with DC-powered hydraulic pump unit.

Tracy Leonardi, Nov. 21, 2007 Signature on file

Rev. H – Added CMR: PC-26-2004-00 for combi. Added life limit for MSN 26273 Combi.

Evgeny Ivanov, Sonia Lee, April 16, 2013 Signature on file

Rev J: 1. Page 9.0-5: Deleted Life Limit for PCC MSN 26273. 2. Page 9.0-7: Added formula for calculating repeat inspections for OEM

structure affected by modification. 2. Pages 9.0-8 to 9.0-13: Revised and retitled AWL tables. 3. Pages 9.0-8 to 9.0-13: Added PCC to Airplane applicability column. 4. Pages 9.0-8 to 9.0-13: Added corresponding PC-0118-05 MPD Supp. Sec 2

task # column to AWL tables. 5. Page 9.0-9 to 9.0-13: Changed SSI number to start with PC-. Old PCF-. 6. Page 9.0-13: Added SSI PC-53-60-07 Splice Middle Frame Station 1661 for

PCF.

Evgeny Ivanov, Dany Daoust December 16, 2013 Signature on file

PRECISION CONVERSIONS LLC

B757-200PCF /PCC MAINTENANCE PLANNING DATA DOCUMENT SUPPLEMENT

REVISIONS

REVISION & REVISION DESCRIPTION

Rev K: 1. Page 9.0.8: Corrected Example Calculation - Revised "Number of Flight

Before Modification" to "Repeat Inspection Interval from 0622N001-DTR." 2. Page 9.0-10: For MPD Item PC-53-412-01 , revised Boeing Job Card

Number to 5310-122-501.

Rev L: - 1. - Page 9.0-11 : Add SSI PC-52-30-07 for MPD item PC-52-1444-00.

PC-0118-05-9

APPROVAL

Submitted By:

David Heath, Feb. 27, 2015

Robert Gabb, Feb. 23, 2017

Feb 23/2017 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT

Approved By:

Signature on file

PAGE 9 0-3



LIST OF EFFECTIVE PAGES Page Date Page Date Page 9.0-1 Feb 23/17 9.0-2 Feb 23/17 9.0-3 Feb 23/17 9.0-4 Feb 23/17 9.0-5 Feb 27/15 9.0-6 Feb 27/15 9.0-7 Feb 27/15 9.0-8 Feb 27/15 9.0-9 Feb 27/15 9.0-10 Feb 27/15 9.0-11 Feb 23/17 9.0-12 Feb 27/15 9.0-13 Feb 27/15 9.0-14 Feb 27/15 9.0-15 Feb 27/15 9.0-16 Feb 27/15 9.0-17 Feb 27/15 9.0-18 Feb 27/15 9.1-1 Feb 27/15 9.1-2 Feb 27/15 9.2-1 Feb 27/15



SECTION 9

TABLE OF CONTENTS

A. SCOPE ................................................................................................................................................................................................9.0-6 B. AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS ................................................................................................9.0-7 C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS ..........................................................................................9.0-15 D. AIRWORTHINESS LIMITATIONS – SYSTEMS .................................................................................................................................9.0-15 E. CERTIFICATION MAINTENANCE REQUIREMENTS (CMR) ............................................................................................................9.0-15 F. PAGE FORMAT: CERTIFICATION MAINTENANCE REQUIREMENTS ...........................................................................................9.0-17 G. CERTIFICATION MAINTENANCE REQUIREMENT TASKS .............................................................................................................9.1-1 H. JAA UNIQUE REQUIREMENTS .........................................................................................................................................................9.2-1


Feb 27/2015 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT PAGE 9.0-6

A. SCOPE

The Airworthiness Limitations Section is FAA-approved and specifies maintenance required under Federal Aviation Regulation 43.16 and 91.403 of the Federal Aviation Regulations, unless an alternative program has been FAA approved. AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONS

The Airworthiness Limitations may only be revised with the approval of the Aircraft Certification Office, FAA Seattle. If the inspections cannot be accomplished due to repairs and / or modifications, an alternate inspection acceptable to the Aircraft Certification Office, FAA Seattle must be used.

ROUGH RUNWAY OPERATION

No changes to this section. See OEM 757 Maintenance Planning Data document. CERTIFICATION MAINTENANCE REQUIREMENTS (CMR)

These scheduled maintenance tasks may only be revised by the Aircraft Certification Office, FAA Seattle. Principal Airworthiness Inspectors (local regulatory authority) may not change these requirements or the intervals associated with these requirements.



B. AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

INTRODUCTION

The Structural Inspection Program contained in Section 2 of this MPD Supplement describes an initial baseline structural maintenance program for all Structural Significant Items (SSI). The program satisfies the requirements of FAR 25.571 by providing accidental and environmental damage detection opportunity for all SSIs. The supplemental structural inspections, listed in this Section 9 Airworthiness Limitations (AWL), are for those SSIs that do not receive adequate fatigue damage opportunity from the initial baseline structural program that is listed in Section 2. The inspections shown in Section 9 Airworthiness Limitations are to be accomplished in conjunction with and not as a substitute for the existing structural maintenance program found in Section 2. Note that the Sec 9 AWL SSI tasks are also included in Section 2 of this MPD Supplement and are designated as Fatigue Items (F under column PGM in Sec 2).

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. This document uses a Flaw Tolerance Rating (FTR) system which is utilized in exactly the same manner.

THRESHOLD

When reaching the threshold of flight cycles, all C-check (3000 FC or 18 Months, whichever comes first) or higher structural inspection repeat intervals must be no greater than those shown in Section 2. The initial inspection structure added due to the freighter modification is calculated from the time of modification not the lifetime of the aircraft.

When determining the initial threshold for the OEM structure affected due to the freighter modification, several parameters must be taken into account, such as the usage before modification (No) and a reduction factor (Rf). The formula that follows will need to be applied to the list of the OEM structure determined to be affected by the freighter modification in order to determine the new initial threshold. The original Boeing threshold is 50,000 flights. It is necessary to re-calculate the inspection threshold based upon the increase in stress levels due to the freighter modification. The formula that follows is used to calculate the new inspection threshold for each OEM curve affected by the freighter modification shown in the “Airworthiness Limitations – Structural Inspections” of this section.

New Inspection Threshold of

o NR

N+

−=

50000

No = number of flights before modification Rf = Reduction Factor listed in Table 1 Reduction Factor for Determining Threshold Example Calculation: Number of flights before modification: 5,000 flights Reduction Factor: 1.13 New Inspection Threshold: 44823



Repeat Inspections for OEM Structure Affected by Modification The repeat inspection listed in the OEM DTR forms are to be adjusted to the reduction factor listed in Table 2: Precision Conversions Repeat Inspection Interval Reduction Factor. The formula below will be applied. It is necessary to re-calculate the repeat inspections based upon the increase in stress levels due to the modification.

New Repeat Inspection

NMPD = repeat inspection in Boeing document D622N001-DTR Rf = reduction factor listed in Table 2 Precision Conversions Repeat Inspection Interval Reduction Factor

Example Calculation

Repeat Inspection Interval from D622N001-DTR: 8000 flights Reduction Factor: 1.25 New Repeat Inspection: 3200

REPORTING RESULTS OF STRUCTURAL INSPECTIONS

All cracks found during these inspections shall be reported within ten (10) days directly to the Manager, Aircraft Certification Office, Transport Airplane Directorate, FAA Seattle and to Precision Conversions using the Discrepant Structure Report form. Refer to PC-0118-05-DTR for the required report form (any suitable alternative which contains the same information may be used). The following pages list the Airworthiness Limitation supplemental structural inspection requirements. Each item is listed by SSI number, MPD Item Number, FTR check form title, inspection zone, airplane applicability and reduction factor. There are corresponding FTR forms in PC-0118-05-DTR for items listed in the table. Where there is more than one listing for a given SSI number, the FTR check form title is the unique identifier. Airplane applicability is listed as:

PCF = B757-200PCF (Freighter) PCC = B757-200PCC (Combi) PCF/PCC = Freighter and Combi

Note: L/N = Airplane Line Number. Where entered with FTR Check Form title, identifies FTR Check Form to specific airplane line number.



AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS

OEM STRUCTURE AFFECTED BY MODIFICATION

Table1 below and Table 2 on the following page lists the OEM structure determined to be affected by the modification. For these structures, the DTR forms contained in Boeing document D622N001-DTR Damage Tolerance Rating Check Form Document must be used, adjusted for Precision Conversions reduction factor.

Table 1 shows the reduction factor which must be applied to calculate the new threshold. The original Boeing threshold is 50000 flights. It is necessary to re-calculate the inspection threshold based upon the increase in stress levels due to the modification.

TABLE 1: REDUCTION FACTOR FOR DETERMINING NEW THRESHOLD

SSI# MPD ITEM NUMBER. OEM STRUCTURE AFFECTED BY THE MODIFICATION AIRPLANE

APPLICABILITY REDUCTION

FACTOR 53-30-11

Line No. 1-57 PC-53-412-01 No. 1 Cargo Door Cutout, BS 560 Edge Frame – Inner Chord, Upper Sill to S-24 PCF/PCC 1.88

53-30-11 Line No. 58 and on PC-53-422-01 No. 1 Cargo Door Cutout, BS 560 Edge Frame – Inner Chord, Upper Sill to S-24 PCF/PCC 1.88

53-30-11 Line No. 1-57 PC-53-410-00 No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 560 Upper Sill to Lower Sill PCF/PCC 1.08

53-30-11 Line No. 58 and on PC-53-414-00 No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 560 Upper Sill to Lower Sill PCF/PCC 1.08

53-30-11 Line No. 1-57 PC-53-412-02 No. 1 Cargo Door Cutout, BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill PCF/PCC 1.20

53-30-11 Line No. 58 and on PC-53-422-02 No. 1 Cargo Door Cutout, BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill PCF/PCC 1.20

53-30-11 Line No. 1-57 PC-53-418-00 No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 620 – Upper Sill to Lower Sill PCF/PCC 1.04

53-30-11 Line No. 58 and on PC-53-420-00 No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 620 – Upper Sill to Lower Sill PCF/PCC 1.04

53-30-12 PC-53-416-00 No. 1 Cargo Door Cutout, Door Stop Intercostals, Door Stop No. 1 & 6 (Forward & Aft) PCF/PCC 1.82

53-40-20 PC-53-522-00 Rear Spar Bulkhead, Inner Chord, BS 1040 S14 – S17, (Left & Right) PCF/PCC 1.14

53-40-20 PC-53-528-00 BS 1040 Rear Spar Bulkhead, Lower Side Fitting, Inboard Leg at WL 187.70, (Left & Right) PCF/PCC 1.10

53-40-25 PC-53-518-00 Overwing Stub Frames, Inner Chord, BS 1000 & 1020, WL 208.1, Left & Right, Area Hidden by Crease Beam Clip PCF/PCC 1.18



Table 2 shows the reduction factor which must be applied to calculate the repeat inspection interval.

TABLE 2: PRECISION CONVERSIONS REPEAT INSPECTION INTERVAL REDUCTION FACTOR

SSI# MPD ITEM NUMBER.

BOEING JOB CARD NUMBER1 OEM STRUCTURE AFFECTED BY THE MODIFICATION AIRPLANE

APPLICABILITY REDUCTION

FACTOR

53-30-11 Line No. 1-57 PC-53-412-01 5310-122-50I No. 1 Cargo Door Cutout, BS 560 Edge Frame – Inner Chord, Upper Sill to S-24 PCF/PCC 1.88

53-30-11 Line No. 58 and on PC-53-422-01 5330-122-53I No. 1 Cargo Door Cutout, BS 560 Edge Frame – Inner Chord, Upper Sill to S-24 PCF/PCC 1.88

53-30-11 Line No. 1-57 PC-53-410-00 5330-122-50E No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 560 Upper Sill to Lower

Sill PCF/PCC 1.08

53-30-11 Line No. 58 and on PC-53-414-00 5330-122-51E No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 560 Upper Sill to Lower

Sill PCF/PCC 1.08

53-30-11 Line No. 1-57 PC-53-412-02 5330-122-50I No. 1 Cargo Door Cutout, BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill PCF/PCC 1.2

53-30-11 Line No. 58 and on PC-53-422-02 5330-122-53I No. 1 Cargo Door Cutout, BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill PCF/PCC 1.2

53-30-11 Line No. 1-57 PC-53-418-00 5330-122-52E No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 620 – Upper Sill to

Lower Sill PCF/PCC 1.04

53-30-11 Line No. 58 and on PC-53-420-00 5330-122-53E No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 620 – Upper Sill to

Lower Sill PCF/PCC 1.04

53-30-12 PC-53-416-00 5330-120-05I 5330-122-04I

No. 1 Cargo Door Cutout, Door Stop Intercostals, Door Stop No. 1 & 6 (Forward & Aft) PCF/PCC 1.82

53-30-12 PC-53-416-00 5330-122-51I No. 1 Cargo Door Cutout, Door Stop Intercostals, Door Stop No. 1 & 6 (Forward & Aft) PCF/PCC 1.82

53-40-20 PC-53-522-00 5340-241-52I 5340-242-52I Rear Spar Bulkhead, Inner Chord, BS 1040 S14 – S17, (Left & Right) PCF/PCC 1.14

53-40-20 PC-53-522-00 5340-241-04I Rear Spar Bulkhead, Inner Chord, BS 1040 S14 – S17, (Left & Right) PCF/PCC 1.14

53-40-20 PC-53-528-00 5340-241-56I 5340-242-56I

BS 1040 Rear Spar Bulkhead, Lower Side Fitting, Inboard Leg at WL 187.70, (Left & Right) PCF/PCC 1.1

53-40-25 PC-53-518-00 5340-241-07I Overwing Stub Frames, Inner Chord, BS 1000 & 1020, WL 208.1, Left & Right, Area Hidden by Crease Beam Clip PCF/PCC 1.18

53-40-25 PC-53-518-00 5340-241-51I 5340-242-51I

Overwing Stub Frames, Inner Chord, BS 1000 & 1020, WL 208.1, Left & Right, Area Hidden by Crease Beam Clip PCF/PCC 1.18

Notes: 1. The Boeing Job Card number can be found in the Boeing document D622N001-DTR Damage Tolerance Rating Check Form Document. This Job card # corresponds to both the revised Boeing and PC MPD Item #s. Example: 5330-122-50E is the Boeing Job Card Number. The corresponding MPD Item Task Number is 53-410-00 (for Boeing) and PC-53-410-00 (for PC).



TABLE 3: CONVERSION-ADDED/MODIFIED STRUCTURE

SSI# MPD ITEM NO. FTR CHECK FORM TITLE (CONVERSION –ADDED/MODIFIED STRUCTURE)

AIRPLANE APPLICABILITY

TYPE / THRESHOLD SINCE MODIFICATION

PC-52-10-01 PC-52-1400-00, PC-52-1420-00 Outer Skin Crew Entry Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-10-07 PC-52-1402-00, PC-52-1422-00 Crew Entry door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-01 PC-52-1404-00, PC-52-1406-00, PC-52-1424-00, PC-52-1426-00, PC-52-1438-00, PC-52-1442-00

Outer Skin, Cargo Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-01 PC-52-1408-00 Inner Skin, Cargo Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-04 PC-52-1410-00 Intercostals, Cargo Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-07 PC-52-1412-00, PC-52-1428-00 Frames, Cargo Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-07 PC-52-1414-00, PC-52-1430-00, PC-52-1440-00 Frames, Lower, Cargo Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-07 PC-52-1444-00 Frame, Lower, Cargo Door – Latch Attachment PCF/PCC TYPE 1, 9750 CYCLES

PC-52-30-13 PC-52-1432-00 Upper Sill, Cargo Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-13 PC-52-1416-00, PC-52-1434-00 Lower Sill, Cargo Door PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-90 PC-52-1436-00 Latch PCF/PCC TYPE 1, 20000 CYCLES

PC-52-30-90 PC-52-1418-00 Door Support Fittings PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-01 PC-53-1010-00, PC-53-1012-00, PC-53-1080-00, PC-53-1082-00, PC-53-1088-00

Skin, Door L1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-01 PC-53-1038-00, PC-53-1040-00, PC-53-1138-00, PC-53-1140-00, PC-53-1148-00

Skin, Door R1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-01 PC-53-1044-00, PC-53-1150-00 Strap, Upper Attachment PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-01 PC-53-1226-00, PC-53-1228-00 Skin and Vent Cutout, Door R1, Combi PCC TYPE 1, 20000 CYCLES

PC-53-10-03 PC-53-1042-00, PC-53-1142-00 Stringer, Door R1 PCF/PCC TYPE 1, 20000 CYCLES






PC-53-10-03 PC-53-1144-00 Fitting, Stringer – Door R1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-03 PC-53-1022-00, PC-53-1112-00 Stringer, Door L1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-03 PC-53-1024-00, PC-53-1114-00 Fitting, Stringer – Door L1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-04 PC-53-1028-00, PC-53-1118-00, PC-53-1136-00 Aft Intercostal, Crew Entry Door PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-04 PC-53-1026-00, PC-53-1116-00 Fwd Intercostal, Crew Entry Door PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1084-00 Splice, Lower Frame - Station 345 Door L1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1086-00 Splice, Lower Frame - Station 365 Door L1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1090-00 Splice, Lower Frame - Station 345 Door R1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1030-00, PC-53-1120-00 Frame, Station 302 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1122-00 Frame, Station 333 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1124-00 Frame, Station 345 - Door L1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1032-00, PC-53-1126-00 Frame, Station 365 - Door L1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-07 PC-53-1146-00 Frame, Station 345 - Door R1 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-13 PC-53-1036-00, PC-53-1130-00 Upper Sill - Crew Entry Door PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-13 PC-53-1034-00, PC-53-1128-00 Lower Sill – Crew Entry Door PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-90 PC-53-1132-00 Splice Upper Frame - Station 333 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-10-90 PC-53-1134-00 Splice, Lower Frame - Station 333 PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-01 PC-53-1000-00, PC-53-1060-00, PC-53-1158-00 Outer Skin PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-01 PC-53-1002-00, PC-53-1006-00, PC-53-1062-00, PC-53-1066-00, PC-53-1068-00

Longitudinal Splice, Outer Skin PCF/PCC TYPE 1, 20000 CYCLES






PC-53-30-01 PC-53-1004-00, PC-53-1008-00, PC-53-1064-00, PC-53-1070-00, PC-53-1076-00

Circumferential Splice, Outer Skin PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-01 PC-53-1054-00, PC-53-1170-00 Inner Skin PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-03 PC-53-1072-00 Stringers PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-03 PC-53-1074-00, PC-53-1078-00 Splice, Stringers PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-04 PC-53-1164-00 Intercostal, Upper Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-04 PC-53-1014-00, PC-53-1092-00 Intercostal, Lower Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1046-00, PC-53-1152-00 Frame, Jamb - Fore/Aft (BS 480 And 620) PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1048-00, PC-53-1154-00 Frame, Jamb - Fore/Aft (BS 460 And 640) PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1156-00 Fitting, Fore/Aft Jambs PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1016-00, PC-53-1094-00, PC-53-1106-00 Frames, Lower Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1096-00 Inner Flange, Frame - Lower Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1098-00, PC-53-1108-00 Splice, Frames - Lower Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1052-00, PC-53-1162-00, PC-53-1172-00, PC-53-1178-00 Frames, Upper Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-07 PC-53-1176-00, PC-53-1180-00 Splice, Frames - Upper Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-13 PC-53-1018-00, PC-53-1100-00 Beam, Lower Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-13 PC-53-1166-00 Beam, Upper Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-17 PC-53-1050-00, PC-53-1160-00 Hinge PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-90 PC-53-1168-00, PC-53-1174-00 Fitting Splice, Upper Sill PCF/PCC TYPE 1, 20000 CYCLES

PC-53-30-90 PC-53-1102-00 Latch Fitting PCF/PCC TYPE 1, 20000 CYCLES






PC-53-30-90 PC-53-1020-00, PC-53-1104-00, PC-53-1110-00 Floor Beam Splice PCF/PCC TYPE 1, 20000 CYCLES

PC-53-60-01 PC-53-1056-00, PC-53-1058-00, PC-53-1182-00, PC-53-1184-00, PC-53-1200-00

Skin, Door 4 PCF TYPE 1, 20000 CYCLES

PC-53-60-03 PC-53-1186-00 Stringer, Door 4 PCF TYPE 1, 20000 CYCLES

PC-53-60-03 PC-53-1188-00 Fitting, Stringer – Door 4 PCF TYPE 1, 20000 CYCLES

PC-53-60-07 PC-53-1190-00, PC-53-1202-00 Frame, Station 1620 PCF TYPE 1, 20000 CYCLES

PC-53-60-07 PC-53-1192-00 Frame, Station 1640 PCF TYPE 1, 20000 CYCLES

PC-53-60-07 PC-53-1194-00 Frame, Station 1661 PCF TYPE 1, 20000 CYCLES

PC-53-60-07 PC-53-1196-00, PC-53-1204-00 Splice, Upper Frame - Station 1661 PCF TYPE 1, 20000 CYCLES

PC-53-60-07 PC-53-1198-00 Splice, Lower Frame - Station 1661 PCF TYPE 1, 20000 CYCLES

PC-53-60-07 PC-53-1206-00, PC-53-1208-00 Splice, Middle Frame - Station 1661 PCF TYPE 1, 20000 CYCLES



C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS

1. No changes to this section. See OEM 757 Maintenance Planning Data document. D. AIRWORTHINESS LIMITATIONS – SYSTEMS

1. No changes to this section. See OEM 757 Maintenance Planning Data document. E. CERTIFICATION MAINTENANCE REQUIREMENTS (CMR)

1. All original Boeing CMRs are still applicable in addition to the new CMRs due to the freighter conversion.



MPD ITEM NUMBER TASK CMR INTERVAL ZONE ACCESS APPLICABILITY 757 CERTIFICATION MAINTENANCE REQUIREMENTS

APL ENG TASK DESCRIPTION PC-XXX-XX-XX-XX (A TO Z) UNIQUE ALPHA IDENTIFIER (1 TO 7) MM PAGE BLOCK

1-100 FAULT LOCATION 2-200 MAINTENANCE PRACTICES 3-300 SERVICING 4-400 REMOVAL/INSTALLATION 5-500 ADJUSTMENT/TEST 6-600 INSPECTION/CHECK 7-700 CLEANING/PAINTING

(A TO Z) USED WHERE NO SPECIFIC MM COVERAGE EXISTS (00 TO 99) MM SUBJECT NUMBER (00 TO 99) MM SECTION NUMBER (12 TO 80) ATA CHAPTER (P OR R) P = P&W 2000 ENGINE,

R = RR RB211-535 ENGINE. PCF- IDENTIFIES PRECISION CONVERSIONS ADDED TASKS

EXAMPLE ILLUSTRATING FORMAT PC-27-51-00-5A OPC 02000 HRS 212 212 PCC/PCF ALL CHECK OPERATION OF THE TE FLAP/SLAT ALTERNATE (ELECTRIC) DRIVE

SYSTEM



F. PAGE FORMAT: CERTIFICATION MAINTENANCE REQUIREMENTS COLUMN EXPLANATION MPD ITEM NUMBER Each task in the MPD is identified with a unique number by zone. The first 6 digits (excluding the P or R engine identifier) correspond to the appropriate ATA

Chapter-Section-Subject in the Boeing Maintenance Manual (MM) that deals generally with the task. When information specific to the task is provided, a seventh digit indicates the first digit of the page block where it can be found in the MM. Alpha characters following the seventh digit differentiate between multiple tasks in the same page block. When information specific to the task is not provided in the MM, the seventh digit is an alpha character.

TASK MSG-3 TASK CATEGORIES LUB = LUBRICATION Any Act of consumable replenishment for the purpose of maintaining inherent design capabilities. SVC = Serving Any Act of consumable replenishment for the purpose of maintaining inherent design capabilities.

VCK = VISUAL CHECK A visual failure finding task to determine if an item is fulfilling its intended purposes. Does not require quantitative

tolerances. OPC = OPERATIONAL CHECK A failure finding task to determine if an item is fulfilling its intended purposes. Does not require quantitative

tolerances. DET = INSPECTION - DETAILED An examination of an item against a specific standard. This is a potential failure finding task. FNC = FUNCTIONAL CHECK A quantitative check to determine if one or more functions of an item performs within specified limits. This is a

potential failure finding task. RST = RESTORATION Reworking, replacement of parts or cleaning necessary to the return an item to a specific standard. DIS = DISCARD The removal and replacement of an item. CMR INTERVAL Task intervals are specified in terms of flight hours, cycles, or calendar time. If the threshold (the first interval listed) and repeat interval differ, the interval listed

underneath is the repeat interval. ZONE Airplane Zone Number (see Zone Diagrams, MPD Appendix A) where task is performed. ACCESS Access Panel/Door Number ((see Access Panel/Door Illustrations, MPD Appendix A) required to be opened to perform the task. APPLICABILITY APL ENG Applicable Airplane Model and Engine. “Note” refers to an explanation under the task description. _________________APL____________________ _________________ENGINE__________________________ PCF = B757-200PCF Precision Conversions Freighter Airplanes

PCC = B757-200PCC Precision Conversion Combi Airplanes PCF/PCC = freighter/combi

ALL = All 757 Engines

NOTE = Airplane Applicability Note NOTE = Engine Applicability Note TASK DESCRIPTION Description of the task to be performed.



The following table lists the new MPD item numbers for the new Certification Maintenance Requirements applicable on all Precision Conversion freighters and combi.

NEW CMRs NEW CMRs NEW CMRs NEW CMRs NEW CMRs MPD ITEM NUMBER MPD ITEM NUMBER MPD ITEM NUMBER MPD ITEM NUMBER MPD ITEM NUMBER

PC-26-10-00-1 PC-26-10-00-5 PC-26-2004-00 PC-52-30-00-5A PC-52-30-00-5B PC-52-30-00-5C PC-52-30-00-5D PC-52-30-00-5E PC-52-30-00-5F PC-52-30-00-5G PC-52-30-00-5H PC-52-30-00-5K PC-52-30-00-5L PC-52-30-00-5M



G. CERTIFICATION MAINTENANCE REQUIREMENTS TASKS


APL ENG TASK DESCRIPTION

PC-26-10-00-1 OPC 0024 HRS NOTE NOTE PCF/PCC ALL Operationally check the main cargo smoke detection system with the CFFU press to test switch (if not checked by crew). ZONE/ACCESS: see chapter 7 of operations manual. INTERVAL NOTE: task should not exceed 24 elapsed clock-hours.

PC-26-10-00-5 FNC 1000

FLIGHT HOURS

NOTE NOTE PCF/PCC ALL CFFU airflow valve control circuits functional test ZONE/ACCESS: see AMM 26-10-00/1 for component location

PC-26-2004-00 FNC 3000 FLIGHT HOURS

NOTE NOTE PCC ALL CFFU squib firing circuits functional test (dummy load) ZONE/ACCESS: see AMM 26-10-00 for component location

PC-52-30-00-5A OPC 5,000 FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door opening test ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5B OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door closing test ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5C OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door reversal test ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5D OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door opening test – Manual ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5E OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door closing test – Manual ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5F OPC 500 FLIGHT

HOURS NOTE NOTE PCF/PCC ALL Cargo door closed, latched, and locked indication test

ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location




APL ENG TASK DESCRIPTION PC-52-30-00-5G OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door closed verification test ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5H OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door air/ground verification test ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5K OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Cargo door inspections ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location

PC-52-30-00-5L OPC 500 FLIGHT

HOURS NOTE NOTE NOTE ALL Test and verify hydraulic pump wiring is not shorted to 28 volt DC power – cargo door

ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location AIRPLANE NOTE: Applicable only to airplanes with DC-powered hydraulic pump unit

PC-52-30-00-5M OPC 5,000

FLIGHT CYCLES

NOTE NOTE PCF/PCC ALL Test and check hydraulic selector valve for excessive leakage – cargo door ZONE/ACCESS NOTE: see AMM 52-30-00/1 for component location



H. JAA UNIQUE REQUIREMENTS



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APPENDIX A – ACCESS DATA AND ZONE DIAGRAMS

A. GENERAL

1. No changes to this section. See OEM 757 Maintenance Planning Data document. B. IDENTIFICATION OF ACCESS DOORS AND PANELS

1. No changes to this section. See OEM 757 Maintenance Planning Data document. C. ACCESS DOORS AND PANEL INFORMATION



PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page B.0-1

APPENDIX B – RESERVED


PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page C.0-1

APPENDIX C – TASKS SORTED BY INTERVAL

A. SCOPE



PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page D.0-1

APPENDIX D – CROSS-REFERENCE INDEXES

A. SCOPE

1. No changes to this section. See OEM 757 Maintenance Planning Data document. B. NOTES

1. No changes to this section. See OEM 757 Maintenance Planning Data document. C. APPLICABILITY

1. No changes to this section. See OEM 757 Maintenance Planning Data document. D. PAGE FORMAT




TASKS SORTED BY MPD ITEM NUMBER

No changes to this section. See OEM 757 Maintenance Planning Data document.



TASKS SORTED BY MRB ITEM NUMBER




TASKS SORTED BY TASK CARD ITEM NUMBER



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APPENDIX E – AIRPLANE DIMENSIONS AND STATION DIAGRAMS

A. GENERAL DIMENSIONS

1. No changes to this section. See OEM 757 Maintenance Planning Data document. B. MAJOR AIRPLANE DIMENSIONS



PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page F.0-1

APPENDIX F – SUPPLEMENTAL STRUCTURAL INSPECTION PROGRAM

A. STRUCTURAL DTRs AND REPORT FORMS

A Supplemental Structural Inspection Program (SSIP) is required to ensure the continued availability of damage tolerance in all structural elements. The modified Boeing Damage Tolerance Rating (DTR) system and the Precision Conversions Fatigue Tolerance Rating (FTR) system have been used to substantiate this requirement. The FTR Check Forms and Discrepant Structure Report forms that were previously found in this appendix have been relocated to Precision Conversions Document PC-0118-05-DTR.


PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page G.0-1

APPENDIX G – PRECLUDED SYSTEMS TASKS

NOTE:



PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page H.0-1

APPENDIX H – RESERVED


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APPENDIX I – CRITICAL SYSTEMS

A. CRITICAL SYSTEMS LIST



PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page J.0-1

APPENDIX J – RESERVED


PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page K.0-1

APPENDIX K – RESERVED


PC-0118-05 May 03/2013 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page L.0-1

APPENDIX L – STRUCTURES AND FATIGUE CROSS-REFERENCE

A. GENERAL

The “Structures and Fatigue Cross-Reference Index” and “Integrated Structural Inspection Program (ISIP) Cross-Reference Index” contained herein, Appendix L, contains the cross-references from the old numbering scheme to the new numbering scheme. These indexes will assist an operator to smoothly transition between the two different numbering schemes.

This renumbering effort came about as a recommendation from the Air Transport Association (ATA).



CURRENT STRUCTURES NUMBER CURRENT ZONAL NUMBER PRE-SEPTEMBER 2005

STRUCTURES MRB NUMBER PRE-SEPTEMBER 2005 CPCP

MRB NUMBER

52-1404-00 PCF-5230-838-101E

52-1406-00 PCF-5230-838-101I

52-1412-00 PCF-5230-838-104I

52-1414-00 PCF-5230-838-105I

52-1424-00 PCF-5230-838-151E

52-1426-00 PCF-5230-838-151I

52-1428-00 PCF-5230-838-152I

52-1430-00 PCF-5230-838-153I

52-1436-00 PCF-5230-838-156I

52-1438-00 PCF-5230-838-157I

52-1440-00 PCF-5230-838-158I



CURRENT STRUCTURES

NUMBER CURRENT ZONAL NUMBER PRE-SEPTEMBER 2005 STRUCTURES MRB NUMBER

PRE-SEPTEMBER 2005 CPCP MRB NUMBER

53-1000-00 PCF-5330-100-101E PCF-5330-200-101E

53-1002-00 PCF-5330-100-102E PCF-5330-200-102E

53-1004-00 PCF-5330-100-103E PCF-5330-200-103E

53-1006-00 PCF-5330-100-102I PCF-5330-200-102I

53-1008-00 PCF-5330-100-103I PCF-5330-200-103I

53-1010-00 PCF-5310-117-101E PCF-5310-221-101E

53-1012-00 PCF-5310-117-101I PCF-5310-221-101I

53-1016-00 PCF-5330-119-102I PCF-5330-121-102I

53-1018-00 PCF-5330-119-105I PCF-5330-121-105I

53-1020-00 PCF-5330-119-107I PCF-5330-121-107I



CURRENT STRUCTURES

NUMBER CURRENT ZONAL NUMBER PRE-SEPTEMBER 2005

STRUCTURES MRB NUMBER


53-1030-00 PCF-5310-221-106I

53-1032-00 PCF-5310-221-109I

53-1036-00 PCF-5310-221-111I

53-1038-00 PCF-5310-222-101E

53-1040-00 PCF-5310-222-101I

53-1044-00 PCF-5310-223-101E PCF-5310-224-101E

53-1046-00 PCF-5330-231-103I PCF-5330-233-103I

53-1048-00 PCF-5330-231-104I PCF-5330-233-104I

53-1050-00 PCF-5330-233-107E

53-1052-00 PCF-5330-233-101I

53-1052-00 PCF-5330-234-101I

53-1056-00 PCF-5360-251-101E PCF-5360-252-101E

53-1058-00 PCF-5360-251-101I PCF-5360-252-101I

53-1060-00 PCF-5330-100-151E PCF-5330-200-151E



CURRENT STRUCTURES




53-1060-00 PCF-5330-100-151E PCF-5330-200-151E

53-1062-00

PCF-5330-100-152E PCF-5330-200-152E

53-1064-00

PCF-5330-100-153E PCF-5330-200-153E

53-1066-00

PCF-5330-100-151I PCF-5330-200-151I

53-1068-00

PCF-5330-100-152I PCF-5330-200-152I

53-1070-00

PCF-5330-100-153I PCF-5330-200-153I

53-1076-00

PCF-5330-100-156I PCF-5330-200-156I

53-1080-00

PCF-5310-117-151E PCF-5310-221-151E

53-1082-00

PCF-5310-117-151I PCF-5310-221-151I



CURRENT STRUCTURES



53-1084-00 PCF-5310-117-152I 53-1086-00 PCF-5310-117-153I

53-1088-00 PCF-5310-117-154I PCF-5310-221-164I

53-1090-00 PCF-5310-118-151I 53-1092-00 PCF-5330-119-151I

53-1094-00 PCF-5330-119-152I PCF-5330-121-152I

53-1096-00 PCF-5330-119-153I PCF-5330-121-153I

53-1098-00 PCF-5330-119-154I PCF-5330-121-154I

53-1100-00 PCF-5330-119-155I PCF-5330-121-155I

53-1102-00 PCF-5330-119-156I PCF-5330-121-156I

53-1104-00 PCF-5330-119-157I PCF-5330-121-157I

53-1106-00 PCF-5330-119-158I PCF-5330-121-158I

53-1108-00 PCF-5330-119-159I PCF-5330-121-159I

53-1110-00 PCF-5330-119-161I PCF-5330-121-161I



CURRENT STRUCTURES




53-1120-00 PCF-5310-221-156I 53-1122-00 PCF-5310-221-157I 53-1124-00 PCF-5310-221-158I 53-1126-00 PCF-5310-221-159I 53-1130-00 PCF-5310-221-161I 53-1132-00 PCF-5310-221-162I 53-1134-00 PCF-5310-221-163I 53-1138-00 PCF-5310-222-151E 53-1140-00 PCF-5310-222-151I 53-1146-00 PCF-5310-222-154I 53-1148-00 PCF-5310-222-155I

53-1150-00 PCF-5310-223-151E PCF-5310-224-151E

53-1152-00 PCF-5330-231-153I PCF-5330-233-153I

53-1154-00 PCF-5330-231-154I PCF-5330-233-154I



CURRENT STRUCTURES




53-1156-00 PCF-5330-231-155I PCF-5330-233-155I

53-1158-00 PCF-5330-233-151E 53-1160-00 PCF-5330-233-157E

53-1162-00 PCF-5330-233-151I PCF-5330-234-151I

53-1166-00 PCF-5330-233-156I 53-1168-00 PCF-5330-233-158I 53-1172-00 PCF-5330-233-160I 53-1174-00 PCF-5330-233-161I 53-1176-00 PCF-5330-234-152I 53-1178-00 PCF-5330-234-153I 53-1180-00 PCF-5330-234-154I

53-1182-00 PCF-5360-251-151E PCF-5360-252-151E

53-1184-00 PCF-5360-251-151I PCF-5360-252-151I

53-1190-00 PCF-5360-251-154I PCF-5360-252-154I



CURRENT STRUCTURES



53-1192-00 PCF-5360-251-155I PCF-5360-252-155I

53-1194-00 PCF-5360-251-156I PCF-5360-252-156I

53-1196-00 PCF-5360-251-157I PCF-5360-252-157I

53-1198-00 PCF-5360-251-158I PCF-5360-252-158I

53-1200-00 PCF-5360-251-159I PCF-5360-252-159I

53-1202-00 PCF-5360-251-160I PCF-5360-252-160I

53-1204-00 PCF-5360-251-161I PCF-5360-252-161I

53-1206-00 PCF-5360-251-162I PCF-5360-252-162I

53-1208-00 PCF-5360-251-163I PCF-5360-252-163I


PC-0118-05 Oct 25/2017 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page M.0-1

APPENDIX M – TASK NUMBER CONVERSION CROSS-REFERENCE INDEX

NOTE:



PC-0118-05 Oct 25/2017 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT Page N.0-1

APPENDIX N – ICA Documents

A. ICA for Freighter and Combi Conversions

1. The ICA (Instructions for Continued Airworthiness) documents for the Freighter and Combi conversions are:

ICA Manual Title B757-200PCF (Freighter)

B757-200PCC (Combi)

Supplemental Illustrated Parts Catalog PC-0118-04 Rev P, Mar 03, 2017 PC-0118-206 Rev IR, Feb 11, 2013

Supplemental Maintenance Manual PC-0118-06 Rev P, Jun 01, 2017 PC-0118-229 Rev A, Mar 25, 2013

Structural Repair Manual Supplement PC-0118-11 Rev F, Apr 14, 2017 PC-0118-219 Rev A, Mar 25, 2013

Electrical Wiring Interconnection System (EWIS) Instructions for Continued Airworthiness (ICA) Source Document for 757-200 Combi Configuration

N/A PC-0118-237 Rev F, 5/2/13

Maintenance Planning Document Supplement PC-0118-05 Rev Oct 25/2017

MPD Supplement Section 9 Airworthiness Limitations and Certification Maintenance Requirements PC-0118-05-09 Rev L (Feb 23/2017)

Damage Tolerance Rating (DTR) Check Form Document Supplement for B757-200 Cargo/Combi Conversion PC-0118-05-DTR Rev C (Feb 23/2017)

Airplane Weight and Balance (W&B) Control and Loading Manual Supplement Chapter 1 OL0182 Ch. 1 – Revision varies by Operator

Airplane Weight and Balance (W&B) Control and Loading Manual Supplement Chapter 2 OL0182 Ch. 2 – Revision varies by Operator

2. The “Maintenance Planning Document Supplement for B757-200 PCF/PCC Conversion,” Doc. No. PC-0118-05, is the “Principal Manual” as

defined by FAR H25.4(b).

3. These ICA manuals are supplements to the Boeing 757 OEM Manuals and are applicable to certain Boeing 757-200 airplanes converted from a passenger to a Freighter or Combi configuration. The information contained herein only applies to items, components and/or systems that have been modified or added and is not intended to duplicate data that is presented in the Boeing OEM Manuals.

4. To review document contents, refer to Precision Conversions supplements provided at conversion, and revisions provided thereafter.

MAINTENANCE PLANNING DOCUMENT SUPPLEMENT FOR B757 … · MAINTENANCE PLANNING DOCUMENT SUPPLEMENT...

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