structural repair manual supplement for b757-200 …1. brought current with boeing 757-200...

STRUCTURAL REPAIR MANUAL SUPPLEMENT FOR B757-200 CARGO

CONVERSION PC-0118-11

PRECISION CONVERSIONS CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 Precision Conversions Unpublished Work – All Rights Reserved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.

ORIGINAL ISSUE DATE: JANUARY 10, 2005

REVISION DATE: SEPTEMBER 20, 2018

COMPILED AND PUBLISHED BY:

PRECISION CONVERSIONS 4900 SW GRIFFITH DRIVE, SUITE 133

BEAVERTON, OREGON 97005 USA

PRECISION B757-200PCF CONVERSIONS LLC Structural Repair Manual Supplement

PC-0118-11

REV

IR

A

B

c

D

E

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LIST OF REVISIONS

DESCRIPTION BY APVD DATE

Initial Release MV WJW 01/10/05

Text Clarification MV WJW 02/10/05

Clarifications DFD WJW 06/17/09

Clarifications DH DH 11/20/14

Clarifications JMD DD 12/16/15

Brought current with Boeing 757-200 Structural Repair JMD DD 04/15/16

Manual D634N201 Jan 20/2016 Revision

See Revision Highlights RMJG DD 04/14/17

See Revision Highlights 5L ~~ </f J.o/ 1?

REVISIONS 200PCF Page 1

Sep 2018 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.

B757-200PCF Structural Repair Manual Supplement

PC-0118-11

HIGHLIGHTS 200PCF Page 1


REVISION HIGHLIGHTS Revised and/or clarified sections are marked with right margin revision bars:

1. Brought current with Boeing 757-200 Structural Repair Manual D634N201.

2. Incorporated Temporary Revisions 25, 26, 27, adding aircraft 085 to 106 to the List of Effective Airplanes.

3. Added aircraft 107 to 109 to the List of Effective Airplanes.

4. Updated aircraft registration numbers on the List of Effective Airplanes.


PC-0118-11 Page Date Page Date Page Date

EFFECTIVE PAGES 200PCF Page 1


TITLE PAGE 1 Sep 2018 LIST OF REVISIONS 1 Sep 2018 HIGHLIGHTS 1 Sep 2018 LIST OF EFFECTIVE PAGES 1 Sep 2018 RECORD OF TEMP. REVISIONS 1 Sep 2018 LIST OF EFFECTIVE AIRPLANES 1 Sep 2018 2 Sep 2018 INTRODUCTION 1 Nov 2014 2 Sep 2018 3 Nov 2014 4 Nov 2014 CONTENTS 1 Jun 2009 CHAPTER 51 STRUCTURES GENERAL 51-CONTENTS 1 Nov 2014 51-00-00 1 Nov 2014 51-00-04 1 Nov 2014 2 Nov 2014 3 Nov 2014 4 Nov 2014 51-10-00 1 Apr 2017 51-10-02 101 Nov 2014 51-70-00 1 Apr 2017 51-70-11 1 Nov 2014 51-70-12 1 Nov 2014 51-70-13 1 Nov 2014 CHAPTER 52 DOORS 52-CONTENTS 1 Nov 2014 52-00-00 1 Nov 2014 52-10-01 1 Nov 2014 2 Nov 2014 3 Nov 2014 52-10-02 1 Nov 2014 2 Nov 2014 201 Nov 2014 52-10-03 101 Nov 2014 201 Nov 2014 202 Nov 2014 52-30-01 1 Jun 2009 2 Jun 2009 3 Jun 2009 52-30-02 1 Nov 2014 2 Nov 2014

52-30-03 101 Nov 2014 201 Nov 2014 CHAPTER 53 FUSELAGE 53-CONTENTS 1 Dec 2015 2 Dec 2015 53-00-00 1 Nov 2014 53-00-01 101 Nov 2014 201 Nov 2014 53-00-03 101 Nov 2014 201 Nov 2014 202 Nov 2014 53-00-04 101 Nov 2014 201 Nov 2014 53-00-07 101 Nov 2014 102 Nov 2014 201 Nov 2014 53-00-13 101 Dec 2015 53-00-51 101 Nov 2014 102 Nov 2014 201 Nov 2014 53-00-52 101 Nov 2014 201 Nov 2014 53-10-01 1 Nov 2014 2 Nov 2014 3 Nov 2014 4 Nov 2014 5 Nov 2014 6 Nov 2014 53-10-03 1 Nov 2014 2 Nov 2014 3 Nov 2014 4 Nov 2014 53-10-07 1 Nov 2014 2 Nov 2014 3 Nov 2014 4 Nov 2014 53-10-08 1 Nov 2014 2 Nov 2014 101 Nov 2014 201 Nov 2014 53-10-13 1 Nov 2014 101 Nov 2014 201 Nov 2014 53-10-15 1 Nov 2014 2 Nov 2014 101 Nov 2014 53-10-52 1 Nov 2014 2 Nov 2014 LIST OF EFFECTIVE PAGES

53-30-01 1 Nov 2014 2 Nov 2014 3 Nov 2014 4 Nov 2014 201 Nov 2014 53-30-03 1 Nov 2014 2 Nov 2014 53-30-04 1 Nov 2014 53-30-07 1 Nov 2014 2 Nov 2014 3 Nov 2014 53-30-15 1 Nov 2014 2 Nov 2014 3 Nov 2014 4 Nov 2014 101 Nov 2014 53-30-52 1 Jun 2009 2 Jun 2009 53-40-52 1 Jun 2009 2 Jun 2009 53-60-01 1 Nov 2014 2 Nov 2014 53-60-03 1 Nov 2014 53-60-07 1 Nov 2014 53-60-51 1 Dec 2015 53-60-52 1 Nov 2014 2 Nov 2014 CHAPTER 54 NACELLES/PYLONS 54-CONTENTS 1 Nov 2014 54-00-00 1 Nov 2014 CHAPTER 55 STABILIZERS 55-CONTENTS 1 Nov 2014 55-00-00 1 Nov 2014 CHAPTER 56 WINDOWS 56-CONTENTS 1 Nov 2014 56-00-00 1 Nov 2014 CHAPTER 57 WINGS 57-CONTENTS 57-00-00 1 Nov 2014


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TEMPORARY REVISIONS 200PCF Page 1 Sep 2018

PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.

RECORD OF TEMPORARY REVISIONS

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

NO. DATE TR NO. DATED B

Y DATE TR NO. DATE

1 06/20/08 DD 06/17/09 2 08/19/10 DD 11/19/14 3 05/10/11 DD 11/19/14 4 06/08/11 TF 11/19/14 5 Cancelled 6 10/21/11 SL 11/19/14 7 07/31/12 DH 11/19/14 8 11/30/12 DH 11/19/14 9 12/21/12 DH 11/19/14

10 08/29/13 DH 11/19/14 11 12/09/13 DH 11/19/14 12 12/26/13 DH 11/19/14 13 05/12/14 SL 11/19/14 14 08/15/14 SL 11/19/14 15 09/23/14 SL 11/19/14 16 10/15/14 SL 11/19/14 17 04/13/15 SL 12/16/15 18 05/12/15 SL 12/16/15 19 07/23/15 SL 12/16/15 20 09/04/15 SL 12/16/15 21 11/30/15 SL 12/16/15 22 07/26/16 RG 04/14/17 23 12/10/16 RG 04/14/17 24 03/14/17 RG 04/14/17 25 10/24/17 SL 09/20/18 26 03/23/18 SL 09/20/18 27 07/20/18 SL 09/20/18


PC-0118-11

EFFECTIVE AIRPLANES 200PCF Page 1 Sep 2018


LIST OF EFFECTIVE AIRPLANES The following list provides a cross reference table of the airplanes that are applicable to the information contained in this manual. Registration numbers are for reference only.

Cargo Conversion Number Model No. Line No. Variable

No. Manufacturing

Serial No. Current Registration

No. 001 757-204 440 NB421 26962 VT-BDO 002 757-23A 257 NB139 24567 C-FLAJ 003 757-23A 255 NB138 24566 C-FKAJ 004 757-26DER 231 NE001 24471 HP-2110DAE 005 757-26DER 235 NE002 24472 9M-RYA 006 757-208ER 273 ND201 24739 TF-FIH 007 757-260ER 348 NE201 25014 ET-AJX 008 757-256ER 553 ND241 26239 EC-FTR 009 757-28A 127 NA441 23767 C-GIAJ 010 757-225 74 NA022 22211 N314ST 011 757-225 75 NA023 22611 VH-PQA 012 757-225 42 NA021 22210 A9C-DHE 013 757-225 117 NA026 22689 N689GX 014 757-225 115 NA025 22688 N688GX 015 757-23N 692 NC059 27598 VT-BDM 016 757-232 111 NA520 22910 N620DL 017 757-236 183 NA395 24121 EC-KLD 018 757-28A 130 NA442 23822 N822PB 019 757-236 279 NA343 24792 C-FKCJ 020 757-25C 475 ND221 25898 VT-BDN 021 757-232 46 NA505 22812 N605DL 022 757-236 441 NA348 25597 VQ-BPY 023 757-21B 232 NB066 24401 B-2899 024 757-27A 910 NT885 29611 HP-1810DAE 025 757-27A 832 NT881 29607 HP-1910DAE 026 757-27A 904 NT884 29610 HP-2010DAE 027 757-2Z0 554 NB293 25887 B-2832 028 757-2Z0 615 NB297 27269 B-2839 029 757-236 449 NA350 25620 VH-TCA 030 757-25CER 565 ND222 25899 B-2828 031 757-21B 389 NB262 25258 B-2817 032 757-222ER 361 NE041 25042 N531UA 033 757-25CER 574 ND223 25900 B-2829 034 757-2B6 106 NC042 23687 N557CM 035 757-2Q8 597 NC071 26273 N751CX 036 757-2Z0 674 NB302 27512 B-2845 037 757-2Z0 622 NB298 27270 B-2840 038 757-28A 704 NB224 26276 VT-BDQ 039 757-2Z0 833 NT202 29793 B-2856 040 757-223 433 ND180 25298 C-FGKJ 041 757-2Z0 624 NB299 27367 B-2841 042 757-2Z0 595 NB294 27258 B-2836 043 757-2Z0 822 NT201 29792 B-2855 044 757-25F 752 NB230 28718 VT-BDA 045 757-2Z0 669 NB301 27511 B-2844 046 757-29JER 588 NE301 27203 N757QM 047 757-2Z0 480 NB292 25886 B-2821 048 757-2Q8 836 NT378 29380 D-ALEN 049 757-230ER 446 NE172 25441 N888LT 050 757-2Q8 821 NT377 29443 D-ALEO 051 757-2Q8 1006 NT346 30046 D-ALEP 052 757-25F 928 NT237 30757 B-6150 053 757-222ER 421 NE147 25397 OO-TFC 054 757-2G5 671 NB446 26278 B-7342


PC-0118-11

EFFECTIVE AIRPLANES 200PCF Page 2 Sep 2018


Cargo Conversion Number Model No. Line No. Variable

No. Manufacturing

Serial No. Current Registration

No. 055 757-25F 932 NT238 30758 B-7082 056 757-23N 737 NC062 27974 VT-BDB 057 757-2Q8 688 NC073 26332 D-ALEQ 058 757-23N 843 NT283 29330 G-DHKA 059 757-28A 738 NB226 27621 B-7689 060 757-2Q8 819 NT376 29442 D-ALES 061 757-2Q8 639 NC072 27351 D-ALER 062 757-23N 814 NT282 27976 G-DHKE 063 757-256ER 943 NT915 29312 G-DHKB 064 757-236 873 NT408 29945 G-DHKF 065 757-23N 779 NT281 27975 G-DHKD 066 757-25CER 685 ND224 27513 B-2848 067 757-222 414 NE145 25368 N547UA 068 757-256 948 NT916 30052 G-DHKC 069 757-236 445 NA349 25598 B-2835 070 757-236 877 NT409 29946 G-DHKG 071 757-2Y0 503 NB328 26156 B-2827 072 757-28A 672 NB222 26275 G-DHKH 073 757-25CER 698 ND225 27517 B-2849 074 757-21B 583 NB266 25889 B-2824 075 757-21K 746 NB571 28674 B-1432 076 757-21B 575 NB265 25888 B-2823 077 757-28A 974 NT248 32449 G-DHKK 078 757-223ER 378 ND163 24605 C-GCJT 079 757-2Y0 482 NB325 26153 B-2831 080 757-28A 865 NT239 28174 G-DHKJ 081 757-28A 723 NB225 28161 G-DHKI 082 757-223ER 847 NT738 29590 G-DHKM 083 757-204 528 NB428 25623 B-1578 084 757-21B 585 NB267 25890 B-2825 085 757-2Z0 613 NB296 27260 B-1463 086 757-28S 966 NT385 32342 B-2813 087 757-223ER 812 NT731 29423 B-1378 088 757-223ER 998 NT981 31308 G-DHKN 089 757-28S 868 NT383 29217 B-2859 090 757-223ER 817 NT733 29425 B-1231 091 757-223ER 1000 NT982 32397 G-DHKO 092 757-28S 961 NT384 32341 B-2812 093 757-223 548 ND182 25730 C-GTCJ 094 757-223ER 816 NT732 29424 B-1252 095 757-223ER 562 ND183 25731 VQ-BKK 096 757-223ER 1002 NT983 32398 G-DHKP 097 757-223ER 828 NT735 29427 G-DHKS 098 757-28S 1015 NT386 32343 B-2830 099 757-223ER 827 NT734 29426 N676AN 100 757-223ER 842 NT737 29589 N679AN 101 757-2B7 655 NB517 27805 B-1145 102 757-223ER 383 ND165 24607 C-GVAJ 103 757-28S 811 NT382 29216 B-2853 104 757-223ER 566 ND184 25696 N690AA 105 757-223ER 837 NT736 29428 N678AN 106 757-2B7 605 NB512 27201 B-1173 107 757-28S 797 NT381 29215 B-2851 108 757-223ER 417 ND175 24617 N659AA 109 757-223ER 661 ND194 27052 B-1177


PC-0118-11

INTRODUCTION 200PCF Page 1

Nov 2014 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.

INTRODUCTION

1. General A. The “Structural Repair Manual (SRM) Supplement for B757-200 Cargo Conversion” is a

supplement to the “Boeing 757-200 Structural Repair Manual” document and is applicable to Boeing 757-200 airplanes converted from a passenger to a Precision Conversions Freighter (PCF) configuration in accordance with FAA STC No. ST01529SE. The information contained in this supplemental SRM only applies to structure that has been added or affected and is not intended to duplicate data that is presented in the Boeing document. This SRM Supplement is in compliance with Part 26 Section 26.47. The added and affected structure is divided into three types: 1) Precision Conversions Freighter Principal Structural Element (PCF PSE) as detailed in Figure

2 of Section 51-00-04. This type of structure is addressed within this SRM Supplement.

2) OEM Principal Structural Element (OEM PSE) affected by the PCF STC as detailed in Figure 3 of Section 51-00-04. This type of structure is addressed within this SRM Supplement.

3) Fatigue Critical Structure (FCS) is structure that is affected by the PCF STC but that does not

result in changes in allowable damage, repairs or inspection thresholds. It is recommended that this type of structure be reviewed by Precision Conversions if damage or repairs exceed requirements detailed in the Boeing 757-200 SRM. Precision Conversions considers all structure within the fuselage pressurized area as FCS.

(PCF PSE)

FCS


PC-0118-11



1) General (Cont’d)

A. The conversion of a B757-200 passenger airplane to an all-cargo airplane includes the following structural modifications: 1) Installation of a main deck cargo door on the left side of the forward fuselage. (See 52-30) 2) Deletion of the No. 1 entry doors, left and right. (See 53-10) 3) Deletion of the No. 4 entry doors, left and right. (See 53-60) 4) Deactivation of the remaining doors and emergency exits in the passenger cabin. 5) Installation of a crew entry door on the left side of the fuselage, forward of the 9G barrier. (See

52-10) 6) Removal of all passenger windows and installation of window plugs. 7) Installation of a rigid 9g cargo barrier behind the flight deck. (See 53-10-08) 8) Reinforce floor beams. 9) Installation of additional seat tracks. (See 53-10-52, 53-30-52, 53-40-52, and 53-60-52) 10) Replacement or modification of floor panels. 11) Modification of frames at aft pallet location.

B. This Supplemental SRM is to be used in conjunction with Boeing 757-200 SRM, D634N201,

dated May 20, 2018. Please contact Precision Conversions Customer Support if the Boeing SRM revision used differs from the above noted revision.


PC-0118-11



1. General (Cont’d)


PC-0118-11



2) Manual Arrangement and Numbering System No change to this section. See original Boeing Structural Repair Manual.

3) How to Use This Manual No change to this section. See original Boeing Structural Repair Manual.

4) How to Use This Manual for Spare Parts Identification No change to this section. See original Boeing Structural Repair Manual.

5) Airplane Effectivity Designations No change to this section. See original Boeing Structural Repair Manual.

6) Publication Change Request No change to this section. See original Boeing Structural Repair Manual.

7) Service Bulletin No change to this section. See original Boeing Structural Repair Manual.

8) Revision Service No change to this section. See original Boeing Structural Repair Manual.

9) Standard Tools No change to this section. See original Boeing Structural Repair Manual.

10) Significant Rework Log A. No change to this section. See original Boeing Structural Repair Manual.

B. If it is necessary to obtain rework data, please contact:

Precision Conversions, LLC 4900 SW Griffith Drive, Suite 133 Beaverton, Oregon 97005 USA


PC-0118-11

CONTENTS 200PCF Page 1

June 2009 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.

LIST OF CHAPTERS SUBJECT CHAPTER

STRUCTURES ................................................................................................................................. 51

DOORS ............................................................................................................................................ 52

FUSELAGE ...................................................................................................................................... 53

NACELLES/PYLONS ....................................................................................................................... 54

STABILIZERS .................................................................................................................................. 55

WINDOWS ....................................................................................................................................... 56

WINGS ............................................................................................................................................ 57


PC-0118-11

51-CONTENTS 200PCF Page 1


CHAPTER 51

STRUCTURES

TABLE OF CONTENTS SUBJECT CHAPTER SECTION

STRUCTURE .............................................................................................................................. 51-00-00

STRUCTURAL CLASSIFICATION ....................................................................................... 51-00-04

Figure 1 – Structural Classification Diagram

Figure 2 – Principal Structural Elements of PCF STC

Figure 3 – OEM Principal Structural Elements (PSEs) Affected By PCF STC

ALLOWABLE DAMAGE REMOVAL – TYPICAL ................................................................. 51-10-00

Typical Blending ............................................................................................................. 51-10-02

Figure 101 – Allowable Blending

REPAIRS – TYPICAL ........................................................................................................... 51-70-00

Typical Formed Section Repair ...................................................................................... 51-70-11

Typical Extruded Section Repair .................................................................................... 51-70-12

Typical Web Repair ........................................................................................................ 51-70-13


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51-00-00 200PCF Page 1


CHAPTER 51 STRUCTURES

1. General A. All information contained in the Boeing 757-200 SRM, D634N201, Chapter 51, is applicable to

aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification, except for any limitations listed in this chapter. 1. STC Structure: No structural reinforcing repairs are applicable to the STC related structure.

This includes but is not limited to repairs noted in the Boeing 757-200 SRM, D634N201, Chapters 51-70-11, 51-70-12 and 51-70-13.

2. OEM Structure: No repairs are allowed on OEM PSE Structure as detailed in Section 51-

00-04 Figure 3 of this SRM supplement. If damage is common to the noted OEM PSE, communicate with Precision Conversions Customer Support for assistance.

Note: It is recommended that any damage exceeding the requirements of the Boeing 757-200 SRM D634N201 or this SRM supplement, on any fuselage structure, be communicated to Precision Conversions customer service for further review prior to next flight.


PC-0118-11

51-00-04 200PCF Page 1


STRUCTURAL CLASSIFICATION Section 51-00-04

Note: Figure 1 displays a diagram of the areas with new or modified structure due to the passenger to freighter conversion. Figure 2 provides a list of principal structure elements (PSE) specified by the Maintenance Planning Data Document (MPD) supplement, PC-0118-05. Figure 3 provides a list of OEM PSE affected by the passenger to freighter conversion.

Structural Classification Diagram Figure 1 (Sheet 1)

Section 51-00-04 Structural Classification


PC-0118-11

51-00-04 200PCF Page 2


STRUCTURAL CLASSIFICATION

TITLE LOCATION PC SRM SECTION REFERENCE

Outer Skin, Crew Entry Door BS 302 to 333, Upper Sill to Lower Sill 52-10-01 007F8348

Crew Entry Door BS 302 to 333, Upper Sill to Lower Sill 52-10-02 007F8349

Outer Skin, Cargo Door BS 480 to 620, S-4L to 17L 52-30-01 007F3125

Inner Skin, Cargo Door BS 480 to 620, S-4L to 17L 52-30-01 007F3105

Intercostals, Cargo Door BS 480 to 620, I-1 to I-9 52-30-02 007F3140

Frames, Cargo Door BS 480 to 620, S-4L to 17L 52-30-02 007F3102 007F3128

Frames, Lower Cargo Door BS 490 to 610, I-7 to S-17L 52-30-02 007F3126

Upper Sill, Cargo Door BS 480 to 620, S-4L 52-30-02 007F3129

Lower Sill, Cargo Door BS 480 to 620, S-17L 52-30-02 007F3130

Latch BS 490 to 610, S-17L 52-30-02 007F3413

Door Support Fittings BS 489 to 500, S-4L to 6L BS 600 to 611, S-4L to 6L 52-30-02 007F3123

Skin, Door L1 BS 297 to 378, S-4L to S-20L 53-10-01 007F8061

Skin, Door R1 BS 324 to 365, Upper Sill to Lower Sill 53-10-01 007F8022

OEM Skin – Strap, Upper Attachment BS 340 to 375, LBL and RBL 45, 30, 12 53-10-01 OEM Part

Stringer, Door R1 BS 324 to 365, DS-1R to DS-7R 53-10-03 007F8152

Fitting, Stringer - Door R1 BS 324 and 365, DS-1R to DS-7R 53-10-03 007F8153

Stringer, Door L1 BS 333 to 376, DS-1L to DS-6L 53-10-03 007F8068

Fitting, Stringer - Door L1 BS 376, DS-1L to DS-6L 53-10-03 007F8069

Aft Intercostal, Crew Entry Door BS 333 to 345, S-8L to 16L 53-10-15 007F8356 007F8380

Fwd Intercostal, Crew Entry Door BS 297 to 333, DS-1L to DS-6L 53-10-15 007F8359

Frame, Station 345 - Door R1 BS 345, S-6L to 17L 53-10-03 007F8151

Splice, Lower Frame - Station 345 Door R1 BS 345, S-17R 53-10-07 007F8151

Frame, Station 345 - Door L1 BS 345, S-6L to 17L 53-10-07 007F8066

Splice, Lower Frame - Station 345 Door L1 BS 345, S-17L 53-10-07 007F8066

Frame, Station 365 - Door L1 BS 365, S-6L to 17L 53-10-07 007F8067

Splice, Lower Frame - Station 365 Door L1 BS 365, S-17L 53-10-07 007F8067

Frame, Station 302 BS 302, S-6L to 17L 53-10-15 007F8017

Frame, Station 333 BS 333, S-6L to 17L 53-10-15 007F8365

Lower Sill - Crew Entry Door BS 302 to 333, S-16L 53-10-15 007F8364

Upper Sill - Crew Entry Door BS 302 to 333, S-8L 53-10-15 007F8016

Splice, Upper Frame - Station 333 BS 333, Upper Sill 53-10-15 007F8366

Splice, Lower Frame - Station 333 BS 333, Lower Sill 53-10-15 007F8366

Principal Structural Elements of PCF STC Figure 2 (Sheet 1)


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51-00-04 200PCF Page 3



TITLE LOCATION PC SRM SECTION REFERENCE

Outer Skin BS 440-660, S-4R to 26L 53-30-01 007F2208 007F2309 007F2405

Longitudinal Splice, Outer Skin BS 440 and 660, S-4R to 26L 53-30-01 See Outer Skin

Circumferential Splice, Outer Skin BS 440 to 660, S-4R, 6L, 14L, 19L, 26L 53-30-01 See Outer Skin

Inner Skin BS 460 to 640, S-3L to 4L 53-30-15 007F2204

Stringers BS 440 to 660, S-3R to 24L 53-30-03 007F2503

Splice, Stringers BS 440 and 660, S-3R to 24L 53-30-03 007F2216

Intercostal, Upper Sill BS 460 to 640, S-3L 53-30-15 007F2211

Intercostal, Lower Sill BS 480 to 500, S-20L 53-30-15 007F2313

Frame, Jamb - Fore/Aft (BS 480 and 620) BS 480 and 620, S-4L to 17L 53-30-15 007F2406

Frame, Jamb - Fore/Aft (BS 460 and 640) BS 460 and 640, S-4L to 17L 53-30-15 007F2404

Fitting, Fore/Aft Jambs BS 460, 480, 620, 640, S-4L and 17L 53-30-15 007F2404 007F2406

Frames, Lower Sill BS 460 to 640, S-17L to 25L 53-30-07 007F2302

Inner Flange, Frame - Lower Sill BS 480 to 580, S-20L to 22L 53-30-07 007F2302

Splice, Frames - Lower Sill BS 460 to 640, S-25L 53-30-07 OEM Part

Frames, Upper Sill BS 460 to 640, S-2R to 2L 53-30-07 007F2202

Splice, Frames - Upper Sill BS 460 to 640, S-3R 53-30-07 007F2206

Beam, Lower Sill BS 440 to 660, S-17L 53-30-15 007F2317

Beam, Upper Sill BS 440 to 660, S-4L 53-30-15 007F2205

Hinge BS 480 to 620, S-4L 53-30-15 007F2905

Fitting Splice, Upper Sill BS 440 and 660, S-4L 53-30-15 007F2408

Latch Fitting BS 490 to 610, Lower Sill 53-30-15 007F2308

Floor Beam Splice BS 460 to 640, S-17L 53-30-15 007F2312

Frame middle Splice BS1661 53-60-07 007F6085

Skin, Door 4 BS 1640 to 1682, Upper Sill to Lower Sill 53-60-01 007F8092

Stringer, Door 4 BS 1640 to 1682, DS-1 to DS-6 53-60-03 007F8086

Fitting, Stringer - Door 4 BS 1640 to 1682, DS-1 to DS-6 53-60-07 007F8087

Frame, Station 1620 BS 1620, S-17 53-60-07 007F8093

Frame, Station 1640 BS 1640, S-16 to 19 53-60-07 007F8094

Frame, Station 1661 BS 1661, S-6 to 17 53-60-07 007F8085

Splice, Upper Frame - Station 1661 BS 1661, S-6 53-60-07 007F8100

Splice, Lower Frame - Station 1661 BS 1661, S-17 53-60-07 007F8099

Principal Structural Elements of PCF STC Figure 2 (Sheet 2)


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51-00-04 200PCF Page 4



TITLE PC MPD ITEM No. 1 Cargo Door Cutout, BS 560 Edge Frame – Inner Chord, Upper Sill to S-24

PC-53-30-11 Line No. 1-57

No. 1 Cargo Door Cutout, BS 560 Edge Frame – Inner Chord, Upper Sill to S-24

PC-53-30-11 Line No. 58 and on

No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 560 Upper Sill to Lower Sill

PC-53-30-11 Line No. 1-57

No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, BS 560 Upper Sill to Lower Sill


No. 1 Cargo Door Cutout, BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill

PC-53-30-11 Line No. 1-57

No. 1 Cargo Door Cutout, BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill


No. 1 Cargo Door Cutout, Edge Frame – Inner Chord, BS 620 – Upper Sill to Lower Sill

PC-53-30-11 Line No. 1-57

No. 1 Cargo Door Cutout, Edge Frame – Inner Chord, BS 620 – Upper Sill to Lower Sill


No. 1 Cargo Door Cutout, Door Stop Intercostals, Door Stop No. 1 & 6 (Forward & Aft) PC-53-30-12

BS1040 Rear Spar Bulkhead, Lower Side Fitting, Inboard Leg at WL 187.70, (Left & Right) PC-53-40-20

Rear Spar Bulkhead, Inner Chord, BS1040 S14 –S17, (Left & Right) PC-53-40-20

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

OEM Principal Structural Elements (PSEs) Affected By PCF STC Figure 3 (Sheet 1)


PC-0118-11

51-10-00 200PCF Page 1

Apr 2017 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.

ALLOWABLE DAMAGE REMOVAL – TYPICAL Section 51-10-00

1. All information contained in the Boeing 757-200 SRM, Chapter 51-10, is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification.


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ALLOWABLE DAMAGE REMOVAL – TYPICAL Section 51-10-02

TYPICAL BLENDING

NOTES:

• Length of Cleanout Boundary (L) is not to exceed 6 inches total length. • The edge of the blend out should not be within 2 x dia of a fastener location. • “D” is as noted in the appropriate chapter. • No other damage or blend out is permitted in the same cross section as the free flange trim out

noted in DETAIL C. • Perform blend out as given in procedures in Boeing 757-200 SRM 51-10-02. • Finish blended area per Boeing 757-200 SRM 51-20. • After blend out is complete per above details, ensure surface is smooth with a 63 RA surface

finish or better and perform a 10X close visual inspection to ensure all damage has been removed per Boeing 757-200 NDT Manual Part 10.

• Perform an HFEC inspection on the blended surface per 757-200 NDT manual Part 6 to ensure no crack indications exist.

• The inspections given in the Precision Conversions Maintenance Planning Data Document (MPD) supplement are sufficient to maintain the Damage Tolerance of the structure with this allowable damage. See specific chapters for inspections on blended areas beyond MPD requirements.

• No Damage is permitted within 1.0 in. from any lap edge.

Allowable Blending Figure 101 (Sheet 1)


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Apr 2017 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.

REPAIRS - TYPICAL Section 51-70-00

1. All information contained in the Boeing 757-200 SRM, Chapter 51-70, is applicable to aircraft

modified in accordance with Precision Conversions 757-200PCF freighter modification.


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REPAIRS – TYPICAL Section 51-70-11

1. Typical Formed Section Repair

A. The typical formed section repair defined in Boeing 757 SRM, D634N201, 51-70-11, Figure 1 is

applicable to aircraft modified by the passenger to freighter modification, except for the following: 1) STC Structure: This repair is not effective on any Precision Conversions STC structure. If

damage is common to the noted structure, communicate with Precision Conversions Customer Support for assistance.

2) OEM Structure: Refer to Section 51-00-04, Figure 3 to determine if this repair is common to an OEM affected PSE. If the repair does affect a PSE item, contact Precision Conversions for further review.

.

Note: It is recommended that any damage or repair exceeding the requirements of the Boeing 757-200 SRM D634N201 or this SRM supplement, on any affected structure within the pressurized fuselage, be communicated to Precision Conversions Customer Support for further review prior to next flight.


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1. Typical Extruded Section Repair

A. The typical extruded section repairs defined in Boeing 757 SRM, D634N201, 51-70-12, Figure 1

and 2 are applicable to aircraft modified by the passenger to freighter modification, except for the following: 1) STC Structure: This repair is not effective on any Precision Conversions STC structure. If





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1. Typical Web Repair

A. The typical web repair defined in Boeing 757 SRM, D634N201, 51-70-13, Figure 1 is applicable

to aircraft modified by the passenger to freighter modification, except for the following: 1) STC Structure: This repair is not effective on any Precision Conversions STC structure. If





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CHAPTER 52

DOORS


DOORS ....................................................................................................................................... 52-00-00

PASSENGER/CREW ENTRY DOOR

PASSENGER/CREW ENTRY DOOR SKIN ......................................................................... 52-10-01

Figure 1 – Crew Entry Door Skin Identification

Figure 2 – R1 Door Skin Plug Identification

Figure 3 – L4/R4 Door Skin Plug Identification

PASSENGER CREW ENTRY DOOR STRUCTURE ........................................................... 52-10-02

Figure 1 – Crew Entry Door Structure Identification

REPAIRS - Passenger/Crew Entry Door Structure

PASSENGER/CREW ENTRY DOOR .................................................................................. 52-10-03

ALLOWABLE DAMAGE – Passenger Crew Entry Door

REPAIRS - Passenger/Crew Entry Door

Figure 201 Repair – Crew Entry Door

MAIN CARGO DOOR

MAIN CARGO DOOR SKIN ................................................................................................. 52-30-01

Figure 1 – Main Cargo Door Skin Identification

MAIN CARGO DOOR STRUCTURE ................................................................................... 52-30-02

Figure 1 – Main Cargo Door Structure Identification

ALLOWABLE DAMAGE - Main Cargo Door Structure .................................................. 52-30-03

REPAIRS - Main Cargo Door Structure


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CHAPTER 52 DOORS 1. All information contained in the Boeing 757-200 SRM, Chapter 52, is applicable to aircraft modified in

accordance with Precision Conversions 757-200PCF freighter modification, except as follows: A. OEM Structure:

1) No damage is allowed on OEM PSE Structure as detailed in Section 51-00-04 Figure 3 of this

supplement SRM. If damage is common to the noted OEM PSE, communicate with Precision Conversions Customer Support for assistance.

B. Skins at Deleted Door 1 R – L Hand and Door 4 R – L Hand Locations:

1) Refer to Section 53-00-01 for identification, allowable damage and repair instructions.

C. Stringers at Deleted Door 1 R – L Hand and Door 4 R – L Hand Locations:

1) Refer to Section 53-00-03 for identification, allowable damage and repair instructions.

D. Frames at Deleted Door 1 R – L Hand and Door 4 R – L Hand Locations: 1) Refer to Section 53-00-07 for identification, allowable damage and repair instructions.



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PASSENGER/CREW ENTRY DOOR SKIN Section 52-10-01

DETAIL I

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 OUTER SKIN 0.063 CLAD 2024-T3 All

Crew Entry Door Skin Identification Figure 1 (Sheet 1)


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PASSENGER/CREW ENTRY DOOR SKIN

R1 Door Skin Plug Identification Figure 2 (Sheet 1)

DOOR SKIN SEE DETAIL I IN SECTION 53-10-01


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PASSENGER/CREW ENTRY DOOR SKIN

L4/R4 Door Skin Plug Identification Figure 3 (Sheet 1)

DOOR SKIN SEE DETAIL I IN SECTION 53-60-01


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PASSENGER/CREW ENTRY DOOR STRUCTURE Section 52-10-02

Crew Entry Door Structure Identification Figure 1 (Sheet 1)


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PASSENGER/CREW ENTRY DOOR STRUCTURE

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 DOOR FRAME FITTING 7050-T7451 PLATE All2 FITTING, DOOR STOP, AFT 7050-T7451 PLATE All3 FITTING, DOOR STOP, FWD 7050-T7451 PLATE All4 FITTING, SWING 7050-T7451 PLATE All5 FITTING 7050-T7451 PLATE All

Crew Entry Door Structure Identification Figure 1 (Sheet 2)


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REPAIRS - PASSENGER/CREW ENTRY DOOR STRUCTURE Section 52-10-02

1. All information contained in the Boeing 757-200 SRM, Chapter 52-10-02, is applicable to aircraft

modified in accordance with Precision Conversions 757-200PCF freighter modification, except as follows: A. Repair 1-FORWARD FRAME OF THE NUMBER 2 LEFT AND RIGHT SIDE PASSENGER

DOORS does not apply to airplanes modified by the Precision Conversions STC.


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ALLOWABLE DAMAGE - PASSENGER/CREW ENTRY DOOR Section 52-10-03

1. Allowable damage defined in the Boeing 757-200 SRM D634N201, Section 52-10-01, Figure 101 is

applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations:

A. Crew Entry Door Skin:

1) 10% blend out is permitted on the crew entry door skin. Ensure that damage does not exist common to attach fasteners. See Section 51-10-02 Figure 101 for blending details.

B. Crew Entry Door Structure:

1) 10% blend out is permitted on the crew entry door structure. Ensure that damage does not exist common to attach fasteners. See Section 51-10-02 Figure 101 for blending details.

2) No damage is permitted on fittings or mechanism common to the crew entry door. . Note: It is recommended that any damage or repair exceeding the requirements of the Boeing 757-200 SRM D634N201 or this SRM supplement, on any affected structure within the pressurized fuselage, be communicated to Precision Conversions Customer Support for further review prior to next flight.


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REPAIRS - PASSENGER/CREW ENTRY DOOR Section 52-10-03

1. Repairs defined in the Boeing 757-200 SRM, D634N201, Section 52-10-01, Repair 1 is applicable to

aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following limitations:

A. Crew Entry Door Skin:

1) The crew entry door as shown in Detail 1 of this section is limited to Repair 1 of the Boeing 757-200 SRM, D634N201, Section 52-10-01. This repair is an interim Category B repair, with repeat inspections as detailed in Table 201, Page 202. See Detail 1 below for Stay Out Zone. Repairs in this Zone are not permitted.

2) Any other damage related to the crew entry door skin must be communicated to Precision Conversions Customer Support for assistance.

B. Crew Entry Door Structure:

1) No other repairs detailed in the Boeing 757-200 SRM, D634N201, Section 52-10 are effective for the crew entry door STC structure.

Detail 1 Repair – Crew Entry Door

Figure 201 (Sheet 1)


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ZONE A – CATEGORY B REPAIR INSPECTION REQUIREMENTS INSPECTION THRESHOLD METHOD INTERVAL REFERENCE

20,000 Flight cycles (Note 1)

External High Frequency Eddy Current (HFEC)

6,500 flight cycles

NDT Part 6 51-00-01

Or 51-00-19

Table 201

Note: 1. The Inspection threshold of this repair is limited to 20,000 total flight cycles from the time of

freighter modification.

2. If this repair deviates from SRM requirements, a Damage Tolerance Evaluation (DTE) is required within 12 months of its initial installation.



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MAIN CARGO DOOR SKIN Section 52-30-01

Main Cargo Door Skin Identification Figure 1 (Sheet 1)


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MAIN CARGO DOOR SKIN

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 SKIN 0.080 CLAD 2024-T3 All



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MAIN CARGO DOOR SKIN




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MAIN CARGO DOOR STRUCTURE Section 52-30-02

Main Cargo Door Structure Identification Figure 1 (Sheet 1)


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MAIN CARGO DOOR STRUCTURE

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY

1 FRAME 0.090 CLAD 2024-T42 All2 SUPPORT ASSEMBLY All

SUPPORT 7050-T7451 AMS4050 All3 FRAME, LOWER 7050-T7451 AMS4050 All4 FRAME, SIDE 0.090 CLAD 2024-T42 All5 BEAM, UPPER 0.090 CLAD 2024-T42 All6 BEAM, LOWER 0.090 CLAD 2024-T42 All7 SUPPORT, CORNER UPPER 0.090 6061-T6 All8 SUPPORT, CORNER LOWER 0.090 6061-T6 All9 FRAME, STUB 0.090 CLAD 2024-T42 All

10 INTERCOSTAL ASSEMBLY AllINTERCOSTAL 0.050 CLAD 2024-T42 All

11 INTERCOSTAL ASSEMBLY AllINTERCOSTAL 0.071 CLAD 2024-T42 All

12 DOUBLER, VENT DOOR 7050-T7451 PLATE All Main Cargo Door Structure Identification

Figure 1 (Sheet 2)


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ALLOWABLE DAMAGE - MAIN CARGO DOOR STRUCTURE Section 52-30-03

1. Allowable Damage 1 defined in the Boeing 757-200 SRM, D634N201, Section 52-30-01, Figure 101

is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except for the following limitations:

A. Main Cargo Door Inner and Outer Skins:

1) 10% blend out is permitted on the main cargo door inner and outer skins. See Section 51-10-02 Figure 101 for blending details.

B. Main Cargo Door Structure:

1) 10% blend out is permitted on the main cargo door general structure. See Section 51-10-02 Figure 101 for blending details, except for the following areas: a) All fittings and machined parts common to door assembly.

b) No blending is permitted on the upper beam (Item 5 in Detail 1) of the main cargo door.



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REPAIRS - MAIN CARGO DOOR STRUCTURE Section 52-30-03

1. Repairs defined in the Boeing 757-200 SRM D634N201, 52-30-01, Figure 201 are applicable to

aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following limitations:

A. Main Cargo Door Inner Skin:

1) The main cargo door inner skin as shown in Detail II of section 52-30 is limited to Repair 2 of the Boeing 757-200 SRM, D634N201, Section 52-30-01. This repair is a Category A repair Inspections listed in the Precision Conversions MPD supplement are sufficient to maintain the damage tolerance capability of the initial structure.

2) Any other damage related to the main cargo door inner skin must be communicated to Precision Conversions Customer Support for assistance.

B. Main Cargo Door Structure:

1) No repairs, other than noted above detailed in the Boeing 757-200 SRM, D634N201, Section 52-30 are effective on the main cargo door STC structure.



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Dec 2015 PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.

CHAPTER 53 FUSELAGE


FUSELAGE ................................................................................................................................. 53-00-00 FUSELAGE SKIN ................................................................................................................. 53-00-01 ALLOWABLE DAMAGE - Fuselage Skin REPAIRS - Fuselage Skin FUSELAGE STRINGERS .................................................................................................... 53-00-03 ALLOWABLE DAMAGE - Fuselage Stringers REPAIRS - Fuselage Stringers FUSELAGE INTERCOSTALS .............................................................................................. 53-00-04 ALLOWABLE DAMAGE - Fuselage Intercostals REPAIRS - Fuselage Intercostals FUSELAGE FRAMES .......................................................................................................... 53-00-07 ALLOWABLE DAMAGE - Fuselage Frames REPAIRS - Fuselage Frames

FUSELAGE BEAMS………………………………………………………………………………53-00-13 REPAIRS – Fuselage Beams

FUSELAGE FLOOR STRUCTURE ...................................................................................... 53-00-51 ALLOWABLE DAMAGE - Fuselage Floor Structure REPAIRS - Fuselage Floor Structure FUSELAGE SEAT TRACKS ................................................................................................ 53-00-52 ALLOWABLE DAMAGE - Fuselage Seat Tracks REPAIRS - Fuselage Seat Tracks FUSELAGE SKIN – SECTION 41 FUSELAGE SKIN – SECTION 41 ........................................................................................ 53-10-01 Figure 1 – Section 41 Skin Identification Figure 2 – R1 Door Skin Plug Identification Figure 3 – Rain Gutter Identification FUSELAGE STRINGER – SECTION 41 .............................................................................. 53-10-03 Figure 1 – Section 41 Stringer Identification Figure 2 – R1 Door Skin Plug Stringer Identification FUSELAGE FRAMES – SECTION 41 ................................................................................. 53-10-07 Figure 1 – Section 41 Frame Identification Figure 2 – R1 Door Plug Frame Identification BULKHEADS – SECTION 41 ............................................................................................... 53-10-08 Figure 1 – Section 41 Bulkhead Identification ALLOWABLE DAMAGE - Bulkhead Section 41 REPAIRS - Bulkhead Section 41 CREASE BEAM AND 9G SHEAR FLOOR – SECTION 41 ................................................. 53-10-13 Figure 1 – Section 41: Crease Beam and 9G Shear Floor ALLOWABLE DAMAGE - Crease Beam and 9g Shear Floor


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CHAPTER 53 FUSELAGE TABLE OF CONTENTS SUBJECT CHAPTER SECTION

CREASE BEAM AND 9G SHEAR FLOOR – SECTION 41 (cont’d) .................................... 53-10-13 REPAIRS - Crease Beam and 9g Shear Floor DOOR SURROUND STRUCTURE – SECTION 41 ................................................................... 53-10-15 Figure 1 – Section 41 Door Surround Structure Identification ALLOWABLE DAMAGE - Door Surround Structure SEAT TRACKS – SECTION 41 .................................................................................................. 53-10-52 Figure 1 – Section 41 Seat Track Identification FUSELAGE SKIN – SECTION 43 FUSELAGE SKIN – SECTION 43 ........................................................................................ 53-30-01 Figure 1 – Section 43 Skin Identification Figure 2 – Section 43 Rain Gutter Identification REPAIRS - Section 43 Fuselage Skin FUSELAGE STRINGERS – SECTION 43 ........................................................................... 53-30-03 Figure 1 – Section 43 Stringer Identification FUSELAGE INTERCOSTALS – SECTION 43 ..................................................................... 53-30-04 Figure 1 – Section 43 Intercostal Identification FUSELAGE FRAMES – SECTION 43 ................................................................................. 53-30-07 Figure 1 – Section 43 Frame Identification DOOR SURROUND STRUCTURE – SECTION 43 ............................................................. 53-30-15 Figure 1 – Section 43 Door Surround Structure Identification ALLOWABLE DAMAGE - Door Surround Structure SEAT TRACKS - SECTION 43 ............................................................................................ 53-30-52 Figure 1 – Section 43 Seat Track Identification FUSELAGE – SECTION 44 SEAT TRACKS – SECTION 44 ............................................................................................ 53-40-52 Figure 1 – Section 44 Seat Track Identification FUSELAGE SKIN – SECTION 46 FUSELAGE SKIN – SECTION 46 ........................................................................................ 53-60-01 Figure 1 – L4/R4 Door Skin Plug Identification FUSELAGE STRINGER – SECTION 46 .............................................................................. 53-60-03 Figure 1 – L4/R4 Door Skin Plug Stringer Identification FUSELAGE FRAMES – SECTION 46 ................................................................................. 53-60-07 Figure 1 – L4/R4 Door Skin Plug Frame Identification

FLOOR STRUCTURE – SECTION 46…………………………………………………………..53-60-51 REPAIRS – Floor Structure

SEAT TRACKS – SECTION 46 ............................................................................................ 53-60-52 Figure 1 – Section 46 Seat Track Identification


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CHAPTER 53 FUSELAGE

1. All information contained in the Boeing 757-200 SRM, D634N201, Chapter 53, is applicable to aircraft

modified in accordance with Precision Conversions 757-200PCF freighter modification, except as noted in this chapter.

A. No damage is permitted on OEM PSE Structure as detailed in Section 51-00-04 Figure 3 of this

SRM supplement. If damage is common to the noted OEM PSE structure, contact Precision Conversions Customer Support for assistance.


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ALLOWABLE DAMAGE - FUSELAGE SKIN Section 53-00-01

1. Allowable damage defined in the Boeing 757-200 SRM D634N201, 53-00-01, Figure 101 is

applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except for the following limitations:

A. STC Fuselage Outer Skin:

The following allowable damage criteria is based on blending that meets requirements detailed in Section 51-10-02 Figure 101 of this SRM supplement only. 1) ONLY up to 8% blend out is permitted on the 0.190 in. thick skin around the main cargo door

between BS610 and BS630 and between Stringers 3L and 4L.

2) Blend out is NOT permitted on the chem-milled 0.056 in. thick skin around the main cargo door. The 0.056 in. thick skin is located from BS450 to BS650 between Stringers 2R and 4R (upper lobe) and between Stringers 22L and 26L (lower lobe).

3) In all other areas, the allowable damage blend out is limited to 10% of the nominal thickness of the STC skin. See Section 51-10-02 Figure 101 for blending details. Note that this is categorized as Chart Area A in Figure 101 of the OEM Allowable Damage 2 in Section 53-00-01.

4) Contact Precision Conversions Customer Support for any damage exceeding the above requirements.

B. STC Fuselage Rain Gutter:

1) 10% blend out is permitted on the rain gutter. Ensure that damage does not exist common to

attach fasteners. See Section 51-10-02 Figure 101 for blending details.

C. OEM Structure: 1) No Damage is permitted common to lap joints S-4R and 26L

2) No damage is permitted common to butt joints, at skins and straps locations common to

BS440 and BS660 from Stringer 4R to 26L.


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REPAIRS - FUSELAGE SKIN Section 53-00-01

Fuselage skin repairs defined in the Boeing 757-200 SRM D634N201, 53-00-01 are applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following exceptions: 1. Fuselage Skin Repair and Inspections

A. STC Fuselage Outer Skin Main Cargo Door Surround (Section 43): 1) The main cargo door surround skins are limited to Repairs 1, 2, 3, 5, and 7, Zones A and B of

the Boeing 757-200 SRM, D634N201, Section 53-00-01. These repairs are determined to be Category B repairs with inspections as listed in Table 101 below. In addition to the requirements listed in the Boeing SRM, ensure to maintain a minimum distance of 10 in. between the edge of the repair and the edge of a lap or butt joint.

2) No repairs are applicable to the crown section of the main cargo door surround skin between BS 600 and BS 660 from Stringer 6R to 6L, identified as Zone C in the Boeing 757-200 SRM, D634N201, Section 53-00-01 Repair General, Figure 202. If damage exceeds allowable damage noted in Chapter 51-10-02 Figure 101, Page 101 of this SRM supplement, contact Precision Conversions Customer Support for further review.

B. STC Fuselage R1, R4 and L4 Door Plug Skins: 1) The door plug skins are limited to Repairs 2, 3, 4, 5, and 7, Zone A, detailed in the Boeing

757-200 SRM, D634N201, Section 53-00-01 These repairs are determined to be Category B repairs with inspections as listed in Table 101 below.

ZONE A - CATEGORY B REPAIR INSPECTION REQUIREMENTS

INSPECTION THRESHOLD METHOD INTERVAL REFERENCE

15,000 Flight Cycles Note 1

High Frequency Eddy Current (HFEC)

3,000 Flight Cycles

NDT Part 6 51-00-01

or 51-00-19

ZONE B – CATEGORY B REPAIR INSPECTION REQUIREMENTS

INSPECTION THRESHOLD METHOD INTERVAL REFERENCE

15,000 Flight cycles Note 1

High Frequency Eddy Current (HFEC)

2,500 Flight Cycles

NDT Part 6 51-00-01

or 51-00-19

Table 101 Note: 1. If this repair deviates from the SRM requirements, a Damage Tolerance Evaluation (DTE) is

required within 12 months of its initial installation.



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ALLOWABLE DAMAGE - FUSELAGE STRINGERS Section 53-00-03


applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations detailed in this section:

A. Fuselage Stringers

1) Damage is NOT permitted on the STC stringers from BS 640 to 660 from Stringer 3R to 3L.

and stringers related to the R1, L4 and R4 door plugs. 2) All other STC stringers are limited to a maximum of 10% blend out from the nominal

thickness. See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage details.

Allowable Damage – Fuselage Stringers Figure 101 (Sheet 1)

L4 and R4 Door Plug Stringers. SRM 53-60-03

Main Cargo Door Surround Structure

Stringers. SRM 53-30-03

Crew entry Door Surround Structure Stringers. SRM 53-10-03

R1 Door Plug Stringers.

SRM 53-10-03


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REPAIRS - FUSELAGE STRINGERS Section 53-00-03

1. Fuselage stringer repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-03 are applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following exceptions:

A. STC Fuselage Stringers common to Main Cargo Door Surround Structure:

1) The stringers common to the main cargo door surround structure are limited to Repair 1 for

Item 1, type 1 stringers, as detailed in the Boeing 757-200 SRM, D634N201, Section 53-00-03. This repair is determined to be a Category B repair with inspections as listed in Table 1.

2) The stringers common to the main cargo door surround structure are limited to repairs as

previously detailed to only 1 repair in the upper lobe and 1 repair in the lower lobe. Contact Precision Conversions Customer Support for any damage exceeding the above requirements.

B. STC Fuselage Crew Entry Door Surround Structure, R1, L1, R4 and L4 Door Plug Stringers:

1) The door plug stringers and related structure at Doors R1, L1, R4, L4 and the CED surround

structure have no applicable repairs detailed in the Boeing 757-200 SRM. Contact Precision Conversions Customer Support for any damage exceeding the allowable damage requirements detailed in Figure 101.


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Table 1

Notes:

1) HFEC to be performed around fasteners and along flanges of the stringer common to the stringer splice.

2) LFEC to be performed around fasteners on the stringer where concealed by splice and skin (hatched area).

3) Inspections are not interchangeable and both inspections must be performed.

4) If this repair is installed on non-applicable structure, a Damage Tolerance Evaluation (DTE) is required within 12 months of its initial installation.

Repair – Fuselage Stringers Figure 201 (Sheet 1)

STRINGER REPAIR INSPECTION REQUIREMENTS

ITEM INSPECTION THRESHOLD METHOD INTERVAL REFERENCE

1 10,000 Flight cycles Internal High Frequency Eddy Current (HFEC) on stringer

4,500 flight cycles

NDT Part 6 51-00-01

or 51-00-19

2 9,500 Flight cycles Internal or External

Low Frequency Eddy Current (LFEC) on stringer.

2,400 flight cycles

NDT Part 6 51-00-07 51-00-08



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ALLOWABLE DAMAGE - FUSELAGE INTERCOSTALS Section 53-00-04

1. Allowable Damage 1 defined in the Boeing 757-200 SRM, D634N201, Section 53-00-04, Figure 101 is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations detailed in this section:

A. Fuselage STC Intercostals:

1) STC Intercostals are limited to a maximum of 10% blend out from the nominal thickness

except for the following locations: See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage details. a) No damage is allowed between BS570 and BS610 of the upper sill intercostals noted in

Section 53-30-04.

b) BL0 intercostals are addressed in Section 53-00-51.


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REPAIRS - FUSELAGE INTERCOSTALS Section 53-00-04

1. Fuselage intercostal repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-04 are

applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following exceptions:

A. All STC Fuselage Intercostals:

1) There is no applicable repair to STC intercostals.



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ALLOWABLE DAMAGE - FUSELAGE FRAMES Section 53-00-07


applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations:

A. STC Structure:

1) STC Frames are limited to a maximum of 10% blend out from the nominal thickness, except for the following listed below. See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage details. a) Door sills and jams are not considered frames and should not be repaired under this

section.

b) No damage is permitted on frames from BS480 to BS580, between stringer 20L to 22L.

c) All STC frame splices that attach to OEM frames have no applicable repairs. Contact Precision Conversions Customer Support for assistance.

d) No damage is permitted on frames at BS345, between stringer 7L to 8L.

B. OEM Structure:

1) No damage is permitted on frames common to floor beam attachments.

2) All OEM frame splices that are attached to STC frames have no applicable repairs. Contact Precision Conversions Customer Support for assistance.

3) No damage is permitted on the No.1 Fwd and Aft Cargo Door frames as noted in the PSE list affected by the PCF STC.

C. Allowable damage defined in the Boeing 757-200 SRM D634N201, 53-00-07, Figure 102 is NOT applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification.


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ALLOWABLE DAMAGE - FUSELAGE FRAMES

Allowable Damage – Fuselage Frames Figure 101 (Sheet 1)

L4 and R4 Door Plug Frames. SRM 53-60-07

Main Cargo Door Surround Structure

Frames. SRM 53-30-07

Crew entry Door Surround Structure Frames. SRM 53-10-07

R1 Door Plug Frame. SRM 53-10-07


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REPAIRS - FUSELAGE FRAMES Section 53-00-07

1. Fuselage Frame repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-07 are


A. STC Frames:

1) All frame sections and related structure common to the cargo conversion STC have no

applicable repairs. Contact Precision Conversions Customer Support for assistance.

2) All STC frame splices that attach to OEM frames have no applicable repairs. Contact Precision Conversions Customer Support for assistance.

B. OEM Frames:

1) No repair is permitted on OEM frames from BS480 to BS580, between stringer 20L to 22L.

2) No repair is permitted on OEM frames at BS345, between stringer 7L to 8L.

3) No repair is permitted on OEM frames common to floor beam attachments.

4) All OEM frame splices that are attached to STC frames have no applicable repairs. Contact Precision Conversions Customer Support for assistance.

5) No repair is permitted on the No.1 Fwd and Aft Cargo Door frames as noted in the PSE list

affected by the PCF STC.



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53-00-13 200PCF Page 101


REPAIRS – FUSELAGE BEAMS Section 53-00-13

1. Fuselage beams repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-13 are


A. Fuselage beams between STA 297 and STA 460:

1) No repairs in the Boeing 757-200 SRM are applicable to the cargo conversion STC crease

beam structure between STA 297 and STA 460. It is recommended to contact Precision Conversion Customer Support for any damage found in this area.


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53-00-51 200PCF Page 101


ALLOWABLE DAMAGE - FUSELAGE FLOOR STRUCTURE Section 53-00-51

1. Allowable Damage 1 defined in the Boeing 757-200, SRM D634N201, Section 53-00-51, Figure 101 is

applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification, except as follows:

A. OEM Floor Beams:

1) Section 41 – Floor Beams: Blend out is NOT permitted on the floor beam web where

cutouts exist in the web at the following locations: BS 395 outboard of LBL 45.5 and RBL 45.5 BS 418 outboard of LBL 45.5 and RBL 45.5 BS 440 outboard of RBL 45.5


cutouts exist in the web at the following locations: BS 460 outboard of RBL 45.5 BS 700 outboard of RBL 45.5 BS 720 outboard of LBL 45.5 BS 740 outboard of LBL 45.5 and RBL 45.5 BS 760 outboard of LBL 45.5 and RBL 45.5 BS 780 outboard of LBL 45.5 and RBL 45.5 BS 800 outboard of LBL 45.5 and RBL 45.5 BS 839 outboard of LBL 45.5 and RBL 45.5 BS 860 outboard of LBL 45.5 and RBL 45.5


cutouts exist in the web at the following locations: BS 1240 outboard of RBL 45.5 BS 1260 outboard of LBL 45.5 and RBL 45.5 BS 1320 between BL 0 and RBL 24.75 BS 1360 between BL 0 and RBL 24.75 BS 1360 outboard of LBL 45.5 BS 1380 between BL 0 and RBL 24.75 BS 1400 outboard of LBL 45.5 and RBL 45.5 BS 1420 outboard of LBL 45.5 BS 1440 outboard of LBL 45.5 and RBL 45.5 BS 1460 outboard of LBL 45.5 and RBL 45.5 BS 1500 outboard of RBL 45.5 BS 1520 outboard of LBL 45.5 and RBL 45.5 BS 1540 outboard of LBL 45.5 BS 1580 outboard of RBL 45.5 BS 1600 outboard of LBL 45.5 and RBL 45.5 BS 1620 outboard of LBL 45.5 BS 1640 outboard of LBL 45.5 BS 1661 outboard of LBL 45.5


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4) Section 41 through 46 – Blend out is NOT permitted on the floor beam webs

Floor Beams Webs: common to the frame attachment locations at the outboard extremities of the floor beams.

B. STC Intercostals at BL0:

1) No damage is permitted to the BL0 intercostals from BS345 to BS1682. If damage is found in this area, contact Precision Conversions Customer Support for further review.

Allowable Damage – Floor Structure

Figure 101 (Sheet 1)

Sec 46

Sec 41

Sec 43

Sec 44

OEM Floor Beams

STC Intercostals at BL0 (007F9208) (007F9210)


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53-00-51 200PCF Page 201


REPAIRS - FUSELAGE FLOOR STRUCTURE Section 53-00-51

1. Repairs defined in the Boeing 757-200 SRM D634N201, 53-00-51, Figure 201 are applicable to aircraft

modified in accordance with Precision Conversions 757-200PCF freighter modification, except as follows.

A. OEM Floor Beam

1) Section 41 – Floor Beams: Repairs are NOT permitted to end at the following locations:

BS 395 outboard of LBL 45.5 and RBL 45.5 BS 418 outboard of LBL 45.5 and RBL 45.5 BS 440 outboard of RBL 45.5


BS 460 outboard of RBL 45.5 BS 700 outboard of RBL 45.5 BS 720 outboard of LBL 45.5 BS 740 outboard of LBL 45.5 and RBL 45.5 BS 760 outboard of LBL 45.5 and RBL 45.5 BS 780 outboard of LBL 45.5 and RBL 45.5 BS 800 outboard of LBL 45.5 and RBL 45.5 BS 839 outboard of LBL 45.5 and RBL 45.5 BS 860 outboard of LBL 45.5 and RBL 45.5


BS 1240 outboard of RBL 45.5 BS 1260 outboard of LBL 45.5 and RBL 45.5 BS 1320 between BL 0 and RBL 24.75 BS 1360 between BL 0 and RBL 24.75 BS 1360 outboard of LBL 45.5 BS 1380 between BL 0 and RBL 24.75 BS 1400 outboard of LBL 45.5 and RBL 45.5 BS 1420 outboard of LBL 45.5 BS 1440 outboard of LBL 45.5 and RBL 45.5 BS 1460 outboard of LBL 45.5 and RBL 45.5 BS 1500 outboard of RBL 45.5 BS 1520 outboard of LBL 45.5 and RBL 45.5 BS 1540 outboard of LBL 45.5 BS 1580 outboard of RBL 45.5 BS 1600 outboard of LBL 45.5 and RBL 45.5 BS 1620 outboard of LBL 45.5 BS 1640 outboard of LBL 45.5 BS 1661 outboard of LBL 45.5

B. BL0 Intercostals

1. No repairs are applicable to the BL0 intercostals detailed in Figure 101 Sheet 1 of this section. If damage is found in this area, Contact Precision Conversions Customer Support for further review.


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53-00-52 200PCF Page 101


ALLOWABLE DAMAGE - FUSELAGE SEAT TRACKS Section 53-00-52

1. Allowable Damage 1 defined in the Boeing 757-200 SRM, D634N201, Section 53-00-52, Figure 101 is

applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification, except as follows: A. Seat Tracks

1) All blending related to seat tracks in the cargo compartment is limited to Detail I, Detail VII, Detail IX

and Detail X, Where the “x” dimension shown in these details cannot exceed 10% blend out from nominal thickness.

2) No blending is permitted in the flange where the seat track is attached to structure, such as the floor beam or other sub-structure.

3) No blending is permitted within 1.0 in. from the edge of any cargo system attachment.


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53-00-52 200PCF Page 201


REPAIRS - FUSELAGE SEAT TRACKS Section 53-00-52

1. Repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-52, Figure 201 are applicable to

aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification, except as follows:

A. STC Seat Tracks

1) Repairs are NOT permitted at BL 0 and BL 62.225 locations.



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53-10-01 200PCF Page 1


FUSELAGE SKIN - SECTION 41 Section 53-10-01

Section 41 Skin Identification Figure 1 (Sheet 1)


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53-10-01 200PCF Page 2


FUSELAGE SKIN – SECTION 41


1 SKIN 0.080 2024-T3 (CHEM-MILLED TO .080" MIN) All2 SCUFF PLATE 0.050 CRES 17-7PH CONDITION TH1050 All



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53-10-01 200PCF Page 3



R1 Door Skin Plug Identification

Figure 2 (Sheet 1)


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53-10-01 200PCF Page 4




R1 Door Skin Plug Identification Figure 2 (Sheet 2)

DOOR PLUG STRUCTURE SEE SECTIONS 53-10-03 AND 53-10-07


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53-10-01 200PCF Page 5



Rain Gutter Identification Figure 3 (Sheet 1)


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53-10-01 200PCF Page 6



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 GUTTER, RAIN 0.032 TIERNAY 60-31545 CLAD 2024-T3 All

Rain Gutter Identification

Figure 3 (Sheet 2)


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53-10-03 200PCF Page 1


FUSELAGE STRINGER – SECTION 41 Section 53-10-03

Section 41 Stringer Identification Figure 1 (Sheet 1)


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53-10-03 200PCF Page 2


FUSELAGE STRINGER – SECTION 41

ITEM DESCRIPTION GAGE MATERIAL STRINGER TYPE REF DWG1 STRINGER 0.070 7050-T7451 PLATE 007F8068



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53-10-03 200PCF Page 3



ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY 1 007F8153 FITTING 7050-T7451 PLATE 001 - 014, 016 2 007F8152 STRINGER 7050-T7451 PLATE 001 - 014, 016 3 007F8154 CLIP 0.063 2024-T42 001 - 014, 016

R1 Door Skin Plug Stringer Identification

Figure 2 (Sheet 1)

(Door 1 Right Plug)


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53-10-03 200PCF Page 4



Detail II

ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY 1 007F8087 FITTING 7075-T6511 015, 017 And on 2 007F8086 STRINGER 0.063 2024-T42 015, 017 And on 3 007F8089 CLIP 0.063 2024-T42 015, 017 And on

R1 Door Skin Plug Stringer Identification Figure 2 (Sheet 2)

2 Typ.

3 Typ.

1 Typ

STA 345 FWD

(Door 1 Right Plug)


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53-10-07 200PCF Page 1


FUSELAGE FRAMES – SECTION 41 Section 53-10-07

Section 41 Frame Identification Figure 1 (Sheet 1)


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53-10-07 200PCF Page 2


FUSELAGE FRAMES – SECTION 41

ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY 1 007F8067 FRAME 7050-T7451 PLATE 001 – 014, 016 007F6066 FRAME 2024-T42 Al Clad 015, 017 And On

2 007F8066 FRAME 7050-T7451 PLATE 001 – 014, 016 007F6066 FRAME 2024-T42 Al Clad 015, 017 And On

3 007F8067 FRAME, SPLICE 7050-T7451 PLATE 001 – 014, 016 4 007F8066 FRAME, SPLICE 7050-T7451 PLATE 001 – 014, 016

Section 41 Frame Identification

Figure 1 (Sheet 2)

(Crew Entry)


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53-10-07 200PCF Page 3



ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY 1 007F8151 FRAME 7050-T7451 PLATE 001 – 014, 016 2 007F8156 CLIP 0.063 2024-T42 All 3 007F8151 FRAME, SPLICE 7050-T7451 PLATE All

R1 Door Plug Frame Identification

Figure 2 (Sheet 1)

(Door 1 Right Plug)

S17R


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53-10-07 200PCF Page 4



`

ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY 1 007F6066 FRAME 2024-T42 015, 017 And On 2 007F8156 CLIP 0.063 2024-T42 All 3 007F8151 FRAME, SPLICE 7050-T7451 PLATE All

R1 Door Plug Frame Identification

Figure 2 (Sheet 2)

1

3

2

FWD

(Door 1 Right Plug)

S17R

STA 345


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53-10-08 200PCF Page 1


BULKHEADS – SECTION 41 Section 53-10-08

Section 41 Bulkhead Identification Figure 1 (Sheet 1)


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53-10-08 200PCF Page 2


BULKHEADS – SECTION 41

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 PLATE, FWD, 9g BARRIER 0.071 7075-T6 All2 PLATE, AFT, 9g BARRIER 7075-T6 PLATE All

Section 41 Bulkhead Identification

Figure 1 (Sheet 2)

(9G Barrier)


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53-10-08 200PCF Page 101


ALLOWABLE DAMAGE - BULKHEADS SECTION 41 Section 53-10-08

1. Allowable damage defined in the Boeing 757-200 SRM D634N201, Section 53-10-08, Figure 101 is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following limitations:

A. Cargo Barrier:

1) Blend out is limited to 10% of nominal thickness of fwd and aft plates. See blending detail in

Section 51-10-02 Figure 101. Note that blend out is NOT permitted on the fwd faceplate and aft faceplate at the same waterline and butt line. Blend out is ONLY permitted on the fwd or aft faceplate at a given cross-section.

2) There is no allowable blending on any other STC structure related to the cargo barrier. Any damage found in this area must be communicated to Precision Conversions Customer Support for assistance.


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53-10-08 200PCF Page 201


REPAIRS - BULKHEADS SECTION 41 Section 53-10-08

1. Repairs defined in the Boeing 757-200 SRM, D634N201, 53-10-08, Figures 101, 201 and 202 are applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations:

A. Cargo Barrier:

1) No repairs in the Boeing 757-200 SRM are applicable to the cargo conversion STC cargo

barrier related structure. It is recommended to contact Precision Conversions Customer Support for any damage exceeding the allowable damage requirements detailed in Figure 101, Page 101.



PC-0118-11

53-10-13 200PCF Page 1


CREASE BEAM AND 9G SHEAR FLOOR – SECTION 41 Section 53-10-13

Section 41: Crease Beam and 9G Shear Floor Figure 1 (Sheet 1)

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 CREASE BEAM 7075-T6 PLATE All2 9G SHEAR FLOOR 7075-T6 PLATE All

Sta 297

Sta 460

007F9521 (1)

(2) 007F9401


PC-0118-11

53-10-13 200PCF Page 101


ALLOWABLE DAMAGE – CREASE BEAMS AND 9G SHEAR FLOOR Section 53-10-13

1. Allowable damage defined in the Boeing 757-200 SRM D634N201, Section 53-00-51, Figure 101 is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following limitations:

A. Crease Beam:

1) There is no allowable blending on any STC structure related to the crease beams. Any

damage found in this area must be communicated to Precision Conversions Customer Support for assistance.

B. 9G Shear Floor:

1) There is no allowable blending on any STC structure related to the 9G shear floor. Any

damage found in this area must be communicated to Precision Conversions Customer Support for assistance.


PC-0118-11

53-10-13 200PCF Page 201


REPAIRS - CREASE BEAMS AND 9G SHEAR FLOOR Section 53-10-13

1. Repairs defined in the Boeing 757-200 SRM, D634N201, 53-00-51, are applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations:

A. 9G Structure:

1) No repairs in the Boeing 757-200 SRM are applicable to the cargo conversion STC 9G

related structure. It is recommended to contact Precision Conversions Customer Support for assistance.



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53-10-15 200PCF Page 1


DOOR SURROUND STRUCTURE – SECTION 41 Section 53-10-15

Section 41 – Door Surround Structure Identification Figure 1 (Sheet 1)


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53-10-15 200PCF Page 2


DOOR SURROUND STRUCTURE – SECTION 41

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 SILL, UPPER 7050-T7451 All2 SILL, LOWER 7050-T7451 All3 FRAME, FWD JAMB 7050-T7451 All4 FRAME, AFT JAMB 7050-T7451 All5 INTERCOSTAL 0.063 2024-T42 All6 INTERCOSTAL 0.090 2024-T42 All7 INTERCOSTAL, FWD JAMB 7050-T7451 All8 INTERCOSTAL, AFT JAMB 7050-T7451 All

Section 41 – Door Surround Structure Identification Figure 1 (Sheet 2)


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53-10-15 200PCF Page 101


ALLOWABLE DAMAGE – DOOR SURROUND STRUCTURE Section 53-10-15

1. Allowable damage defined in the Boeing 757-200 SRM, D634N201, Sections 53-10-15, Figure 101 is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with the following limitations:

A. Crew Entry Door Surround Structure:

1) A maximum of 10% blend out is acceptable on the fwd and aft jambs per Section 51-10-02

Figure 101 of this SRM.

2) A maximum of 10% blend out is acceptable on the upper and lower sills per Section 51-10-02 Figure 101 of this SRM.

3) There is no allowable blending on any STC fittings or machined parts related to the crew entry door surround structure. Any damage found in these areas must be communicated to Precision Conversions Customer Support for assistance.



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53-10-52 200PCF Page 1


SEAT TRACKS – SECTION 41 Section 53-10-52

Section 41 Seat Track Identification Figure 1 (Sheet 1)


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53-10-52 200PCF Page 2


SEAT TRACKS – SECTION 41

ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 SEAT TRACK BAC 1520-2934 7075-T6511 All2 SEAT TRACK TIERNAY 60-6549 7075-T6511 All3 SEAT TRACK TIERNAY 60-31137 7075-T6511 All



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53-30-01 200PCF Page 1


FUSELAGE SKIN – SECTION 43 Section 53-30-01



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53-30-01 200PCF Page 2



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 SKIN 0.190 CLAD 2024-T3 (CHEM-MILLED TO .056" MIN) All2 SKIN 0.190 CLAD 2024-T3 (CHEM-MILLED TO .080" MIN) All3 SKIN 0.190 CLAD 2024-T3 (CHEM-MILLED TO .080" MIN) All4 SKIN 0.190 CLAD 2024-T3 (CHEM-MILLED TO .056" MIN) All



PC-0118-11

53-30-01 200PCF Page 3



Section 43 – Rain Gutter Identification Figure 2 (Sheet 1)


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53-30-01 200PCF Page 4



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 GUTTER, RAIN 0.032 BAC1496-356 CLAD 2024-T3 All

Section 43 – Rain Gutter Identification

Figure 2 (Sheet 2)


PC-0118-11

53-30-01 200PCF Page 201


REPAIRS - SECTION 43 FUSELAGE SKIN Section 53-30-01

1. Repairs defined in the Boeing 757-200 SRM, D634N201, 53-30-01, are applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations:

A. Repair 2 - PARTIAL SKIN PANEL REPLACEMENT BETWEEN BS 540 TO 640 AND

STRINGERS 14L TO 19L does not apply to airplanes modified by the Precision Conversions STC.


PC-0118-11

53-30-03 200PCF Page 1


FUSELAGE STRINGERS – SECTION 43 Section 53-30-03



PC-0118-11

53-30-03 200PCF Page 2


FUSELAGE STRINGERS – SECTION 43

ITEM DESCRIPTION GAGE MATERIAL STRINGER TYPE REF DWG1 STRINGER 0.063 CLAD 7075-T6 007F25032 STRINGER 7050-T7451 PLATE 007F2403

Section 43 Stringer Identification

Figure 1 (Sheet 2)


PC-0118-11

53-30-04 200PCF Page 1


FUSELAGE INTERCOSTALS – SECTION 43 Section 53-30-04

Section 43 Intercostal Identification Figure 1 (Sheet 1)


PC-0118-11

53-30-07 200PCF Page 1





PC-0118-11

53-30-07 200PCF Page 2



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 FRAME 0.100 CLAD 2024-T42 All2 FAILSAFE 0.080 CLAD 2024-T42 All



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53-30-07 200PCF Page 3



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 FRAME 0.090 CLAD 2024-T42 All2 FAILSAFE 0.090 CLAD 2024-T42 All

Section 43 Frame Identification

Figure 1 (Sheet 3)


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53-30-15 200PCF Page 1


DOOR SURROUND STRUCTURE – SECTION 43 Section 53-30-15

Section 43 Door Surround Structure Identification Figure 1 (Sheet 1)


PC-0118-11

53-30-15 200PCF Page 2



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 FRAME, JAMB - FORE/AFT JAMB 7050-T7451 PLATE All2 FRAME, OUTER JAMB - FORE/AFT JAMB 7050-T7451 PLATE All3 INTERCOSTAL 0.080 CLAD 2024-T42 All4 SPACER, DOOR GUIDE - FORE/AFT JAMB 2024-T351 PLATE All



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53-30-15 200PCF Page 3



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 BEAM - UPPER SILL 7050-T7451 PLATE All2 FITTING, SPLICE, STRINGER-UPPER 7050-T7451 PLATE All3 SKIN, INNER - UPPER SILL 0.080 CLAD 2024-T3 All4 SUPPORT ASSEMBLY - UPPER SILL 7050-T7451 PLATE All



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53-30-15 200PCF Page 4




1 BEAM - LOWER SILL 0.125 CLAD 2024-T42 All2 ANGLE, COVER - LOWER SILL 0.063 CLAD 2024-T3 All3 LATCH - FITTING CRES 17-4 PH BAR All4 SPOOL, LATCH - LOWER SILL PH 13-8Mo CONDITION H 950 BAR All5 FITTING 7050-T7451 PLATE All

Section 43 Door Surround Structure Identification

Figure 1 (Sheet 4)


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53-30-15 200PCF Page 101


ALLOWABLE DAMAGE - DOOR SURROUND STRUCTURE Section 53-30-15

1. Allowable damage defined in the Boeing 757-200 SRM, D634N201, Section 53-30-15, Figure 101 is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification except the following limitations:

A. Upper Sill Intercostals:

1) See Section 53-00-04, Figure 101 for allowable damage.

B. Upper Sill Inner Skin: 1) The inner skin of the sill is limited to a maximum of 10% blend out from the nominal

thickness. See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage details.

C. Upper Sill Support Assembly Fittings:

1) Damage is NOT permitted.

D. Upper Sill Stringer 4 Splice: 1) Damage is NOT permitted.

E. Fuselage Lower Sill:

1) No damage is permitted on the STC lower sill between BS620 and BS640. All other areas of the sill is limited to a maximum of 10% blend out from the nominal thickness. See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage details

F. Fuselage Upper Sill:

1) No damage is permitted on the STC Upper Sill between BS620 and BS630. All other areas of the sill are limited to a maximum of 10% blend out from the nominal thickness. See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage details.

G. Longitudinal Splices:

1) Damage is NOT permitted between BS440 and BS660.

H. Circumferential Splices: 1) Blend out is NOT permitted at BS440 and BS660 between Stringer 4R and 26L.

I. Latch Fitting: 1) Girt fittings 007F2312 are limited to 10% blend out from the nominal thickness. See Section

51-10-02, Figure 101 of this SRM supplement for allowable damage details.

J. Fittings: 1) No damage is permitted on all other fittings not listed above.



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53-30-52 200PCF Page 2



ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY1 SEAT TRACK BAC 1520-2934 7075-T6511 All2 SEAT TRACK TIERNAY 60-6549 7075-T6511 All3 SEAT TRACK TIERNAY 60-31137 7075-T6511 All4 SEAT TRACK TIERNAY 60-5034 7075-T6511 All5 SEAT TRACK TIERNAY 60-13859 7178-T6511 All6 SEAT TRACK TIERNAY 60-29394 7178-T6511 All

Section 43 Seat Track Identification

Figure 1 (Sheet 2)


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53-40-52 200PCF Page 1





PC-0118-11

53-40-52 200PCF Page 2




Section 44 Seat Track Identification

Figure 1 (Sheet 2)


PC-0118-11

53-60-01 200PCF Page 1


FUSELAGE SKIN – SECTION 46 Section 53-60-01



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53-60-01 200PCF Page 2



DESCRIPTION GAGE MATERIAL EFFECTIVITYSKIN 0.063 CLAD 2024-T3 All


DOOR PLUG STRUCTURE SEE SECTIONS 53-60-03 AND 53-00-07


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53-60-03 200PCF Page 1


FUSELAGE STRINGER – SECTION 46 Section 53-60-03

ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY 1 007F8086 STRINGER 0.063 CLAD 2024-T42 All 2 007F8087 CLIP TIERNAY 60-15738 7075-T651 All 3 007F8089 CLIP 0.063 7050-T7451 PLATE All

L4/R4 Door Skin Plug Stringer Identification Figure 1 (Sheet 1)


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53-60-07 200PCF Page 1



ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY 1 007F8085 FRAME 7050-T7451 PLATE 001 – 015 007F6085 FRAME 2024-T42 016 And On

2 007F8099 SPLICE 7050-T7451 PLATE All 3 007F8100 PLATE, SPLICE 7075-T6 PLATE All 4 007F8094 FITTING 7050-T7451 PLATE All 5 007F8096 CLIP 0.063 CLAD 2024-T42 All 6 007F8095 STRAP 0.1 CLAD 2024-T3 All 7 007F8089 CLIP 0.063 CLAD 2024-T3 All 8 007F8093 FITTING 7050-T7451 PLATE All

L4/R4 Door Skin Plug Frame Identification Figure 1 (Sheet 1)


PC-0118-11

53-60-51 200PCF Page 1


REPAIRS – FLOOR STRUCTURE Section 53-60-51

1. Floor structure repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-60-51 are


A. Repairs 14 through 18:

1) Repairs 14, 15, 16, 17, and 18 in the Boeing 757-200 SRM Section 53-60-51 are not

applicable to the cargo conversion STC. It is recommended to contact Precision Conversion Customer Support for any damage found in this area.


PC-0118-11

53-60-52 200PCF Page 1





PC-0118-11

53-60-52 200PCF Page 2






PC-0118-11



CHAPTER 54

NACELLES AND PYLONS


NACELLES/PYLONS .................................................................................................................. 54-00-00


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54-00-00 200PCF Page 1


CHAPTER 54 NACELLES/PYLONS

1. All information contained in the Boeing 757-200 SRM, D634N201, Chapter 54, is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification.


PC-0118-11



CHAPTER 55

STABILIZERS


STABILIZERS ............................................................................................................................. 55-00-00


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55-00-00 200PCF Page 1


CHAPTER 55 STABILIZERS

1. All information contained in the Boeing 757-200 SRM, Chapter 55, is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification.


PC-0118-11



CHAPTER 56

WINDOWS


WINDOWS .................................................................................................................................. 56-00-00


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56-00-00 200PCF Page 1


CHAPTER 56 WINDOWS



PC-0118-11



CHAPTER 57

WINGS


WINGS ........................................................................................................................................ 57-00-00


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57-00-00 200PCF Page 1


CHAPTER 57 WINGS


structural repair manual supplement for b757-200 …1. brought current with boeing 757-200...

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