757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-1**757 MAINTENANCE PLANNING DATA (MPD) DOCUMENT** **SECTION 9 AIRWORTHINESS LIMITATIONS (AWLs) AND** **CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs) D622N001-9** **NOVEMBER 2010**COMPILED AND PUBLISHED BY:MAINTENANCE PROGRAMS ENGINEERINGCOMMERCIAL AVIATION SERVICESBOEING COMMERCIAL AIRPLANE GROUPSEATTLE, WASHINGTONNOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-2757 MAINTENANCE PLANNING DATATHIS PAGE INTENTIONALLY LEFT BLANKBLANK757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-3TABLE OF CONTENTSREVISIONS .................................................................................................................................................................................................................................. 9.0-5LIST OF EFFECTIVE PAGES .................................................................................................................................................................................................... 9.0-15A. SCOPE................................................................................................................................................................................................................................... 9.0-17B. AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONS ..................................................................................................................................... 9.0-19C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS .............................................................................................................................. 9.0-42D. AIRWORTHINESS LIMITATIONS – SYSTEMS..................................................................................................................................................................... 9.0-43E. AIRWORTHINESS LIMITATIONS – FUEL SYSTEMS........................................................................................................................................................... 9.0-44F. PAGE FORMAT: FUEL SYSTEMS AIRWORTHINESS LIMITATIONS ................................................................................................................................... 9.0-47G. AIRWORTHINESS LIMITATIONS – FUEL SYSTEM AWLS .................................................................................................................................................. 9.0-48H. AIRWORTHINESS LIMITATIONS – NITROGEN GENERATION SYSTEM (NGS) ALIS AND CDCCLS .............................................................................. 9.0-67I. CERTIFICATION MAINTENANCE REQUIREMENTS (CMRS)............................................................................................................................................... 9.0-70J. PAGE FORMAT: CERTIFICATION MAINTENANCE REQUIREMENTS (CMRS) .................................................................................................................. 9.0-71K. CERTIFICATION MAINTENANCE REQUIREMENTS TASKS............................................................................................................................................... 9.0-73L. JAA UNIQUE REQUIREMENTS ............................................................................................................................................................................................ 9.0-77NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-4757 MAINTENANCE PLANNING DATATHIS PAGE INTENTIONALLY LEFT BLANKBLANK757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-5**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALJUNE 1990Although this information was previously issued as Revision "B" to Section 9 of theMPD, this issue is considered the original release because it is now assigneda new document number (D622N001-9).Prepared by:N. Ramdin (Boeing) 6/6/90Supervised by:S. J. Bradbury(Boeing) 6/6/90Approved by:S. R. Miller for D. L.Riggin (FAA) 6/15/90DECEMBER 1995Deleted CMR 28-41-00-5A since Airworthiness Directive 83-15-05 requiredinstallation of a new FQIS.Prepared by:R. Moore (Boeing) 11/28/95Supervised by:S. R. Williford (Boeing)2/19/93Approved by:D. L. Riggin (FAA)2/19/93MAY 1997Revised the Airworthiness Limitations section to reflect the reassessment of the"50-series" Supplemental Structural Inspection Program.Submitted by:S. R. Williford (Boeing) 5/21/97Approved by:D. L. Riggin (FAA) 7/22/97NOVEMBER 1998Added Rough Runway Operation requirements. Revised Airworthiness Limitationssection to show changed airplane applicability and to add 757-300 requirements.Added Engine Mount safe life limits. Deleted CMR Task Category column fromSubsection E and F. Interval for CMR 26-10-00-6A changed from DAILY to 0048HRS. Added CMRs R78-34-00-5A, R78-34-00-5B, R78-34-00-5C, R78-34-00-5Dand R78-34-00-5E applicable only to the 757-300 thrust reverser system. AddedCMR 26-23-01-6B for the fire protection system.Revised Airworthiness Limitations section to add JAA unique 757-300requirements (Section G).Submitted by:N. E. Hennigs (Boeing) 1/20/99Approved by:D. L. Riggin (FAA) 1/21/99NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-6757 MAINTENANCE PLANNING DATAMARCH 2002Revised ATA 57 Wing Airworthiness Limitations to add 3 AWLs for the Front Spar.Prepared by:G. R. Palafox (Boeing) 3/20/02Approved by:A Pasion (FAA)MAY 2002Revised JAA unique 757-300 requirements (Section G) to add words Rolls RoyceEngine to 757-300 Mounts.Deleted "Note: The DTR Check Forms for the listed 757-300 AirworthinessLimitations will be included in the MAY 99 revision of the 757 MPD Appendix B" asthis information is now included at every revision.Revised statement in preamble to Airworthiness Limitations that specifies rollbackof any escalated baseline structural inspection intervals when reaching theAWL threshold.AWL airplane applicability list changed to delete PW for the Struts and add 200PWand 300PW.Submitted by:G. R. Palafox (Boeing) 5/1/02Approved by:A Pasion (FAA)**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-7MAY 2002 (Continued)Revised ATA 54 Strut Airworthiness Limitations to delete 2 PW AWL and 2 200RRAWL. Revised ATA 54 Strut Airworthiness Limitations to add 1 200PW AWL,5 200RR AWL and 4 300PW AWL. Revised 3 300RR ATA 54 Strut AirworthinessLimitations to correct Zone Reference from /434 to /443.Revised Safe Life Limits to add words Rolls Royce Engine to 757-300 Mounts.Revised page format explanation for Certification Maintenance Requirements toadd PW 2043 engine.Revised CMR 29-11-00-6E by adding the word "FUNCTIONALLY" to clarify thetype of task. Also, revised the note in SB 29-0026 by changing the word from"DELETED" to "TERMINATED" for clarification.Revised CMR 29-11-00-6F by adding the words “FUNCTIONALLY" and "POWER'and deleting the word "GROSS” to clarify the type and level of this task.Added CMRs P78-34-00-5A, P78-34-00-5B, P78-34-00-5C, and P78-34-00-5Dapplicable to the 757-200/300 PW2000 Engine.CMRs are applicable to Engine 1 and 2 Thrust Reverser Sync-Lock and AutoRestow System.Added CMRs 26-23-01-6D and 26-23-01-6E applicable to the 757-300 PW2000Engine. CMRs are applicable to the Environmental Control System (ECS) - SmokeDetection and Fire Protection System. Revised CMRs 26-23-01-6C to limit theAirplane and Engine Applicabilities as a result of the new PW Engine.Submitted by:G. R. Palafox (Boeing) 5/1/02Approved by:A Pasion (FAA)**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-8757 MAINTENANCE PLANNING DATAAUGUST 2002Added new Section D. AIRWORTHINESS LIMITATIONS - SYSTEMS and reidentified subsequent Sections E to H. This new section resulted from 757-300PWcertification and contains a list of failures that are reportable.Revised 54-50-I01 MID SPAR CHORD to show correct SSI# 54-50-I01/54-50-I02.DELETED 54-50-I08 FORWARD ENGINE MOUNT and added two items 54-50-I08FORWARD ENGINE MOUNT BEAM and 54-50-I08 FORWARD ENGINE MOUNTBOLTS to match certification data.Revised Structural Safe Life Limits for 757-300 ROLLS ROYCE ENGINEFORWARD MOUNT from 10,000 to 40,000 LANDINGS.Revised Structural Safe Life Limits for 757-300 ROLLS ROYCE ENGINE AFTMOUNT from 16,000 to 80,000 LANDINGS.Revised the following CMR numbers to agree with the corresponding tasks listed inSection 6 for consistency.P78-34-00-5A changed to P78-31-00-5CP78-34-00-5B changed to P78-31-00-5AP78-34-00-5C changed to P78-31-00-5JP78-34-00-5D changed to P78-31-00-5GRevise JAA Unique Requirements to increase Safe Life Limit of 757-300 ROLLSROYCE ENGINE FORWARD MOUNT from 6,000 to 25,000 LANDINGS and757-300 ROLLS ROYCE ENGINE AFT MOUNT from 10,000 to50,000 LANDINGS.Submitted by:G. R. Palafox (Boeing) 8/29/02Approved by:L. Liu-Nelson (FAA) forNOVEMBER 2002Revised threshold of Airworthiness Limitations 54-50-I01/54-50-I02, 54-50-I03,54-50-I04, 54-50-I08 and 54-50-I08 from 10,000 Cycles to 50,000 Cycles. AddedCMR 52-51-00-5A to perform a functional check of the locking and unlocking latchbolt mechanism on the flight deck door decompression panel.Submitted by:G. R. Palafox (Boeing) 11/13/02Approved by:Jeffrey Duven (FAA)**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-9MAY 2003Revised Page 9.0-15 preamble to Airworthiness Limitations that specifies rollbackof any escalated baseline structural inspection intervals when reaching the AWLthreshold to clarify that restriction applies to flight cycles only and not calendarescalation.Revised Airworthiness Limitations Pages 9.0-29 to 9.0-35 to include flap failuremitigation requirements for 757-200 airplanes.This has resulted in revision to 26 existing limitations to change applicability from-300 to ALL and the addition of 29 limitations applicable to -200 only.Revised page 9.0-38 preamble to Certification Maintenance Requirements to makereference to Advisory CircularAC 25-19.Revised the task statements of 10 CMRs on Pages 9.1-1 through 9.1-4 to beconsistent with their task codes.Submitted by:S. A. Pierini (Boeing) 8/18/03Approved by: Jeffrey Duven (FAA)JULY 2004Revised CMR 52-51-00-5A to 52-51-00-5C to correct typographical error onPage 9.1-3.Submitted by:S. A. Pierini (Boeing) 7/21/04Approved by: Jeffrey Duven (FAA)JUNE 2005Revised CMR 31-41-02-4A Interval from 04000 Hrs to 10800 Hrs.Submitted by:S. A. Pierini (Boeing)Approved by: Jeffrey Duven (FAA)**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-10757 MAINTENANCE PLANNING DATAJANUARY 2006Added new fuel system airworthiness limitation which includes inspections of thecenter tank auto shutoff system and fuel quantity indicating system hot shortprotector.Added FAA AMOC Letter 120S-05-457 to reflect the approval of the June 2005revision of Section 9.Submitted by:S. A. Pierini (Boeing)Approved by: Dorr Anderson (FAA)FEBRUARY 2006Added Boost pump ground fault interrupt and motor operated valves AWLs.Submitted by:S. A. Pierini (Boeing)Approved by: Dorr Anderson (FAA)MARCH 2006Added nineteen fuel system AWLs to satisfy SFAR 88 requirements.Revised 28-AWL-22 to clarify concern statement because the densitometer is notoptional in the center tank.Revised 28-AWL-23 to clarify concern statement and location of bondingmeasurement in step 1.f.Submitted by:G. R. Palafox (Boeing)Approved by: A. J. Pasion (FAA)OCTOBER 2006The front matter has been changed to reference the new DTR DocumentD622N001-DTR rather than Appendix B of the 757 MPD. D622N001-DTR waspublished in April 2006 and superseded Appendix B.Revised 28-AWL-23 to ensure that all motor operated valve configurations areaddressed.Added new motor operated valve inspection number 28-AWL-25 applicable toairplanes that have incorporated Service Bulletin 737-28A0088Submitted by:G. R. Palafox (Boeing)Approved by: Jeffrey Duven (FAA)**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-11JANUARY 2007Revised Section E, Airworthiness Limitations - Fuel Systems, to include revisionsrecommended by the Seattle FAA Flight Standards Group.Revised 28-AWL-06 to add CMM Number and revision level for HoneywellFQIS system.Revised 28-AWL-07 to add CMM Number and revision level for Honeywell FQIS systemfuel tank units and compensator.Revised 28-AWL-22 to clarify the bonding test requirement.Revised 28-AWL-24 to remove the ITT Actuator Part Number from theApplicability column.Added Airworthiness Limitation Number 28-AWL-26 "Center Tank Fuel Boost PumpPower Failed On Protection System" This AWL is applicable to airplanes that haveincorporated Service Bulletin 757-28A0105.Submitted by:S. A. Pierini (Boeing)Approved by: Dorr Anderson (FAA)NOVEMBER 2007Revised Section D. Airworthiness Limitations - Systems to incorporate "ReportingUncontrollable High Thrust Failure Conditions" per FARs 121.703 and 135.415.Revised the first sentence of Section E. Airworthiness Limitations - Fuel Systems byadding “scheduled inspections and design limitations”, and revised the information onExceptional Short-Term Extensions to clarify notification requirements.Revised the title of Section F to read “Page Format: Fuel Systems AirworthinessLimitations”.Revised the 28-AWL-21 interval from 3 years to 1 year based on updated Ground FaultInterrupter Relay supplier reliability data.Submitted by: E. B. Lange (Boeing) Approved by: Phillip Forde (FAA)**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-12757 MAINTENANCE PLANNING DATAMARCH 2008Revised 28-AWL-01 to remove 36000FH task interval limitation based uponengineering review and operator maintenance practice and removed body station andbuttock line text and replaced with "per AMM 28-11-00".Revised 28-AWL-03 to reflect the new maximum loop resistance values associated withthe lightning protection of the unpressurized FQIS wire bundle installations so as tosatisfy the Airworthiness Limitation Instructions required by SFAR 88. Also removedthe joint resistance values and 36000FH task interval limitation based upon engineeringreview and operator maintenance practice.Revised 28-AWL-12 to add an additional CMM references 28-22-05 Revision Number 4and 28-22-06 Revision Number 6 to task.Revised 28-AWL-14 by removing the 36000FH task interval limitation based uponengineering review and operator maintenance practice.Revised 28-AWL-17 to change the fay surface bond limit call out for the pressure reliefvalve from 1 ohm or less to 0.010 ohms (10 milliohms) or less.Submitted by: John Sabolchy (Boeing) Approved by: Phillip Forde (FAA)DECEMBER 2008Revised 28-AWL-03 to reflect the new maximum Loop Resistance Values andadditional airplane configurations associated with the lightning protection of theunpressurized FQIS wire bundle installations to satisfy the Airworthiness LimitationInstructions required by SFAR 88.Revised 28-AWL-04 to provide additional clarification for Step 3.Revised 28-AWL-06 to include additional CMM reference and revision level information.Revised 28-AWL-07 to include additional CMM reference and revision level information.Revised 28-AWL-12 to include additional CMM reference and revision level information.Revised 28-AWL-16 to include updated procedures.Revised 28-AWL-17 to include updated procedures.Revised 28-AWL-23 to include updated procedures.Revised 28-AWL-24 to include additional CMM reference and revision level information.Revised 28-AWL-25 to include additional CMM reference and revision level informationand updated procedures.Submitted by: Jason Onorati (Boeing) Approved by: Robert D. Breneman (FAA)**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-13JULY 2010Revised Sections C and K by adding Service Letter Numbers and updating tables toreflect the Part Numbers for the Rolls Royce Engine Forward Mount.Submitted by John Sabolchy, Boeing Approved by Robert Breneman, FAASIGNATURE ON FILE08/31/2010NOVEMBER 2010Added new Airworthiness Limitations - Nitrogen Generation System ALIs andCDCCLs. This newly added AWL Section is now Section H with the subsequentsections being revised to I, J, K, and L, respectively.Added a new table in Section H for AWLs 47-AWL-01 through 47-AWL-06.Revised Section I by removing the CMR illustration (Figure 2) to eliminate redundancy,since the data is available for reference in the Page Format table (Section J).Revised Section J (Page Format: CMRs) by updating the MPD Item Number, Task,Zone, and Access definitions to reflect the latest publishing format and publishinglocations.Revised Section K by updating the MPD Item Number and Task columns to reflect thenew numbering and publishing format.Please Note: For Sections J and K, the CMR intervals/descriptions/zone/etc. for theseitems were not changed. For example, MPD Item Number 26-010-04 (OPC) used tobe identified as MPD Item Number 26-23-01-6C (OP). Detailed Zone and Accessinformation in Section 3 and 4 of the 757 MPD has been relocated to Appendix A of the757 MPD.Submitted by John Sabolchy, Boeing Approved by Robert Breneman, FAASIGNATURE ON FILE01/25/2011**REVISIONS**REVISION AND REVISION DESCRIPTIONAPPROVALNOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-14757 MAINTENANCE PLANNING DATATHIS PAGE INTENTIONALLY LEFT BLANKBLANKSection Page Date Section Page Date Section Page Date Section Page Date Section Page DateD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-15**LIST OF EFFECTIVE PAGES**757 MAINTENANCE PLANNING DATA9.0 i NOV 20109.0 ii NOV 20109.0 1 NOV 20109.0 2 BLANK9.0 3 NOV 20109.0 4 BLANK9.0 5 NOV 20109.0 6 NOV 20109.0 7 NOV 20109.0 8 NOV 20109.0 9 NOV 20109.0 10 NOV 20109.0 11 NOV 20109.0 12 NOV 20109.0 13 NOV 20109.0 14 BLANK9.0 15 NOV 20109.0 16 BLANK9.0 17 NOV 19989.0 18 NOV 19989.0 19 NOV 20109.0 20 MAY 19979.0 21 NOV 20109.0 22 OCT 20069.0 23 MAY 20039.0 24 MAY 20039.0 25 MAY 20039.0 26 MAY 20039.0 27 MAY 20039.0 28 MAY 20039.0 29 MAY 20039.0 30 MAY 20039.0 31 MAY 20039.0 32 MAY 20039.0 33 MAY 20039.0 34 MAY 20039.0 35 MAY 20039.0 36 MAY 20039.0 37 MAY 20039.0 38 MAY 20039.0 39 MAY 20039.0 40 MAY 20039.0 41 MAY 20039.0 42 JUL 20109.0 43 NOV 20079.0 44 NOV 20079.0 45 NOV 20079.0 46 NOV 20079.0 47 NOV 20079.0 48 DEC 20089.0 49 DEC 20089.0 50 DEC 20089.0 51 DEC 20089.0 52 DEC 20089.0 53 DEC 20089.0 54 DEC 20089.0 55 DEC 20089.0 56 DEC 20089.0 57 DEC 20089.0 58 DEC 20089.0 59 DEC 20089.0 60 DEC 20089.0 61 DEC 20089.0 62 DEC 20089.0 63 DEC 20089.0 64 DEC 20089.0 65 DEC 20089.0 66 DEC 20089.0 67 NOV 20109.0 68 NOV 20109.0 69 NOV 20109.0 70 NOV 20109.0 71 NOV 20109.0 72 MAY 20029.0 73 NOV 20109.0 74 NOV 20109.0 75 NOV 20109.0 76 NOV 20109.0 77 NOV 20109.0 78 BLANKNOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-16**LIST OF EFFECTIVE PAGES**757 MAINTENANCE PLANNING DATASection Page Date Section Page Date Section Page Date Section Page Date Section Page DateBLANK757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-17**A. SCOPE**The scheduled maintenance requirements described in this section result from Model 757 airplane certification activities with the U.S. Federal AviationAdministration (FAA). Accordingly, this FAA approved Airworthiness Limitations and Certification Maintenance Requirements document is crossreferenced in the Model 757 Type Certificate Data Sheet. These maintenance actions are mandatory.This Airworthiness Limitations Section is FAA approved and specifies maintenance required under Federal Aviation Regulation (FAR) 43.16 and 91.403unless an alternative program has been FAA approved.**AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONS**The Airworthiness Limitations may only be revised with the approval of the FAA Seattle Aircraft Certification Office (ACO).If the inspections cannot be accomplished due to repairs and/or modifications, an alternate inspection acceptable to the Seattle FAA ACO must be used.**ROUGH RUNWAY OPERATION**The scheduled maintenance requirements described in this section may not be valid for any 757-300 which has accumulated 500 ormore landings on therunways listed below.• All runways in the Commonwealth of Independent States (CIS), except as defined in Boeing Document D682332, Runway Roughness Classification forFatigue and Damage Tolerance.Subsection B, Airworthiness Limitations - Structural Inspections, and Subsection C, Airworthiness Limitations - Structural SafeLife Parts, must bereviewed and modified as necessary to address the increased damage which may result from operation on these rough runways. When a 757-300accumulates 500 landings on the runways defined above, the operator has 3000 flight cycles (accumulated on any runway) to implement necessarychanges to this program. Contact Boeing for assistance.NOTE: Any changes to this program must be approved by the Seattle FAA ACO.Any 757-300 which uses the CIS runways defined above, must comply with the inspections specified by Service Bulletin 757-32A0124, "Landing Gear -Main Landing Gear Truck and Inner Cylinder Pivot Bushing and Bore Inspection".NOV 1998D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-18757 MAINTENANCE PLANNING DATA**CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs)**These scheduled maintenance tasks may only be revised by the Seattle FAA ACO. Principal Airworthiness Inspectors (local regulatory authority) may notchange these requirements or the intervals associated with these requirements.NOV 1998757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-19**B. AIRWORTHINESS LIMITATIONS - STRUCTURAL INSPECTIONS INTRODUCTION** The Structural Inspection Program approved in Section 3 of the 757 Maintenance Review Board (MRB) Report and contained in Section 2 of this MPDdescribes an initial baseline structural maintenance program for all Structural Significant Items (SSIs). This program was developed in accordance withthe guidelines of MSG-3 and partially satisfies the requirements of FAR 25.571 by providing accidental and environmental damagedetection opportunityfor all SSIs, and in some cases, fatigue damage detection opportunity. The supplemental structural inspections listed in thisSection 9 AirworthinessLimitations, are for those SSIs that do not receive adequate fatigue damage detection opportunity from the initial baseline structural program that is listedin Section 2. The inspections shown in this section are to be accomplished in conjunction with and not as a substitute for theexisting structuralmaintenance program found in Section 2.The supplemental structural inspection program uses the Damage Tolerance Rating (DTR) system to determine the inspections (andrepeat intervals)necessary to provide adequate fatigue damage detection. The DTR system defines a required DTR (a numerical value) that must beachieved for eachSSI. DTR check forms which define the inspection options and the required DTR are contained in Document D622N001-DTR.**THRESHOLD**The certifying authority (Seattle FAA ACO) requires designation of all SSIs into two categories. These two categories are referred to as Type 1 andType 2. Type 1 structure requires the implementation threshold to be established by crack growth analysis. Type 2 structure isallowed to have theimplementation threshold established by fatigue analysis (supported by test evidence) and allows for the future escalation of the inspection threshold whensufficient data from the initial inspections statistically support an increased threshold.The tables shown on Pages9.0-19through9.0-37of this section (Airworthiness Limitations - Structural Limitations) defines the inspection implementationthreshold. Some items are sensitive to flight length and identified by Flight Length Sensitive (FLS) in the threshold column of the table. FLS Items requireboth flight hours and flight cycles to determine the implementation threshold. Refer to Figure 1, shown on the next page, to determine the threshold forFLS Items.NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-20757 MAINTENANCE PLANNING DATAFIGURE 1. Flight Length Sensitive (FLS) Threshold GraphInstructions for the use of the FLS Threshold Graph:1. Determine, for each airplane, the accumulated flight cycles and flight hours.2. Enter the FLS Threshold Graph at the appropriate flight cycles and flight hours and plot the point.3. The initial supplemental inspection must be accomplished before crossing into the shaded area on the FLS Threshold Graph.10504030201801601401201008060

CYCLES ( X 1,000)FLIGHT HOURS ( X 1,000)MAY 1997757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-21In addition to the thresholds described above, a calendar threshold of 20 years applies unless an initial inspection of an FAAapproved CorrosionPrevention and Control Program (CPCP) has occurred, constituting CPCP implementation.When reaching the threshold of 50,000 flight cycles or the FLS cycles and hours (whichever comes first), all C-check (or higher) structural inspectionrepeat intervals must be no greater than those shown in the MPD Section 2. Structures C-check interval is defined in Section 1as 3,000 flight cycles or18 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 hasescalated the structures program by changing either task intervals (flight cycles) or the C-check interval (flight cycles), must reduce the repeat frequenciesback to the MPD baseline structures program intervals before accumulating 50,000 flight cycles or the FLS cycles and hours (whichever comes first). Thereason for this is that the FAR 25.571 damage tolerance evaluation takes credit for the baseline structures program. The airworthiness limitations listed inSection 9 cover structure for which the required DTR is not satisfied by the baseline structural inspections of Section 2. Anycontinued escalation beyondthe MPD baseline structures program may result in additional structure not meeting the required DTR which was the basis of certification.**REPEAT INSPECTION INTERVAL**A repeat inspection interval for the fatigue inspection of an SSI is established from its Damage Tolerance Rating (DTR) Check Form. Revision to therequired DTR or the DTR curve is not allowed without approval from the Seattle FAA ACO.**REPORTING RESULTS OF STRUCTURAL INSPECTIONS**All cracks found during these inspections shall be reported within ten (10) days directly to the Manager of the Seattle FAA ACO, the Transport AirplaneDirectorate, and to Boeing Commercial Airplanes using the Discrepant Structure Report Form. Refer to Document D622N001-DTR forthe required reportform (any suitable alternative which contains the same information may be used).NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-22757 MAINTENANCE PLANNING DATAThe following table on Pages 9.0-19 through 9.0-40 lists the Airworthiness Limitation Structural Inspection requirements. Each item is listed bySSI Number, DTR Check Form Title, Inspection Zone, Airplane Applicability, Type and Threshold. There are corresponding DTR Forms in DocumentD622N001-DTR for each item listed in the table. Where there is more than one listing for a given SSI Number, the DTR Check Form Title is the uniqueidentifier. Airplane applicability is listed as:NOTE: L/N = Airplane Line Number. Where entered with DTR Check Form Title, identifies DTR Check Form to specific airplane linenumber.ALL= All 757 AirplanesPASS= All Passenger Airplanes200= 757-200 Airplanes200PASS = 757-200 Passenger AirplanesPF= Package FreighterCOMBI= Combi Airplanes300= 757-300 Airplanes200RR= 200 Airplane Nacelle Strut for Rolls Royce RB211-535300RR= 300 Airplane Nacelle Strut for Rolls Royce RB211-535200PW= 200 Airplane Nacelle Strut for Pratt & Whitney PW2000300PW= 300 Airplane Nacelle Strut for Pratt & Whitney PW2000OCT 2006757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-23**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** 52-10-06 Fuselage Main Deck Cargo Door Skin and Frames BS480 to BS620 Upper Hinge Line to S-14 838PFCOMBIType 2,50,000 Cycles52-10-06 Fuselage Main Deck Cargo Door Frames BS487.1 BS500 BS520 BS540 BS560 BS580 BS600BS612.9 below S-14838PFCOMBIType 2,50,000 Cycles52-30-02 Fuselage Lower Lobe Cargo Compartment Door No. 1 & No. 2, Stop Beams Outer Chord 821/822ALLType 2,50,000 Cycles52-30-04 Fuselage Lower Lobe Cargo Compartment Door No. 3, Stop Beams Outer Chord (if No. 3 CargoDoor Installed)823 200PASSType 2,50,000 Cycles53-10-14 No. 1 Window Cutout Structure AB Post211/212ALLType 1,50,000 Cycles53-10-14 No. 1 Window Cutout Structure BD Sill, L & R211/212ALLType 1,50,000 Cycles53-10-15 No. 2 Window Cutout Structure EF Post, L & R211/212ALLType 1,50,000 Cycles53-10-18 BS 263 Bulkhead, Inner Chord BL27 to BL50 L & R113/114ALLType 2,50,000 Cycles53-10-18 BS 263 Bulkhead, Outer Chord S-23L to S-23R113/114ALLType 2,50,000 Cycles53-10-18 BS 263 Bulkhead, Outer Chord BL27L to BL27R115/116ALLType 1,50,000 Cycles53-10-18 BS 263 Bulkhead, Outer Chord BL27L to BL27R (Flange Not Covered)115/116ALLType 2,50,000 Cycles53-10-18 BS 263 Bulkhead, Outer Chord BL27L to BL27R (Flange Covered)115/116ALLType 1,50,000 Cycles53-10-18 BS 263 Bulkhead, Outer Chord Sensor Locations LBL 6.5, L & R115/116ALLType 1,50,000 Cycles53-10-18 BS 263 Bulkhead, Outer Chord Intercostal Locations BL27L to BL27R113/114ALLType 2,50,000 CyclesMAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-24757 MAINTENANCE PLANNING DATA53-10-21 BS 395 Bulkhead, Outer Chord S-20 to S-26 L & R115/116,119ALLType 2,50,000 Cycles53-10-21 BS 395 Bulkhead, Outer Chord S-26L to S-26R115/116,119ALLType 2,50,000 Cycles53-10-21 BS 395 Bulkhead, Outer Chord S-28 L & R115/116,119ALLType 1,50,000 Cycles53-10-21 BS 395 Bulkhead, Outer Chord S-27 L & R115/116,119ALLType 2,50,000 Cycles53-10-3053-30-2453-40-3253-60-24Typical Upper Frame BS 365.25 to BS 1720, S-13L to S-13R200ALLType 2,50,000 Cycles53-10-3053-30-2453-40-3253-60-24Typical Lower Frame BS 365.25 to BS 1720, S-13L to S-13R100/200ALLType 2,50,000 Cycles53-30-0753-60-07Fuselage Skin Lap Splices, Upper Fastener Row, L & R100/200 200PASSCOMBIType 2,50,000 Cycles53-30-0753-60-07Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row, S-4, S-10, S-19, S-20, L & R 100/200 200PASSCOMBIType 2,50,000 Cycles53-30-0753-60-07Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row, S-14, L & R100/200 200PASSCOMBIType 2,50,000 Cycles53-30-0753-60-07Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row, S-26, L & R100/200 200PASSCOMBIType 2,50,000 Cycles53-30-0753-60-07Fuselage Skin Lap Splices, Upper Fastener Row, L & R100/200PFType 2,50,000 Cycles53-30-0753-60-07Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-4, S-10, S-14, S-19, S-20,L & R100/200PFType 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-2553-30-0753-60-07Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-26, L & R 100/200 PF Type 2,50,000 Cycles53-30-0753-60-07Fuselage Skin Lap Splices, Upper Fastener Row, L & R 100/200 300 Type 2,50,000 Cycles53-30-0753-60-07Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-4, S-10, S-14, S-19, S-20,L & R100/200 300 Type 2,50,000 Cycles53-30-0753-60-07Fuselage Longitudinal Lap Splices, Inner Skin Lower Fastener Row S-26, L & R 100/200 300 Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Inner Chord Upper Sill to S-24, L/N 1 - 57 122 200PASS Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Inner Chord Upper Sill to S-24, L/N 58 and on 122 ALL Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 1 - 57 122 200PASS Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 560 Edge Frame Outer Chord Upper Sill to Lower Sill,L/N 58 and on122 ALL Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Inner Chord S-20 to Lower Sill, L/N 1 - 57 122 200PASS Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Inner Chord S-20 to Lower Sill, L/N 58 and on 122 ALL Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 1 -57 122 200PASS Type 2,50,000 Cycles53-30-11 No. 1 Cargo Door Cutout BS 620 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 58and on122 ALL Type 2,50,000 Cycles53-30-12 No. 1 Cargo Door Cutout Door Stop Intercostals at Stops 1 & 6 122 ALL Type 2,50,000 Cycles53-10-1053-30-13No. 1 & 2 Passenger Door Cutouts Forward Frame Inner Chord 221, 231/222, 232PASSCOMBIType 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-26757 MAINTENANCE PLANNING DATA53-10-1053-30-13No. 1 & 2 Passenger Door Cutouts Forward Frame Outer Chord 221, 231/222, 232PASSCOMBIType 2,50,000 Cycles53-10-1053-30-131 & 2 Passenger Door Cutouts Upper Main Sill Outer Chord 221, 231/222, 232PASSCOMBIType 2,50,000 Cycles53-10-1053-30-13No. 1 & 2 Passenger Door Cutouts Upper Main Sill Inner Chord 221, 231/222, 232PASSCOMBIType 2,50,000 Cycles53-30-22 Main Deck Cargo Door Cutout Frames BS480 and BS620 Inner Chord Upper to Lower Sill 231 PFCOMBIType 2,50,000 Cycles53-30-22 Main Deck Cargo Door Cutout Frames BS480 and BS620 Outer Chord Upper to Lower Sill 231 PFCOMBIType 2,50,000 Cycles53-30-22 Main Deck Cargo Door Cutout Upper Sill Inner Chord BS470 to BS495 and BS605 to BS630 231 PFCOMBIType 2,50,000 Cycles53-30-22 Main Deck Cargo Door Cutout Upper Sill Outer Chord BS470 to BS487 and BS613 to BS630 231 PFCOMBIType 2,50,000 Cycles53-30-22 Main Deck Cargo Door Cutout Lower Sill Outer Chord BS470 to BS510 and BS600 to BS630 231 PFCOMBIType 2,50,000 Cycles53-30-2453-60-24Typical Upper Frame BS680 to BS800 and BS1400 to BS1620 200 PFCOMBIType 2,50,000 Cycles53-30-2453-60-24Typical Lower Frame BS460 to BS540, BS560 to BS620, BS1320 to BS1440 and BS1540 toBS1701100 PFCOMBIType 2,50,000 Cycles53-40-05 Circumferential Skin Splice, BS900, S-6L to S-6R 233, 234/243, 244200 Type 1,50,000 Cycles53-40-05 Circumferential Skin Splice, BS1180, S-6L to S-6R 243, 244/253, 254200 Type 1,50,000 Cycles53-40-17 Transverse Floor Beam Upper Chord, BS1100 & BS1140, BL 36 to Frame Splice, L & R 141/142 ALL Type 2,50,000 Cycles53-40-17 Transverse Floor Beam Upper Chord, BS1100 & BS1140, LBL 45.5 & RBL 45.5 141/142 ALL Type 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-2753-40-17 Transverse Floor Beam Lower Chord, BS1120 & BS1140, BL 17 to BL 45.5 at HorizontalStiffener Locations, L & R141/142 ALL Type 2,50,000 Cycles53-40-17 Transverse Floor Beam Lower Chord, BS1120 & BS1140, BL 17 to BL 45.5 between HorizontalStiffener Locations, L & R141/142 ALL Type 2,50,000 Cycles53-40-17 Transverse Floor Beam Lower Chord, BS1140 at BL 37, L & R 141/142 ALL Type 2,50,000 Cycles53-40-20 Rear Spar Bulkhead Inner Chord BS1040 S-14 to S-17 L & R 241/242 ALL Type 2,50,000 Cycles53-40-20 Rear Spar Bulkhead Lower Side Fitting Inboard Leg BS1040 L & R 241/242 ALL Type 2,50,000 Cycles53-40-21 BS 1180 Aft Wheel Well Bulkhead Inner Chord at S-12L & S-12R 241/242 ALL Type 2,50,000 Cycles53-40-21 BS 1180 Aft Wheel Well Bulkhead Inner Chord from S-11 to S-15, L & R 241/242 ALL Type 2,50,000 Cycles53-40-21 BS 1180 Aft Wheel Well Bulkhead Lower Chord from S-21 to S-26, L & R 151/152 ALL Type 1,50,000 Cycles53-40-21 BS 1180 Aft Wheel Well Bulkhead Vertical Beam, L & R 151/152 ALL Type 2,50,000 Cycles53-40-2253-40-24MLG Beam Support Frame Inner Chord BS1080 & BS1140 S-14 to S-16 L & R 241/242 ALL Type 2,50,000 Cycles53-40-23 MLG Beam Support Frame Inner Chord BS1120 S-14 to S-16 L & R 241/242 ALL Type 2,50,000 Cycles53-40-2353-40-24MLG Beam Support Frame at Floor Beam Splice BS1120 and BS1140 L & R 241/242 ALL Type 2,50,000 Cycles53-40-25 Overwing Stub Frames Inner Chord BS1000 and BS1020 L and R (Not Applicable to OverwingExit Models)241/242 200PASS Type 2, FlsSee Graph53-40-28 Overwing Exit Cutout Upper Sill Inner Chord BS950 to BS976 and BS990 to BS1012 L & R 241/242 PASSCOMBIType 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-28757 MAINTENANCE PLANNING DATA53-40-28 Overwing Exit Cutout Upper Sill Outer Chord BS960 to BS1020241/242 PASSCOMBIType 2,50,000 Cycles53-40-28 Overwing Exit Cutout Lower Sill Outer Chord BS1004 to BS1030 L & R241/242 200PASSCOMBIType 2,50,000 Cycles53-40-28 Overwing Exit Cutout Lower Sill Outer Chord BS1004 to BS1030 L & R241/242300Type 2,50,000 Cycles53-60-09 Circumferential Splice Plate BS1460 S-6L to S-6R253/254ALLType 2,50,000 Cycles53-60-09 Circumferential Splice Plate BS1620 S-6L to S-6R253/254ALLType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Inner Chord S-23 to Lower Sill, L/N 1 - 57154 200PASSType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Inner Chord S-23 to Lower Sill, L/N 58 and on 154ALLType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Outer Chord S-21 to Lower Sill, L/N 1 - 57154 200PASSType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1380 Edge Frame Outer Chord S-21 to Lower Sill, L/N 58 and on 154ALLType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Inner Chord S-20 to Lower Sill, L/N 1 - 57154 200PASSType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Inner Chord S-20 to Lower Sill, L/N 58 and on 154ALLType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 1 - 57 154 200PASSType 2,50,000 Cycles53-60-11 No. 2 Cargo Door Cutout BS1440 Edge Frame Outer Chord Upper Sill to Lower Sill, L/N 58and on154ALLType 2,50,000 Cycles53-60-12 No. 2 Cargo Door Cutout Corner Door Stop Intercostals, Web at Stops 1 and 6154ALLType 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-2953-60-12 No. 2 Cargo Door Cutout Door Stop Intercostal, Web at Stop 4154ALLType 2,50,000 Cycles53-60-13 No. 3 Emergency Exit Cutout Forward Frame Inner Chord BS1320 S-12 to S-16 L & R(Not Applicable to 757-200 Overwing Exit Models)251/152 PASSType 2,50,000 Cycles53-60-13 No. 3 Emergency Exit Cutout Forward Frame Inner Chord BS1320, S-17 at Sill L & R(Not Applicable to 757-200 Overwing Exit Models)251/252 PASSType 2,50,000 Cycles53-60-13 No. 3 Emergency Exit Cutout Aft Frame Outer Chord BS1350 S-10 to S-12 L & R(Not Applicable to 757-200 Overwing Exit Models)251/252 PASSType 2,50,000 Cycles53-60-13 No. 3 Emergency Exit Cutout Aft Frame Inner Chord BS1350 S-10 to S-12 L & R(Not Applicable to 757-200 Overwing Exit Models)251/252 PASSType 2,50,000 Cycles53-60-13 No. 3 Emergency Exit Cutout Upper Main Sill Outer Chord between BS1300 to BS1320 andBS1350 to BS1380 L & R (Not Applicable to 757-200 Overwing Exit Models)251/252 PASSType 2,50,000 Cycles53-60-13 No. 3 Emergency Exit Cutout Upper Main Sill Inner Chord BS1350 to BS1380 L & R(Not Applicable to 757-200 Overwing Exit Models)251/252 PASSType 2,50,000 Cycles53-60-13 No. 3 Emergency Exit Cutout - Fwd and Aft Frames - Outer Chord BS1320 & BS1350 - Upper SillIntersection (Not Applicable to 757-200 Overwing Exit Models)251/252 PASSType 2,50,000 Cycles53-60-15 No. 4 Passenger Door Cutout Forward Frame Outer Chord BS1640 S-9 to S-17 L & R251/252 PASSCOMBIType 2,50,000 Cycles53-60-15 No. 4 Passenger Door Cutout Forward Frame Inner Chord BS1640 S-14 to S-17 L & R251/252 PASSCOMBIType 2,50,000 Cycles53-60-15 No. 4 Passenger Door Cutout Upper Main Sill Outer Chord BS1681.8 to BS1720 L & R251/252 PASSCOMBIType 2,50,000 Cycles53-60-15 No. 4 Passenger Door Cutout Upper Main Sill Inner Chord BS1681.1 to BS1720 L & R251/252 PASSCOMBIType 2,50,000 Cycles53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Inner Chord S-23 to Lower Sill, L/N 1 - 57(if No. 3 Door Installed)162 200PASSType 2,50,000 Cycles53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Inner Chord S-23 to Lower Sill, L/N 58 - and on(if No. 3 Door Installed)162 200PASSType 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-30757 MAINTENANCE PLANNING DATA53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Outer Chord S-21 to S-26, L/N 1 - 57(if No. 3 Door Installed)162 200PASS Type 2,50,000 Cycles53-60-21 No. 3 Cargo Door Cutout BS1540 Edge Frame, Outer Chord S-21 to S-26, L/N 58 and on(if No. 3 Door Installed)162 200PASS Type 2,50,000 Cycles53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Inner Chord Upper Sill to S-25, L/N 1 - 57(if No. 3 Door Installed)162 200PASS Type 2,50,000 Cycles53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Inner Chord Upper Sill to S-25, L/N 58 and on(if No. 3 Door Installed)162 200PASS Type 2,50,000 Cycles53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Outer Chord S-20 to S-25, L/N 1 - 57(if No. 3 Door Installed)162 200PASS Type 2,50,000 Cycles53-60-21 No. 3 Cargo Door Cutout BS1592 Edge Frame, Outer Chord S-20 to S-2, L/N 58 and on(if No. 3 Door Installed)162 200PASSType 2,50,000 Cycles53-60-22 No. 3 Cargo Door Cutout Door Stop Intercostals, Web (if No. 3 Door Installed)162 200PASSType 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 9.2, at Back to Back Stiffeners fromWL 219.5 to WL 246.2311/312ALLType 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 9.2, between Stiffeners fromWL 219.5 to WL 246.2311/312ALLType 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 26.7, at Back to Back Stiffeners fromWL 219.5 to WL 246.2311/312ALLType 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 26.7, between Back to Back Stiffenersfrom WL 219.5 to WL 246.2311/312ALLType 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 45.7, at Back to Back Stiffeners fromWL 219.5 to WL 255.8311/312ALLType 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Vertical Stiffener, RBL & LBL 45.7, between Back to Back Stiffenersfrom WL 219.5 to WL 255.8311/312ALLType 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, RBL & LBL 26.7 at BL 26.7Stiffener Fitting311/312200Type 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-3153-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, RBL & LBL 26.7 at BL 26.7Stiffener Fitting311/312 300 Type 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, between Vertical Stiffeners at BL 9.2 &BL 26.7, Left and Right311/312 200 Type 2,50,000 Cycles53-80-03 BS1720 Pressure Bulkhead, Transverse Beam, WL 265, between Vertical Stiffeners at BL 9.2 &BL 26.7, Left and Right311/312 300 Type 2,50,000 Cycles53-80-20 Horizontal Stabilizer Jackscrew Support Fitting Support Lug, BS1771.1 311/312 ALL Type 1,50,000 Cycles53-80-21 Horizontal Stabilizer Hinge Fitting Pivot Lugs, BS1858.9 313/314 ALL Type 1,50,000 Cycles54-50-I02Basic Chord StructureDeleted54-50-I03 Forward Engine Mount Bulkhead433/443 200PWType 2,50,000 Cycles54-50-I03 Forward Engine Mount Fitting Pad NSta 106 and NSta 116433/443 200PWType 2,50,000 Cycles54-50-I03Forward Engine Mount Fitting AssemblyDeleted54-50-I03Basic Chord StructureDeleted54-50-I04 Aft Engine Mount Bulkhead - Barrel Nut Bore434/444 200PWType 1,50,000 Cycles54-50-I07Midchord StructureDeleted54-50-01 Basic Upper Spar Center Chord Structure NSta 150 to 170432/442 200RRType 2,50,000 Cycles54-50-03 Lower Spar Chord NSta 150 to 160433/443 200RRType 2,50,000 Cycles54-50-03 Aft Mount Barrel Nut Bores NSta 185.35434/444 200RRType 1,50,000 Cycles54-50-04 Forward Engine Mount Bulkhead Flange NSta 100434/444 200RRType 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-32757 MAINTENANCE PLANNING DATA54-50-04 Forward Engine Mount Bulkhead Barrel Nut Bores NSta 100434/444 200RRType 1,50,000 Cycles54-50-I0154-50-I02Mid Spar Chord433/443 300PWType 2,50,000 Cycles54-50-I03 Forward Engine Mount Fitting433/443 300PWType 2,50,000 Cycles54-50-I04 Aft Engine Mount Bulkhead434/444 300PWType 2,50,000 Cycles54-50-I08 Forward Engine Mount Beam433/443 300PWType 2,50,000 Cycles54-50-I08 Forward Engine Mount Bolts433/443 300PWType 2,50,000 Cycles54-50-03 Lower Spar Chord NSta 110.00 to 125.00433/443 300RRType 1,50,000 Cycles54-50-03 Lower Spar Chord NSta 119.30, Lower Flange433/443 300RRType 1,50,000 Cycles54-50-03 Lower Spar Chord NSta 170.00 Beneath Precooler Fitting433/443 300RRType 2,50,000 Cycles54-50-03 Aft Mount Barrel Nut Bores NSta 185.35, NWL 134.85434/444 300RRType 1,50,000 Cycles54-50-04 Fwd Mount Barrel Nut Bores NSta 103.01, NWL 143.29433/443 300RRType 1,50,000 Cycles55-10-03 Horizontal Stabilizer Rear Spar Upper Chord Horizontal Flanges (Chord at Rib 3 BBL 34.90) 331/341ALLType 1,50,000 Cycles55-10-03 Horizontal Stabilizer Rear Spar Upper Chord Vertical Leg (Chord at Rib 3 BBL 34.90)331/341ALLType 1,50,000 Cycles55-10-08 Horizontal Stabilizer Upper Surface Stiffened Panel Inboard of Rib 3 (Stringer Number 1 atCenterline Splice BBL 0.0)331/341ALLType 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-3355-10-08 Horizontal Stabilizer Upper Surface Stiffened Panel Inboard of Rib 3 (Stringer Number 1 at Rib 3) 331/341ALLType 2,50,000 Cycles55-10-10 Horizontal Stabilizer Rear Spar Upper Chord at Center Line Splice (Chord and Skin at BBL 0.0) 331/341ALLType 2,50,000 Cycles55-10-17 Horizontal Stabilizer Rear Spar Splice Fitting, Centerline Splice (BBL 0.0)331/341ALLType 2,50,000 Cycles55-10-19 Horizontal Stabilizer Hinge Pivot Support Fitting (Side of Body at Rear Spar - Fwd of Bore) 331/341ALLType 1,50,000 Cycles55-10-19 Horizontal Stabilizer Hinge Pivot Support Fitting (Side of Body at Rear Spar - Aft of Bore) 331/341ALLType 1,50,000 Cycles55-10-20 Horizontal Stabilizer Jackscrew Fitting Lugs and Attachments (Lugs at BBL 0.0)331/341ALLType 1,50,000 Cycles55-10-22 Horizontal Stabilizer Rear Spar Web at Rib 3 (Web at Pivot Attachment BBL 34.9)331/341ALLType 1,50,000 Cycles55-10-24 Horizontal Stabilizer Rear Spar StiffenedWeb Inboard of Rib 3, (Web at Centerline SpliceBBL 0.0)331/341ALLType 1,50,000 Cycles55-10-27 Horizontal Stabilizer Pivot Fitting Chordwise Attachment Splice Rib 3 (Upper and Lower Surfaceof Splice Plates BBL 34.9)331/341ALLType 1,50,000 Cycles57-10-07 Lower Rear Spar Chord, WBL 7.5133/134ALLType 1, FLSSee Graph57-10-07 Lower Rear Spar Chord, WBL 10.0 to 53.0133/134ALLType 1,25,000 Cycles57-10-10 Side of Body, Lower Chord, Center Wing,WBL 70.75, Rear Spar to Stringer 8 Centerline(1) All Except L/N 804, 810, 818, 839, 846, 849 and 855.(2) L/N 804, 810, 818, 839, 846, 849 and 855.133/134ALLSee (1) and (2)(1) Type 1, FLSSee Graph(2) Type 1,25,000 Cycles /80,000 Flt Hrs(whichever comes first)**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-34757 MAINTENANCE PLANNING DATA57-10-17 Lower Rear Spar Chord, Side of Body Splice, Center Wing, WBL 70.75133/134200Type 1, FLSSee Graph57-10-17 Lower Rear Spar Chord, Side of Body Splice, Center Wing, WBL 70.75133/134300Type 1, FLSSee Graph57-20-07 Typical Stringer at Shear Tie, Skin Under Fitting Stringer 11 at WS 313.5541/641ALLType 2, FLSSee Graph57-20-10 Lower Splice Stringer 5 and Stringer 10 WS 231.5541/641ALLType 2, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 177.5551/651200Type 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 177.5531, 551/631, 651300Type 1, FLSSee Graph57-20-11 Lower Spar Rear Chord WS 204.5, Horizontal Flange531/631ALLType 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 204.5, Vertical Flange551/651200Type 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 204.5, Vertical Flange551/651300Type 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 210.3 & WS 222.2, MLG Trunnion Support531/631ALLType 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 231.5551/651200Type 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 231.5551/651300Type 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 285551/651ALLType 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WS 302541/641ALLType 1, FLSSee Graph**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-3557-20-11 Lower Rear Spar Chord WS 313.5541/641ALLType 1, FLSSee Graph57-20-11 Lower Rear Spar Chord WBL 70.75 to WS 204.5, General Section531/631300Type 2,50,000 Cycles57-20-11 Front Spar Lower Chord WS 258.5 Under Rib Post, L/N 1010 and on511/611200Type 1, FLSSee Graph57-20-11 Front Spar Lower Chord WS 285.65 at Rib Fitting and Nacelle Support Fitting, L/N 1010 and on 511/611200Type 1, FLSSee Graph57-20-11 Front Spar Lower Chord Outboard Wing - WSta 294511/611ALLType 1, FLSSee Graph57-20-15 Typical Stringer In Dry Bay Region Stringer at Seal Pans, Skin Under Fitting, Stringer 13 atWS 285.65532/632ALLType 2, FLSSee Graph57-20-15 Typical Stringer In Dry Bay Region Stringer Hidden, Skin Under Fairing, Stringer 13 at WS 313.5 532/632ALLType 2, FLSSee Graph57-20-17 Side of Body Lower Chord, Outboard Wing, WBL 70.75, Rear Spar to Stringer 8(1) All Except L/N 804, 810, 818, 839, 846, 849 and 855.(2) L/N 804, 810, 818, 839, 846, 849 and 855.531/631ALLSee (1) and (2)(1) Type 1, FLSSee Graph(2) Type 125,000 Cycles /80,000 Flt Hrs(whichever comes first)57-20-25 Lower Rear Spar Chord, Side of Body Splice, Outboard Wing, WBL 70.75551/651200Type 1, FLSSee Graph57-20-25 Lower Rear Spar Chord, Side of Body Splice, Outboard Wing, WBL 70.75551/651300Type 1, FLSSee Graph57-53-01 Outboard Flap, Outboard Track Assembly (Track # 1) Forward Clevis574/674ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-0157-53-03Outboard Flap, Inbd & Outbd Track Assys (Tracks # 1 & # 2) Forward Section573, 574/673, 674ALLType 1,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-36757 MAINTENANCE PLANNING DATA57-53-0257-53-04Outboard Flap, Inbd & Outbd Flap Tracks (Tracks # 1 & # 2) Support Fitting Assembly 573, 574/673, 674ALL Type 1 (300),Type 2 (200),50,000 Cycles57-53-03 Outboard Flap, Inboard Track Assembly (Track # 2) Forward Clevis 573/673 ALL Type 1 (300),Type 2 (200),50,000 Cycles57-53-05 Inboard Flap, Outbd Track Assy (Track # 3) Track at Fwd Attach Lug 572/672 ALL Type 1,50,000 Cycles57-53-05 Inboard Flap, Outboard Track Assy (Track # 3) Forward Clevis 572/672 200 Type 2,50,000 Cycles57-53-05 Inboard Flap, Outboard Track Assy (Track # 3) Forward Clevis 572/672 300 Type 1,50,000 Cycles57-53-05 Inboard Flap, Outboard Track (Track # 3) Midsection 572/672 200 Type 2,50,000 Cycles57-53-06 Inboard Flap, Outboard Track (Track # 3) Forward Support Fitting 572/672 200 Type 2,50,000 Cycles57-53-06 Inboard Flap, Outboard Track (Track # 3) Forward Support Fitting 572/672 300 Type 2,50,000 Cycles57-53-06 Inboard Flap, Fwd Support, Outboard Track (Track # 3) Fuse Pin 572/672 ALL Type 1,50,000 Cycles57-53-07 Inboard Flap, Inboard Support Aft Link Assy, Lower Lug 143/144 ALL Type 1 (300),Type 2 (200),50,000 Cycles57-53-07 Inboard Main Flap, Inboard Carriage #4, Aft Link Assy 143/144 200 Type 2,50,000 Cycles57-53-07 Inboard Flap, Inboard Support Aft Link Assy, Upper Clevis 143/144 300 Type 1,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-3757-53-08 Inboard Flap, Aft Link Assy Upper and Lower Special Bolts143/144ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-09 Inboard Flap, Inboard Track (Track # 4) Forward Lug143/144ALLType 1,50,000 Cycles57-53-09 Inboard Flap, Inboard Track (Track # 4) Aft Lug143/144ALLType 1,50,000 Cycles57-53-09 Inboard Flap, Inboard Track (Track # 4) Aft Curved "T" Section143/144200Type 1,50,000 Cycles57-53-09 Inboard Flap, Inboard Track (Track # 4) Aft Curved "T" Section143/144300Type 1,50,000 Cycles57-53-10 Inboard Flap, Inboard Track (Track # 4) Forward Support Fitting143/144ALLType 1,50,000 Cycles57-53-10 Inboard Flap, Forward Support Fitting Special Bolt143/144ALLType 1,50,000 Cycles57-53-11 Inboard Flap, Inboard Support Beam Inboard Lug143/144ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-11 Inboard Flap, Inboard Support Beam Assy Outboard Lug143/144ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-12 Inboard Flap, Front Spar Upper, MF Sta 90-190555/655200Type 1,50,000 Cycles57-53-12 Inboard Flap, Front Spar at Upper Skin Attachment MF Sta 80-190555/655300Type 1,50,000 Cycles57-53-12 Inboard Flap, Front Spar at Upper SkinAttachment MF Sta 147-153.4555/655200Type 1,50,000 Cycles57-53-12 Inboard Flap, Front Spar Lower, MF Sta 210-247555/655200Type 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-38757 MAINTENANCE PLANNING DATA57-53-12 Inboard Flap, Front Spar at Lower Skin Attachment MF Sta 210-235555/655300Type 1,50,000 Cycles57-53-13 Inboard Flap, Rear Spar Upper, MF Sta 91-190555/655200Type 1,50,000 Cycles57-53-13 Inboard Flap, Rear Spar at Upper Skin Attachment MF Sta 80-190555/655300Type 1,50,000 Cycles57-53-13 Inboard Flap, Rear Spar Upper, MF Sta 147-153.4555/655200Type 1,50,000 Cycles57-53-13 Inboard Flap, Rear Spar Lower, MF Sta 210-247555/655200Type 2,50,000 Cycles57-53-13 Inboard Flap, Rear Spar at Lower Skin Attachment MF Sta 210-235555/655300Type 1,50,000cycles57-53-13 Inboard Flap, Rear Spar Lower, MF Sta 215.67, 227.28, 235.1555/655200Type 1,50,000 Cycles57-53-13 Inboard Flap - Rear Spar Cutouts555/655200Type 1,50,000 Cycles57-53-13 Inboard Main Flap - Rear Spar Cutouts MF Sta 88, 150.3, 212.5555/655300Type 1,50,000 Cycles57-53-14 Inboard Flap, Upper Skin MF Sta 147, 153.5555/655200Type 1,50,000 Cycles57-53-15 Inboard Main Flap, Lower Skin MF Sta 235, 227555/655200Type 2,50,000 Cycles57-53-16 Inboard Flap, Carriage Rib555/655200Type 150,000 Cycles57-53-20 Inboard Flap - Torque Tube143/144ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-22 Inboard Flap, Outbd Carriage (Carriage # 3) Fwd Airload Roller Lug572/672200Type 2,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-3957-53-22 Inboard Flap, Outbd Carriage (Carriage # 3) Fwd Airload Roller Lug572/672300Type 2,50,000 Cycles57-53-22 Inboard Flap, Outbd Carriage (Carriage # 3) Aft Airload Roller Lug572/672ALLType 1,50,000 Cycles57-53-22 Inboard Flap, Outboard Carriage Support (Carriage # 3) Aft Roller Support - Flange572/672ALLType 1,50,000 Cycles57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Aft Roller Support - Upper Attachment Bolt 143/144ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Upper Fitting Flange (Bolt Attachments)143/144ALLType 150,000 Cycles57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Aft Roller Support143/144ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-23 Inboard Main Flap, Inboard Carriage, Carriage Flange143/144200Type 1,50,000 Cycles57-53-23 Inboard Flap, Inboard Carriage (Carriage # 4) Carriage Flanges143/144300Type 1,50,000 Cycles57-53-24 Outboard Flap, Inboard and Outboard Carriages (# 1 & # 2) Airload Roller Bosses (Lugs) 573, 574/673, 674ALLType 1,50,000 Cycles57-53-25 Outboard Flap, Inboard and Outboard Carriages (# 1 & # 2) Aft Bridge Fitting Lugs573, 574/673, 674ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-26 Outboard Flap, Front Spar Upper, WBL 405-471566/666200Type 1,50,000 Cycles57-53-26 Outboard Flap, Front Spar at Upper Skin Attachment MF Sta 405-471566/666300Type 1,50,000 Cycles57-53-26 Outboard Main Flap, Front Spar Lower Chord, WBL 349-405 & 471-506566/666200Type 1,50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-40757 MAINTENANCE PLANNING DATA57-53-26 Outboard Flap, Front Spar at Lower Skin Attachment MF Sta 300-405566/666300Type 1,50,000 Cycles57-53-27 Outboard Main Flap, Rear Spar WBL 405-471 Upper Chord566/666200Type 1,50,000 Cycles57-53-27 Outboard Main Flap, Rear Spar Lower WBL 349-405 & 471-506566/666200Type 1,50,000 Cycles57-53-27 Outboard Flap, Rear Spar at Lower Skin Attachment MF Sta 300-405566/666300Type 2,50,000 Cycles57-53-27 Outboard Flap, Rear Spar at Lower Skin Attachment MF Sta 494-554566/666300Type 2,50,000 Cycles57-53-27 Outboard Flap Rear Spar, Rear Spar Cutouts566/666200Type 1,50,000 Cycles57-53-27 Outboard Main Flap, Rear Spar Cutouts566/666300Type 1,50,000 Cycles57-53-28 Outboard Flap, Upper Skin Splice, Upper Skin, WBL 405.4566/666200Type 1,50,000 Cycles57-53-28 Outboard Flap, Torque Box Upper Skin Splice at WBL 405566/666300Type 1,50,000 Cycles57-53-29 Outboard Flap, Lower Skin WBL 361 & 494566/666200Type 1,50,000 Cycles57-53-30 Outboard Flap, Carriage Support Rib566/666200Type 1,50,000 Cycles57-53-31 Outboard Main Flap, Front Spar Support Fittings566/666200Type 2,50,000 Cycles57-53-31 Outboard Flap Front Spar Support Fittings573, 574/673, 674300Type 2,50,000 Cycles57-53-32 Outboard Flap Rear Spar Support Fittings573, 574/673, 674ALLType 1 (300),Type 2 (200),50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-4157-53-33 Outboard Flap, Carriage # 1 Aft Link Lugs, WBL 493.0574/674200Type 2,50,000 Cycles57-53-33 Outboard Flap, Outboard Carriage (Carriage # 1) Aft Link574/674ALLType 2,50,000 Cycles57-53-34 Outboard Flap, Inboard Carriage (Carriage # 2) Aft Link573/673ALLType 1 (300),Type 2 (200),50,000 Cycles57-53-34 Outboard Flap, Inboard Carriage # 2 Aft Link Lugs, WBL 361.0573/673200Type 2,50,000 Cycles57-53-34 Outboard Flap, Inbd and Outbd Carriages (# 1 & # 2) Aft Link - Lugs573, 574/673, 674300Type 1,50,000 Cycles57-53-34 Outboard Flap, Inbd and Outbd Carriages (# 1 & # 2) Aft Link Attach Bolts573, 574/673, 674ALLType 1 (300),Type 2 (200),50,000 Cycles**AIRWORTHINESS LIMITATIONS – STRUCTURAL INSPECTIONS SSI # DTR CHECK FORM TITLE** **ZONE REF** **AIRPLANE APPLICABILITY TYPE AND THRESHOLD** MAY 2003D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-42757 MAINTENANCE PLANNING DATA**C. AIRWORTHINESS LIMITATIONS – STRUCTURAL SAFE LIFE PARTS**NOTE: Boeing Drawing 161N0006, 757 Main Landing Gear Component Interchangeability List, and 162N0006, 757 Nose Landing Gear ComponentInterchangeability List, identify the 757 landing gear and support structure safe-life (life limited) parts. These drawings are distributed byService Letter 757-SL-32-030.NOTE: Boeing Document D101N801-45, 757 Rolls Royce Engine Mount Safe Life Part Numbers, identifies all 757-300 Rolls Royce Engine safe-life(life limited) parts. This document is distributed by Service Letter 757-SL-71-019.**ITEM LIFE LIMIT** 757 Nose Landing Gear103,000 Landings(1)757 Main Landing Gear103,000 Landings(1)757 Main Landing Gear Support Structure103,000 Landings(1)(1)These values are based on fatigue tests and analysis. They also assume the incorporation of the following Service Bulletins onapplicable airplanes:**SERVICE BULLETIN # EFFECTIVITY** **LINE NUMBER DESCRIPTION LIFE LIMIT (LANDINGS)** **PRIOR TO INCORPORATION**757-32-00131-30, 32-34, 36MLG Downlock SpindlePart # 161N30063,500757-57-00041-33MLG Forward Trunnion Support Bearing HousingPart # 113N106213,700757-57-0016 1-89 & 90-133, 136MLG Rear Trunnion SupportPart # 113N101122,000757-57-00151-82MLG Actuator Yoke FittingPart # 113N103236,000**ITEM LIFE LIMIT** 757-300 Rolls Royce Engine Forward Mount except P/N FW6296880,000 Landings757-300 Rolls Royce Engine Forward Mount P/N FW6296836,000 Landings(2)757-300 Rolls Royce Engine Aft Mount80,000 Landings(2)Rolls Royce Service Bulletin RB.211-71-AG051 replaces thrust bearing housing P/N LK83059 with P/N FW62968, which will be includedin the Group B Parts Mandatory Inspections section of the RB.211-535 Time Limits Manual, 05-20-02.JUL 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-43**D. AIRWORTHINESS LIMITATIONS – SYSTEMS REPORTING UNCONTROLLABLE HIGH** **THRUST FAILURE CONDITIONS**Title 14 Code of Federal Regulations Sections 121.703 and 135.415 state that “each certificate holder shall report any failure,malfunction, or defect in anaircraft, system, component, or powerplant that occurs or is detected at any time if, in its opinion, that failure, malfunction, or defect has endangered ormay endanger the safe operation of an aircraft”. Section 125.409 also requires reporting of failures, malfunctions, or defects. In many cases a reportablefailure or malfunction will be obvious, but there are some failure modes related to uncontrollable high thrust that are reportable but may not be obvious.The following information is provided, as required by FAA Exemption No. 7798 to assist the operators in identifying reportablemalfunctions related touncontrollable high thrust.The FAA has concluded that the loss of capability to control thrust due to a failure of the engine thrust control system may endanger the aircraft. Thisincludes any malfunctions having one or more of the following characteristics:• Auto-acceleration or uncommanded thrust change to higher power• Stuck thrust lever above idle power• Inability to reduce thrustAlthough some of these incidents may not appear to be safety related, documenting the events is important to ensure the presentlevel of safety is maintainedand/or to identify failure conditions that must be corrected.When filing a report of such an event with the FAA, the operator is requested to include in the description of the event, one or more of the following phrases:• “thrust control”• “no response to thrust lever”• “auto-acceleration”• “uncontrolled high thrust”NOV 2007D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-44757 MAINTENANCE PLANNING DATAIn addition, the following information should be included in the report:• Event description• Flight Crew action• Maintenance action• List of affected or removed componentsReports should be submitted to the local representative of the FAA Administrator that handles the appropriate reporting responsibility for § 121.703,125.409, and 135.415. In addition to filing reports with the FAA, it is recommended that a copy be sent to Boeing and to the engine manufacturer.**E. AIRWORTHINESS LIMITATIONS – FUEL SYSTEMS**This section of the Airworthiness Limitations contains an FAA approved program of scheduled inspections and design limitationsfor operators toincorporate into their maintenance program for this type design to meet the new standards and assumptions introduced by § 25.981 and Special FederalAviation Regulation (SFAR) No. 88. SFAR 88 - Fuel Tank System Fault Tolerance Evaluation Requirements and Title 14 Code of Federal Regulations§ 25.981 - Fuel Tank Ignition Prevention require maintenance instructions, and control limitations for certain fuel tank critical design configurations.Paragraph 2(a) of SFAR 88 and paragraph (b) of the new standard introduced by § 25.981 requires certain design approval holdersof Type Certificates(TCs) and Supplemental Type Certificates (STCs) of large transport airplanes to conduct a safety review of the fuel tank systems. The purpose of thesafety review is to identify design features that may result in development of ignition sources in the fuel tank systems. Fuelsystem AirworthinessLimitations (AWLs) are mandatory maintenance actions required to ensure that unsafe conditions identified by the safety reviewdo not occur or are notintroduced into the fuel tank system as a result of configuration changes, repairs, alterations, or deficiencies in the maintenance program throughout theoperational life of the airplane. An AWL may be an Airworthiness Limitation Instruction (ALI) or a Critical Design Configuration Control Limitation (CDCCL).NOV 2007757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-45CDCCLs are a means of identifying certain design configuration features intended to preclude a fuel tank ignition source for the operational life of theairplane. CDCCLs are mandatory and cannot be changed or deleted without the approval of the Seattle FAA ACO that is responsible for the airplanemodel Type Certificate, or applicable regulatory agency. A critical fuel tank ignition source prevention feature may exist inthe fuel system and its relatedinstallation or in systems that, if a failure condition were to develop, could interact with the fuel system in such a way thatan unsafe condition woulddevelop without this limitation. Strict adherence to configuration, methods, techniques, and practices as prescribed is required to ensure compliance withthe CDCCL. Any use of parts, methods, techniques or practices not contained in the applicable CDCCL must be approved by the Seattle FAA ACO that isresponsible for the airplane model Type Certificate, or applicable regulatory agency.ALIs identify inspection tasks related to fuel tank ignition source prevention which must be done to maintain the design levelof safety for the operationallife of the airplane. These ALIs are mandatory and cannot be changed or deleted without the approval of the Seattle FAA ACO, orapplicable regulatoryagency. Strict adherence to methods, techniques and practices as prescribed is required to ensure the ALI is complied with. Any use of methods,techniques or practices not contained in these ALIs must be approved by the Seattle FAA ACO, or applicable regulatory agency.**USE OF ALTERNATE TOOLS**For AWLs which require use of certain tools, use of alternate tools requires prior approval from the Seattle FAA ACO.**EXCEPTIONAL SHORT-TERM EXTENSIONS**Since AWL intervals are based on estimations of the probability of an event, an exceptional short-term extension for each fuelsystem AWL listed in thisdocument may be made without jeopardizing safety. The local regulatory authority (e.g. a Principle Maintenance Inspector) must concur with anyexceptional short-term extensions before they take place using procedures established with the local regulatory authority in the operators’ manuals. The“exceptional short-term extension” process is applicable to AWL intervals. It should not be confused with the operator’s “short-term escalation” program fornormal maintenance tasks described in the operators’ manuals and in the Flight Standards Handbook 8300.10.NOV 2007D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-46757 MAINTENANCE PLANNING DATAThe Seattle FAA ACO has accepted that these exceptional short-term extensions may be granted without consultation with that office:1. The term “exceptional short-term extension” is defined as an increase in a fuel system AWL interval that may be needed to cover an uncontrollable orunexpected situation. All AWLs listed in this section have been approved with an exceptional short-term extension of 30 days.2. Repeated use of extensions, either on the same airplane or on similar airplanes in an operator’s fleet, should not be used asa substitute for goodmanagement practices. Exceptional short-term extensions must not be used for fleet AWL extensions.After a fuel system AWL has experienced an exceptional short-term extension, the AWL interval will revert back to its intervallisted in this document. TheSeattle FAA ACO must approve, prior to its use, any desired extension not explicitly listed above.The exceptional short-term extension listed above applies to airlines that fall under the United States FAA jurisdiction only.Operators who are not underU.S. FAA jurisdiction should obtain interval extension approvals from their local regulatory agency.**REGULATORY AGENCY APPROVAL**Any deviations from the published AWL instructions included in this document require approval from the Seattle FAA ACO. This applies to operatorsunder the United States FAA jurisdiction only and to airplanes registered in the U.S. All other operators should obtain approval from their own localregulatory agency for any deviations from the listed AWL instructions.**AWL REVISION PROCESS**In the event that an AWL is revised, Boeing will prepare a revision to this document that will be approved by the Seattle FAA ACO. This revision will thenbe forwarded to all 757 operators and the Seattle FAA ACO.NOV 2007757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-47**F. PAGE FORMAT: FUEL SYSTEM S AIRWORTHINESS LIMITATIONS** COLUMNEXPLANATIONAWL NumberEach task is given a unique AWL Item Number. The first and second digits are the ATA Chapter Number.TaskALI = Airworthiness Limitation Instruction. These tasks are inspections that should be performed at the listed intervals.CDCCL = Critical Design Configuration Control Limitation.IntervalTask frequencies are specified in terms of a usage parameter such as flight hours, cycles or calendar time.ApplicabilityAirplane model applicability.DescriptionDescription of the task to be performed or critical design configurations aspects that cannot be changed without violating the intent ofthe design.NOV 2007D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-48757 MAINTENANCE PLANNING DATA**G. AIRWORTHINESS LIMITATIONS – FUEL SYSTEM AWLs AWL Number Task Interval Applicability** **Description**28-AWL-01 ALI 10 YrsAll External Wires Over Center Fuel TankConcern: Potential for Wire chafing and arcing to Center Fuel Tank Upper Panel.Perform a detailed inspection of the wire bundles routed over the center fuel tank and under the main deckfloor boards per AMM 28-11-00 to detect damaged clamps, wire chafing, and that the wire bundle is not incontact with surface of the center fuel tank. If discrepancies are found, repair per the Boeing Standard WiringPractices Manual, D6-54446.28-AWL-02 CDCCL N/AAll External Wires Over Center Fuel TankConcern: Potential for Wire chafing and arcing to Center Fuel Tank Upper Panel.If any maintenance is performed in the area under the floor boards and over the center fuel tank, verifythe following:1. Maintain the existing wire bundle routing and clamping.2. Installation of any new wire bundles must be per Boeing Standard Wiring Practices Manual D6-54446.3. All wire bundles over the center fuel tank are inspected per 28-AWL-01.DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-4928-AWL-03 ALI 10 Yrs See DescriptionFuel Quantity Indicating System (FQIS) – Out of Tank Wiring Lightning Shield to Ground TerminationConcern: Potential for Lightning induced voltages on the FQIS wiring to enter the Fuel Tank.Perform the following inspection to ensure the functional integrity of the FQIS wiring shield to groundtermination per Boeing AMM 20-55-54:757-200 Airplanes with BF Goodrich without individually shielded wiring to the densitometer for enhancedlightning protection:Left Main Tank-Hi-Z: The loop resistance shall not exceed 506 milliohms for connector D42220P (nearE3-4 shelf) and the wire bundle number W4024.Left Main Tank-Lo-Z: The loop resistance shall not exceed 282 milliohms for connector D41268P (nearE3-4 shelf) and the wire bundle number W4024.Right Main Tank-Hi-Z: The loop resistance shall not exceed 572 milliohms for connector D42222P(near E3-4 shelf) and the wire bundle number W4026.Right Main Tank-Lo-Z: The loop resistance shall not exceed 326 milliohms for connector D41270P(near E3-4 shelf) and the wire bundle number W4026.Left Center Tank-Hi-Z: The loop resistance shall not exceed 183 milliohms for connector D42224P(near E3-4 shelf) and the wire bundle number W4024.Right Center Tank-Hi-Z: The loop resistance shall not exceed 200 milliohms for connector D42226P(near E3-4 shelf) and the wire bundle number W4026.Left Main Tank Densitometer Overbraid: The loop resistance shall not exceed 48 milliohms near thepressure seal and the wire bundle number W4020.Right Main and Center Tank Densitometer Overbraid: The loop resistance shall not exceed48 milliohms near the pressure seal and the wire bundle number W4022.757-200 Airplanes with BF Goodrich with individually shielded wiring on the densitometer wiring for enhancedlightning protection.Left Main Tank-Hi-Z: The loop resistance shall not exceed 486 milliohms for connector D42220P (nearE3-4 shelf) and the wire bundle number W4024.(Continued on next page)**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-50757 MAINTENANCE PLANNING DATA28-AWL-03,ContinuedSee DescriptionLeft Main Tank-Lo-Z: The loop resistance shall not exceed 280 milliohms for connector D41268P (nearE3-4 shelf) and the wire bundle number W4024.Right Main Tank-Hi-Z: The loop resistance shall not exceed 608 milliohms for connector D42222P(near E3-4 shelf) and the wire bundle number W4026.Right Main Tank-Lo-Z: The loop resistance shall not exceed 336 milliohms for connector D41270P(near E3-4 shelf) and the wire bundle number W4026.Left Center Tank-Hi-Z and Lo-Z: The loop resistance shall not exceed 183 milliohms for connectorD42224P (near E3-4 shelf) and the wire bundle number W4024.Right Center Tank-Hi-Z and Lo-Z: The loop resistance shall not exceed 234 milliohms for connectorD42226P (near E3-4 shelf) and the wire bundle number W4026.Left Main Tank Densitometer Shield: The loop resistance shall not exceed 250 milliohms for connectorD41272P (near E3-4 shelf) and the wire bundle number W4020.Right Main and Center Tank Densitometer Shield: The loop resistance shall not exceed 142 milliohmsfor connector D41276P (near E3-4 shelf) and the wire bundle number W4022.757-300 airplanes with BF Goodrich (All):Left Main Tank-Hi-Z: The loop resistance shall not exceed 600 milliohms for connector D42220P (nearE3-4 shelf) and the wire bundle number W4024.Left Main Tank-Lo-Z: The loop resistance shall not exceed 341 milliohms for connector D41268P (nearE3-4 shelf) and the wire bundle number W4024.Right Main Tank-Hi-Z: The loop resistance shall not exceed 700 milliohms for connector D42222P(near E3-4 shelf) and the wire bundle number W4026.Right Main Tank-Lo-Z: The loop resistance shall not exceed 382 milliohms for connector D41270P(near E3-4 shelf) and the wire bundle number W4026.Left Center Tank-Hi-Z and Lo-Z: The loop resistance shall not exceed 237 milliohms for connectorD42224P (FWD Cargo) and the wire bundle number W4024.Right Center Tank-Hi-Z and Lo-Z: The loop resistance shall not exceed 284 milliohms for connectorD42226P (FWD Cargo) and the wire bundle number W4026.(Continued on next page)**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-5128-AWL-03,ContinuedSee Description Left Main Tank Densitometer: The loop resistance shall not exceed 296 milliohms for connectorD41272P (FWD Cargo) and the wire bundle number W4020.Right Main and Center Tank Densitometer: The loop resistance shall not exceed 164 milliohms forconnector D41276P (FWD Cargo) and the wire bundle number W4022.757-200 airplanes with Honeywell, with 20 gauge HI-Z wire, and without HI-Z disconnect bracket on the HI-Zwire. This would be a delivered airplane configuration, or a configuration after incorporation of ServiceBulletin 757-28-0015, but not with Service Bulletin 757-28-0020 installed.Right Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 154 milliohms forconnector D41620P or D41270P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Tank Hi-Z Shield: The loop resistance shall not exceed 1336 milliohms for connectorD42222P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 100 milliohms for connectorD41196P or D41396P (near the vapor seal) and the wire bundle number W3424 or W3486.Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2814(spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 130 milliohms forconnector D41636P or D41268P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 1186 milliohms for connectorD42220P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 101 milliohms at connector D41192P(near the vapor seal) and the wire bundle number W3342 or W3372.Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2788(spar connector) and the wire bundle number W3326.Left Center Tank Hi-Z Shield: The loop resistance shall not exceed 738 milliohms for connectorD42224P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Right Center Tank Hi-Z Shield: The loop resistance shall not exceed 908 milliohms for connectorD42226P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.(Continued on next page)**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-52757 MAINTENANCE PLANNING DATA28-AWL-03,ContinuedSee Description 757-200 airplanes with Honeywell, with 18 gauge HI-Z wire, without HI-Z disconnect brackets. This would bea delivered airplane configuration or a configurationafter incorporation of Service Bulletin 757-28-0020.Right Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 154 milliohms forconnector D41620P or D41270P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Tank Hi-Z Shield: The loop resistance shall not exceed 630 milliohms for connectorD42222P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Lo-Z Shield: The loop resistance shall not exceed 100 milliohms for connector D41196P orD41396P (near the vapor seal) and the wire bundle number W3424 or W3486.Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2814(spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 130 milliohms forconnector D41636P or D41268P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 522 milliohms for connector D42220P(near the E3-4 shelf) and the wire bundle number W4206 or W4024.Left Main Lo-Z Shield: The loop resistance shall not exceed 101 milliohms for connector D41192P(near the vapor seal) and the wire bundle number W3342 or W3372.Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2788(spar connector) and the wire bundle number W3326.Left Center Tank Hi-Z Shield: The loop resistance shall not exceed 348 milliohms for connectorD42224P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Right Center Tank Hi-Z Shield: The loop resistance shall not exceed 398 milliohms for connectorD42226P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.(Continued on next page)**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-5328-AWL-03,ContinuedSee Description 757-200 airplanes with Honeywell, with 20 gauge wire and, with HI-Z disconnect brackets. This would be adelivered airplane configuration or a configuration without incorporation of any of the following ServiceBulletins: 757-28-020 or 757-28-0015.Right Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 154 milliohms forconnector D41620P or D41270P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Tank Hi-Z Shield: The loop resistance shall not exceed 854 milliohms for connectorD42222P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Tank Hi-Z Shield: The loop resistance shall not exceed 446 milliohms for connectorD41398P or D42334P or D41396P (near the vapor seal) and the wire bundle number W3424 or W3486.Right Main Tank Hi-Z Shield: The loop resistance shall not exceed 74 milliohms for connector D41396J(near vapor seal) or at D2818 (spar connector) and the wire bundle number W3426.Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 100 milliohms for connectorD41196P or D41396P (near vapor seal) and the wire bundle number W3424 or W3486.Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2814(spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 130 milliohms forconnector D41636P or D41268P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 724 milliohms for connector D42220P(near the E3-4 shelf) and the wire bundle number W4206.Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 444 milliohms for connector D42312Por D41194P (near the vapor seal) and the wire bundle number W3424.Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 82 milliohms for connector D40304Por D41392J (near disconnect AW1333) or D2792 (spar connector) and the wire bundle number W3326.Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 101 milliohms for connectorD41192P (near disconnect AW1333) and the wire bundle number W3342 or W3372.Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2788(spar connector) and the wire bundle number W3326.(Continued on next page)**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-54757 MAINTENANCE PLANNING DATA28-AWL-03,ContinuedSee Description Left Center Tank Hi-Z Shield: The loop resistance shall not exceed 776 milliohms for connectorD42224P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Right Center Tank Hi-Z Shield: The loop resistance shall not exceed 906 milliohms for connectorD42226P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.757-200 airplanes with BF Goodrich converted from Honeywell system. These airplanes have disconnectbrackets for some of the tank unit signal wiring. All have 18 gauge HI-Z wiring without disconnects onHI-Z wires.Right Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 162 milliohms forconnector D41620P or D41270P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Tank Hi-Z Shield: The loop resistance shall not exceed 630 milliohms for connectorD42222P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 82 milliohms for connector D41196Por D41396P (near the vapor seal) and the wire bundle number W3424 or W3486.Right Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2814(spar connector) and the wire bundle number W3462.Left Main and Center Tank Lo-Z Shield: The loop resistance shall not exceed 130 milliohms forconnector D41636P or D41268P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Left Main Tank Hi-Z Shield: The loop resistance shall not exceed 522 milliohms for connector D42220P(near the E3-4 shelf) and the wire bundle number W4206 or W4024.Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 102 milliohms for connectorD41192P (near the E3-4 shelf) and the wire bundle number W3342 or W3372.Left Main Tank Lo-Z Shield: The loop resistance shall not exceed 40 milliohms for connector D2788(spar connector) and the wire bundle number W3326.Left Center Tank Hi-Z Shield: The loop resistance shall not exceed 348 milliohms for connectorD42224P (near the E3-4 shelf) and the wire bundle number W4206 or W4024.Right Center Tank Hi-Z Shield: The loop resistance shall not exceed 398 milliohms for connectorD42226P (near the E3-4 shelf) and the wire bundle number W4218 or W4026.(Continued on next page)**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-5528-AWL-03,ContinuedSee Description Left Main Tank Densitometer Overbraid: The loop resistance shall not exceed 48 milliohms nearPressure Seal and the wire bundle number W4020 and overbraid test location GD-LTNG.Right Main and Center Tank Densitometer Overbraid: The loop resistance shall not exceed48 milliohms near Pressure Seal and the wire bundle number W4022 and overbraid test locationGD-LTNG.28-AWL-04 CDCCL N/A All Fuel Quantity Indicating System (FQIS) – Out of Tank Wiring Lightning Shield to Ground TerminationConcern: Potential for Lightning induced voltages on the FQIS wiring to enter the fuel tank.If any maintenance is performed on the FQIS wire bundle in the un-pressurized zone at the spar or the side ofbody pressure seal, verify the following:1. Presence of shielded wiring.2. The shield ground is terminated per the Boeing SWPM 20-10-15.3. The installation is inspected per 28-AWL-03 if the wire bundle shield (or wire bundle if shield is integral)is repaired or replaced.28-AWL-05 CDCCL N/AAll Fuel Quantity Indicating System (FQIS) – Out of Tank Wiring Installation Separation RequirementConcerns: Potential for hot shorts and EMI induced voltages on the FQIS wiring to enter the fuel tank.Routing and installation of any new wiring must use wire types BMS 13-48, BMS 13-60 or BMS 13-58, andnot be within a 2-inch radius of the FQIS wiring. Under single failures of clamps or brackets, a separationgreater than 1⁄2 inch must be maintained from FQIS wiring.28-AWL-06 CDCCL N/AAll Fuel Quantity Indicating System (FQIS) – Repair of Processor UnitConcern: Potential for maintenance error during FQIS processor repair.The FQIS processor is designed to limit the levels of energy, voltage, current, and power allowed within theFQIS circuit to intrinsically safe levels in order to preclude the potential of an ignition source within anyfuel tank.Repair and overhaul of FQIS processor units must beper the Goodrich (V89305) CMM 28-41-68 Revision 3and IPC 28-41-68 Revision 4, or Honeywell (V58960) CMM 28-41-37 Revision 7 and IPC 28-41-37 Revision7, or later revisions of these CMMs/IPCs that have been approved by the Seattle FAA ACO.**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-56757 MAINTENANCE PLANNING DATA28-AWL-07 CDCCL N/AAll Fuel Quantity Indicating System (FQIS) – Repair of In-Tank Hardware (Tank Units, Compensatorsand Densitometers)Concern: Potential for maintenance error during repair of in-tank hardware (tank units, compensators anddensitometers). Arc gaps may develop that could result in an ignition source inside the fuel tank.Repair and overhaul of FQIS tank units, compensators and densitometers must be per the Goodrich(V89305) CMM 28-40-56 Revision 4, CMM 28-40-62 Revision 3, CMM 28-40-59 Revision E, Honeywell(V65507) CMM 28-41-18 Revision 6, CMM 28-41-09 Revision 6, or later revisions of these CMMs that havebeen approved by the Seattle FAA ACO.28-AWL-08 CDCCL N/AAllFuel Quantity Indicating System (FQIS) – Repair or Replacement of In-Tank Wire HarnessConcern: Potential for error during repair or replacement of in-tank wire harness. Arc gaps may develop thatcould result in an ignition source inside the fuel tank.Repair and overhaul of FQIS in-tank wire harness must be per Boeing SWPM 20-14-12.Installation of FQIS in-tank wire harness must be per Boeing AMM 28-41-09.Installation of the FQIS In-tank Wire Harness mustbe per Boeing AMM 28-41-09. Wire slack clearancebetween wires and structure must be greater than 0.125 inches. Verify the following when installing the sparpenetration receptacle:1. The mating surface of the tank wiring harness on the front spar is clean.2. New O-ring(s) are installed.3. The Jamnuts are tightened to a torque as specified in the Boeing AMM Task 28-41-09.4. Sealant is installed per instruction in the Boeing AMM Task 28-41-09.**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-5728-AWL-09 CDCCL N/AAllLightning Protection – Hydraulic Line Fuel Tank PenetrationConcern: Potential for arcing or sparking inside the tank at the interface between the bulkhead fitting and thespar during a lightning strike event.The following design features must be maintained per Boeing AMM 29-11-26 if the bulkhead fitting isremoved and replaced:1. Verify electrical fay surface bond from bulkhead fitting to structure outside the tank is 0.001 ohms(1 milliohm) or less,2. Install fillet seal on the fitting to the tank wall interface outside the tank,3. Install full bodied fillet seal encapsulating the fitting to the tank wall interface inside the tank,4. Verify an electrostatic bonding jumper exists between the structure and the Hydraulic Heat Exchangerinside the tank, and5. Verify electrical bond from structure to the Hydraulic Heat Exchanger inside the tank is 0.0025 ohms(2.5 milliohms) or less if the bonding jumper was removed and replaced.**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-58757 MAINTENANCE PLANNING DATA28-AWL-10 CDCCL N/A 757-200 and-300 airplanes LineNumbers 1042 andon and airplanesthat haveincorporatedService Bulletins757-28A0076 or757-28A0077Lightning Protection – Engine Fuel Feed Line Tank PenetrationConcern: Potential for arcing or sparking inside the tank at the interface between the bulkhead fitting and thespar during a lightning strike event.The following design features must be maintained per Boeing AMM 28-22-07 if the fuel hose end fittings orattached tubing are removed and replaced:1. Verify electrical fay surface bond from the fuel hose end fitting to the aft side of the front spar is0.0005 ohms (0.5 milliohms) or less,2. Install fillet seal around the entire perimeter of the washer and jam nut on the forward side of thefront spar,3. Install full bodied fillet seal around the entire perimeter of the washer, the entire hex and partway on theferrule of the hose assembly end fitting on the aft side of the front spar,4. Install full bodied fillet seal around the entire perimeter of the washer, the entire hex and partway on theferrule of the hose assembly end fitting on the forward side of the dry bay wall,5. Install full bodied fillet seal around the entire perimeter of the washer, the entire perimeter of the jam nut,the exposed part of the hose assembly end fitting, the entire surface of the coupling nut, and extendingonto the tube assembly on the aft side of the dry bay wall (tank side),6. Verify an electrostatic bonding jumper exists between the structure and the first tube mating with the hoseassembly end fitting inside the tank, and7. Verify electrical bond from structure to first tube mating with the hose assembly end fitting inside the tankis 0.010 ohms (10 milliohms) or less if the bonding jumper was removed and replaced.28-AWL-11 CDCCL N/AAll Lightning, Fault Current or Hot Short Protection – Fuel Tank PenetrationsConcern: Potential for arcing or sparking inside the tank at a conductive metal-to-ground structure interfaceas a result of electrical fault currents or lightning strike events due to insufficient bonding within the groundelectrical path.Addition of any new penetrations to the fuel tanks (such as adding a bracket or bulkhead fitting or equipment)or change to the design features of the existing equipment penetrations (such as fuel measuring sticks,sump drain valves, fueling manifold, fuel temperature sensor, and motor operated fuel shutoff valve adaptorplate) requires approval by the Seattle FAA ACO.**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-5928-AWL-12 CDCCL N/AAll AC and DC Electrical Fuel Tank Pump MaintenanceConcern: Potential for maintenance error during pump overhaul. Fuel pump designs contain ignition sourceprevention means (i.e., flame arrestor, thermal fuses, materials, leadwire retention means, etc.) that must bemaintained if pump is overhauled.Repair and overhaul of AC Fuel Pumps must be per Crane (V81982) CMM 28-22-05 Revision 4, CMM 28-22-06 Revision 6, CMM 28-22-08 Revision 4, CMM 28-22-09 Revision 2, or later revisions of these CMMs thathave been approved by the Seattle FAA ACO.Repair and overhaul of DC Fuel Pump must be per Intertechnique (VF0553) CMM 28-20-02 Revision 9, or alater revision of this CMM that has been approved by the Seattle FAA ACO.28-AWL-13 CDCCL N/AAll AC Fuel Pump Fault Current Bonding Strap InstallationConcern: Potential for fault current path through the pump housing to structure inside the tank. Electricalfaults internal to the fuel pump motor impeller are by design routed through the motor impeller assembly tothe bonding straps on the front face of the motor impeller assembly to structure outside the tank. Thebonding straps ensure that fault currents are conducted to structure outside the tank until the circuit breakerand/or GFI has had time to remove power from the pump.The following features must be maintained during pump replacement per Boeing AMM-28-22-03:1. Install two bonding straps between the pump motor impeller end-cap and structure, and2. Verify Motor Impeller bonding resistance to structure is 0.0004 ohms (0.4 milliohms) or less.28-AWL-14 ALI 10 Yrs All 757-200/-300airplanes prior toLine Number 865Center Wing Tank Fueling Shutoff Valve Actuator – Fault Current BondConcern: Potential for arcing or filamentheating inside the center wing fuel tank.Verify electrical bond from the valve body studs protruding through the rear spar to the adjacent structure is0.012 ohms (12 milliohms) or less per Boeing AMM 28-21-02. Accomplish the following per Boeing AMM28-21-02 if the measured resistance is greater than 0.012 ohms (12 milliohms):1. Restore the valve electrical fay surface bond inside the tank to 0.0025 ohms (2.5 milliohms) or less.2. Install a fillet seal around the entire perimeter of the gaskoseal and the valve body inside the tank.Verification of existence or addition of the fillet seal per item “2” above and meeting the bonding resistancerequirement 0.012 ohm (12 milliohms) or less eliminates the repetitive inspection requirement of this AWL.**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-60757 MAINTENANCE PLANNING DATA28-AWL-15 CDCCL N/AAll Center Wing Tank Fueling Shutoff Valve Actuator – Fault Current BondConcern: Potential for arcing or filamentheating inside the center wing fuel tank.The following features must be maintained per Boeing AMM 28-21-02 if the fueling shutoff valve body isremoved and replaced:1. Verify electrical fay surface bond between the valve body to structure inside the tank is 0.0025 ohms(2.5 milliohms) or less,2. Install fillet seal around the entire perimeter of the gaskoseal and the valve body inside the tank, andThe following feature must be maintained per Boeing AMM 28-21-12 if the fueling valve actuator is removedand replaced:1. Install a bonding jumper bonding the valve control unit (actuator) to the adjacent structure and verify theresistance is 0.008 ohms (8 milliohms) or less; applicable to 757-200/-300 airplanes from Line Number865 and on.28-AWL-16 CDCCL N/AAll Fuel Tank Access Doors – Lightning Protection BondConcern: Potential for arcing or sparking inside the tank at the interface between the door and the tankstructure as a result of a direct strike or conducting currents through the wing skin.The following features must be maintained during fuel tank access door installation per Boeing AMMs28-11-01, 28-11-02 and 28-11-03 as applicable:Verify presence of a phenolic strip positioned around the outermost periphery of the door that mates with thewing skin inside the tank.Do a check of the knitted aluminum mesh gasket for serviceability and replace if necessary,Apply anti-corrosion compound (grease or CIC) to both sides of the knitted aluminum mesh gasket, andInstall the prepared knitted aluminum mesh gasket between the outside face of the door and the wing skin toestablish the electrical conductivity between the access door and the wing skin using the Clamp Ring andfasteners torqued to that specified in the applicable AMM.Not applicable to Access Doors 543AB, 543BB, 643AB & 643BB (Surge Tank Access Doors with thePressure Relief Valve and NACA Vent Scoop).**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-6128-AWL-17 CDCCL N/AAll Surge Tank Access Doors (543AB and 643AB) – Lightning Protection BondConcern: Potential for arcing or sparking inside the tank at the interface between the door and the tankstructure as a result of a direct strike or conducting currents through the wing skin.During surge tank access door installation, perform the following actions per Boeing AMM 28-11-03:Verify presence of a phenolic strip positioned around the outermost periphery of the door that mates with thewing skin inside the tank.Maintain the electrical fay surface bond between the pressure relief valve and the door 0.010 ohms(10 milliohms) or less if the valve is removed and re-installed or replaced per Boeing AMM 28-13-04,Do a check of the knitted aluminum mesh gasket for serviceability and replace if necessary,Apply anti-corrosion compound (grease or CIC) to both sides of the knitted aluminum mesh gasket, andInstall the prepared knitted aluminum mesh gasket between the outside face of the door and the wing skin toestablish the electrical conductivity between the access door and the wing skin using the Clamp Ring andfasteners torqued to that specified in the Boeing AMM.28-AWL-18 CDCCL N/AAll Surge Tank Access Doors (543BB and 643BB) – Lightning Protection BondConcern: Potential for arcing or sparking inside the tank at the interface between the door and the tankstructure as a result of a direct strike or conducting currents through the wing skin.During surge tank access door installation, perform the following actions per Boeing AMM 28-11-03:Clean the countersinks on the door,Maintain the electrical fay surface bond between the housing of the vent flame arrestor and the door 0.0025ohms (2.5 milliohms) or less if the housing of the vent flame arrestor is removed and re-installed or replacedper Boeing AMM 28-13-05, andInstall door using the same part number conductive fasteners and torque to that specified in theBoeing AMM.28-AWL-19 CDCCL N/AAll Resetting Tripped Fuel Pump Circuit Breakers or Ground Fault Interrupters (GFIs)Concern: Potential for arcing or sparking inside the tank between fuel pumps and fuel pump housings andoutside the tank between pump wiring and structure in flammable leakage zones.Verify it is safe to reset the Circuit Breaker(s) or GFI(s) by following the applicable troubleshootingprocedures. The fault(s) that resulted in circuit breaker or GFI trip must be isolated and corrected priorto reset.**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-62757 MAINTENANCE PLANNING DATA28-AWL-20 ALI 1 Yr 757 airplanes thathave incorporatedService Bulletins757-28A0081 or757-28A0082.Center Tank Fuel Boost Pump Automatic Shutoff SystemConcern: Dry running the center tank fuel pumps has the potential for single failure ignition sourcesdeveloping at the pump inlet due to either frictional heating or sparking as a result of FOD contacting thepump rotating elements, rotating elements contacting stationary parts, or hot journal bearings due to bearingcontamination or failure.The automatic shutoff system is installed and designed to limit continuous dry running condition to15 seconds.The following test is required in order to protect against latent faults:Functionally check the center tank Fuel Boost Pump Automatic Shutoff System per Boeing AMM 28-22-00.28-AWL-21 ALI 1 Yr 757 airplanes thathave incorporatedService Bulletins757-28A0078 or757-28A0079.Boost Pump Ground Fault Interrupter (GFI)Concern: Potential for pump housing burn-through, either internal or external to the fuel tank, as a result ofmajor arcing due to electrical failure (i.e., damaged electrical connector, stator windings or leadwire tohousing/end cap shorting).The GFI is designed to detect electrical faults and open the circuit prior to pump housing burn-through. Thefollowing maintenance check is required in order to ensure continued functionality of the GFI circuit:Operationally check the GFI of all AC Fuel Tank Boost Pumps per Boeing AMM 28-22-00.28-AWL-22 CDCCL N/A 757 airplanes thathave incorporatedService Bulletin757-28A0085.Fuel Quantity Indicating System (FQIS)**–**Installation of Center Fuel Tank Hot Short Protector (HSP)Concern: Potential for wire to wire hot short voltages on the center tank fuel quantity densitometer wiring toenter the fuel tank.The FQIS HSP is designed to prevent wire to wire external hot short voltages from entering the fuel tankwhere it may cause an ignition. The following features must be maintained during replacement of the HSPper Boeing AMMs 28-41-24 and 28-41-25:1. Verify the bonding straps are installed per AMM task.2. Verify the bonds from HSP to spar web is 0.0025 ohms (2.5 milliohm) or less.3. A new unit must be used.The HSP unit is not repairable.**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-6328-AWL-23 CDCCL N/A 757 airplanes thathave incorporatedSB 757-28A0088Lightning and Fault Current Protection – Motor Operated Valve (MOV) ActuatorConcern: Potential for arcing or sparking inside the fuel tank at a conductive metal-to-ground structureinterface as a result of electrical fault current or lightning events.The following design features must be maintained per Boeing AMM 28-22-01, 28-22-02, 28-22-11,28-22-12, 28-26-01, or 28-26-02 during actuator, index plate, or adapter plate replacement:1. Maintain the following if the Spar Valve, Crossfeed Valve, or Defuel Valve actuator adapter plate isremoved and replaced:a. Verify electrical fay surface bond resistance between the adapter plate and the spar web is0.0005 ohms (0.5 milliohms) or less.b. Install fillet seal around the periphery of the adapter plate and the spar outside the tank.c. Wet install and cap seal the four bolts that attach the adapter plate to the spar inside the tank andfillet seal around the edge of the hole and on the stationary part of the adapter plate inside the tank.d. Install sealed electrical fay surface bond between the serrated mating surfaces of the index plateand the adapter plate. Wet install the index plate screws using same sealant.e. Install sealed electrical fay surface bond between the mating surfaces of the actuator and the indexplate. Wet install the actuator screws using same sealant.f. With the bonding jumper and the electrical connector not installed, verify electrical bondingresistance between the actuator upper housing and the spar web is 0.003 ohms (3.0 milliohms)or less.g. Prior to attachment of the bonding jumper to the actuator, verify electrical bonding resistancebetween the loose end of the bonding jumper and the stiffener is 0.0015 ohms (1.5 milliohms)or less.h. Attach the bonding jumper to the upper housing of the actuator using a sealed electrical fay surfacebond and verify electrical bonding resistance between the actuator housing and the attachedbonding jumper terminal is 0.001 ohms (1 milliohms) or less.2. Maintain the following if the Spar Valve, Crossfeed Valve, or Defuel Valve actuator index plate is removedand replaced:a. Install sealed electrical fay surface bond between the serrated mating surfaces of the index plateand the adapter plate. Wet install the index plate screws using same sealant.b. Install sealed electrical fay surface bond between the mating surfaces of the actuator and the indexplate. Wet install the actuator screws using same sealant.c. With the bonding jumper and the electrical connector not installed, verify electrical bondingresistance between the actuator upper housing and the spar web is 0.004 ohms (4.0 milliohms)or less.(Continued on next page)**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-64757 MAINTENANCE PLANNING DATA28-AWL-23,ContinuedLightning and Fault Current Protection – MOV Actuator (Continued)d. Prior to attachment of the bonding jumper to the actuator, verify electrical bonding resistancebetween the loose end of the bonding jumper and the stiffener is 0.0015 ohms (1.5 milliohms)or less.e. Attach the bonding jumper to the upper housing of the actuator using a sealed electrical fay surfacebond and verify electrical bonding resistance between the actuator housing and the attachedbonding jumper terminal is 0.001 ohms (1 milliohms) or less.3. Maintain the following if the Spar Valve, Crossfeed Valve, or Defuel Valve actuator is removed andreplaced:a. Install sealed electrical fay surface bond between the mating surfaces of the actuator and the indexplate. Wet install the actuator screws using the same sealant.b. With the bonding jumper and the electrical connector not installed, verify electrical bondingresistance between the actuator upper housing and the spar web is 0.004 ohms (4.0 milliohms)or less.c. Prior to attachment of the bonding jumper to the actuator, verify electrical bonding resistancebetween the loose end of the bonding jumper and the stiffener is 0.0015 ohms (1.5 milliohms)or less.d. Attach the bonding jumper to the upper housing of the actuator using a sealed electrical fay surfacebond and verify electrical bonding resistance between the actuator housing and the attachedbonding jumper terminal is 0.001 ohms (1 milliohms) or less.The following design features must be maintained per Boeing AMM 28-25-11 during APU actuatorreplacement:1. Maintain the following if the APU Shutoff Valve actuator is removed and replaced:a. Prior to attachment of the bonding jumper to the actuator, verify electrical bonding resistancebetween the loose end of the bonding jumper and the spar web is 0.004 ohms (4.0 milliohms)or less.b. Attach the bonding jumper to the upper housing of the actuator using a sealed electrical fay surfacebond and verify electrical bonding resistance between the actuator housing and the attachedbonding jumper terminal is 0.001 ohms (1 milliohms) or less.**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-6528-AWL-24 CDCCL N/A 757 airplanes thathave incorporatedSB 757-28A0088Motor Operated Valve (MOV) Actuator – RepairConcern: Potential for arcing or sparking inside the fuel tank at a conductive metal-to-ground structureinterface as a result of lightning or electrical fault current event. An electrical isolator on the actuator outputshaft is intended to disconnect the output shaft electrically from the motor internal electrical circuitry andground path structure.To verify the integrity of the electrical isolation feature, conduct the following bench test per ITT (V73760)CMM 28-20-21:A Dielectric Strength test on the completed actuator assembly shall be performed by applying 3000 VACRMS, 60 Hz for one (1) minute between any mounting foot of the actuator and the output shaft spline. Thereshall be no evidence of disruptive discharge in the form of leakage current in excess of 1.0 milli-amps. The3000V test is a bench test only and must not be performed on the aircraft.28-AWL-25 ALI 6 Yrs 757 airplanes thathave incorporatedService Bulletin757-28A0088Lightning & Fault Current Protection – Motor Operated Valve (MOV) ActuatorConcern: Potential for arcing or sparking inside the fuel tank at a conductive metal-to-ground structureinterface as a result of lightning or electrical fault current event.Perform the following functional check (per BoeingAMM 28-22-11, 28-22-12, and 28-26-01) to ensure theintegrity of the Spar Valve, Crossfeed Valve, and Defuel Valve actuator electrical bonding path:a. With the actuator electrical connector and the bonding jumper disconnected, verify electrical bondingresistance between the connector flange and the spar web is 0.010 ohms (10.0 milliohms) or less.b. Attach the bonding jumper to the upper housing of the actuator using a sealed electrical fay surfacebond and verify electrical bonding resistance between the actuator housing and the attached bondingjumper terminal is 0.001 ohms (1 milliohm) or less.Perform the following functional check (per Boeing AMM 28-25-11) to ensure the integrity of the APU ShutoffValve actuator electrical bonding path:a. With the actuator electrical connector disconnected, verify electrical bonding resistance between theconnector flange and the spar web is 0.010 ohms (10.0 milliohms) or less.**AWL Number Task Interval Applicability Description** DEC 2008D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-66757 MAINTENANCE PLANNING DATA28-AWL-26 ALI 1 Yr Airplanes that haveincorporatedService Bulletin757-28A0105Center Tank Fuel Boost Pump Power Failed On Protection SystemConcern: Dry running the center tank fuel pumps has the potential for single failure ignition sourcesdeveloping at the pump inlet due to either frictional heating or sparking as a result of FOD contacting thepump rotating elements, rotating elements contacting stationary parts, or hot journal bearings due to bearingcontamination or failure.The power failed on protection system is installed and designed in order to protect against a single failure(i.e., wiring faults or a welded fuel pump control relay) keeping power on the pump when the associated fuelpump control switch is positioned to OFF.The following test is required in order to protect against latent faults:Verify continued functionality of the center tank fuel boost pump Power Failed On Protection System perAMM 28- 22-00.**AWL Number Task Interval Applicability Description** DEC 2008757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-67**H. AIRWORTHINESS LIMITATIONS – NITROGEN GENERATION SYSTEM (NGS) ALIs and CDCCLs**The following list of AWLs (ALIs and CDCCLs) contain FAA-approvedscheduled inspections for operators to incorporate into theirmaintenance programfor this type design to meet the requirements for the introduction of the Flammability Reduction Means (FRM) Nitrogen Generation System (NGS). TheFAA operational rule change E8-16084 Final Flammability Rule requires maintenance instructions and control limitations for certain NGS critical designconfigurations. § 25.981(d) also requires CDCCLs to preclude ignition sources inside the fuel tank that may be introduced by the addition of NGS.E8-16084, Final Flammability Rule, Paragraph III(F), Section 7, Identification of Airworthiness Limitations: Paragraph M25.4(a)requires that if FRM is usedto comply with Paragraph M25.1, AWLs must be identified for all maintenance or inspection tasks required to identify failures of components within theFRM that are needed to meet Paragraph M25.1. NGS AWLs are mandatory maintenance actions that ensure that unsafe conditions thatarise due to NGSfailures do not occur or are not introduced into the airplane as a result of configuration changes, repairs, alterations, or deficiencies in the NGSmaintenance program throughout the operational life of the airplane.NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-68757 MAINTENANCE PLANNING DATA**AWL Number Task Interval Applicability Description** 47-AWL-01 CDCCL N/A 757 airplanes thathave incorporatedService Bulletin757-47-0001Lightning Protection – NGS Nitrogen Enriched Air (NEA) Distribution Line Fuel Tank PenetrationConcern: Potential for arcing or sparking at the interface between the bulkhead fitting and the spar during alightning strike event. The following must be maintained if the bulkhead fitting or attached tubing are removedand replaced or reinstalled (refer to Boeing AMM 47-21-05):1. Install the same part number bulkhead fitting.2. Verify electrical fay surface bond between the bulkhead fitting and the front spar structure inside the tankis 0.0005 ohms or less,3. Install full-bodied fillet seal encapsulating the first coupling connecting the tube to the bulkhead fittinginside the tank and that part of the bulkhead fitting inside the tank,4. Verify electrical bond from structure to first tube mating with the bulkhead fitting is 0.010 ohms(10 milliohms) or less.Note: The bulkhead fitting is a special part which has an integral flame arrestor. Any change to this partrequires approval by the Seattle FAA ACO.47-AWL-02 CDCCL N/A 757 airplanes thathave incorporatedService Bulletin757-47-0001Center Fuel Tank Vent System – Auxiliary TanksConcern: The addition of an Auxiliary Fuel Tank System via a Supplemental Type Certificate (STC) mayreduce the effectiveness of the NGS resulting in an increase in flammability exposure of the center tank.The NGS installation is designed to provide the proper level of nitrogen to the center wing tank in order toreduce the fleet wide average flammability exposure to levels equal to that of wing fuel tanks. Auxiliary fueltank installations typically transfer fuel and ullage gases to and from the center wing tank.Any new STC design auxiliary tank system that communicates ullage directly to or from the center wing tankmust not significantly affect the performance of the FRS. All new STC auxiliary tank installations must bereviewed and approved by the Seattle FAA ACO. Refer to Boeing AMM ATA 28 for a description of the FuelSystem and Fuel Venting System.NOV 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-69**AWL Number Task Interval Applicability Description** 47-AWL-03 CDCCL N/A 757 airplanes thathave incorporatedService Bulletin757-47-0001Lightning Protection – NGS NEA Distribution Line Fuel Tank PenetrationConcern: Potential for arcing, sparking or filament heating inside the tank at the interface between thedielectric isolator hose and the NEA tubing during a lightning strike event.The NGS installation is designed to prevent lightning currents from entering the center wing fuel tank byadding a dielectric isolator hose in the forward leading edge fairing area NEA distribution line. The isolatormust be maintained if the dielectric isolator hose or attached tubing are removed and replaced (refer toBoeing AMM 47-21-00).Note: The isolator hose is a special part with dielectric properties for lightning protection. Any change to thispart requires approval by the Seattle FAA ACO.47-AWL-04 ALI 17,300 HRS 757 airplanes thathave incorporatedService Bulletin757-47-0001NGS – NEA Distribution Ducting InspectionConcern: The NEA Distribution System ducting outside the fuel tank may fail, latently allowing NEA to leakwithout reaching the fuel tank, resulting in the fuel tank not reaching required inert levels.Inspect the NEA distribution lines from the ASU to the fuel tank front spar for damage and leaks (refer toBoeing AMM 47-21-00).47-AWL-05 ALI 17,300 HRS 757 airplanes thathave incorporatedService Bulletin757-47-0001NGS – Cross-Vent Check Valve – Operational CheckConcern: The Cross-Vent Check Valve may fail open, latently allowing air to flow through the center tank,diluting the nitrogen rich environment created by the NGS.Operationally check the Cross-Vent Check Valve by accessing the left wing surge tank and verifying thevalve opens and closes (refer to Boeing AMM 47-21-05).47-AWL-06 CDCCL N/A 757 airplanes thathave incorporatedService Bulletin757-47-0001Industry Fleet Average Flammability ExposureConcern: NGS performance is dependent on industry descent times. Industry efforts to reduce descent timemay result in NGS performance that does not meet FAA requirements.Fleet Average flammability exposure for the fuel tanks with flammability reduction of this airplane type mustbe maintained in accordance with 14 CFR Part 25, Appendix M. Boeing will monitor U.S. descent statisticsand, if necessary to maintain compliance, will publish service information. If Boeing publishes such serviceinformation, this CDCCL requires either that operators implement these FAA approved design changes orthat operators implement other design changes or operational procedural changes approved by the SeattleAircraft Certification Office to maintain compliance with 14 CFR Part 25, Appendix M.NOTE: This CDCCL does not require individual operators to monitor descent rates of their fleets. Boeing willmonitor US descent statistics and provide any needed service instructions to operators. To preventincreasing flammability exposure above permissible levels, this CDCCL requires operators to incorporatefuture Boeing published service instructions denoted to maintain compliance with this CDCCL, or otherapproved actions, within the compliance times stated in the service instructions.NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-70757 MAINTENANCE PLANNING DATA**I. CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs)**Maintenance requirements arising from aircraft certification activities are described in FAR 25.1309 and AC 25.1309. Independent of the MSG-3 Analysisprocess, these CMRs are developed as part of the aircraft systems safety analyses required for aircraft certification. CMR Tasks are identified wheneversystem probabilities and failure effects are not expected to fall within an acceptable range without a periodic maintenance requirement.There are two categories of CMRs. The first are those tasks associated with items critical to safety of flight; these "critical" systems must have anexpected probability of failure within the "extremely improbable" range. The second category of CMRs are those tasks associated with items essential tosafety of flight; these "essential" systems must have an expected probability of failure within the "improbable" range.The following notes apply to all CMR Tasks:1. CMRs are a part of the aircraft's certification basis.2. Approval of CMRs and escalation of CMR Task Frequencies are the exclusive responsibility of the Seattle FAA ACO.3. There shall be no short-term escalation of CMRs (except as provided in Advisory Circular AC 25-19 Certification Maintenance Requirements).4. There shall be no reliability program escalation of CMRs (except as provided in Advisory Circular AC 25-19 Certification Maintenance Requirements).5. There shall be no Flight Standards inspector escalation of CMRs (except as provided in Advisory Circular AC 25-19 Certification MaintenanceRequirements).NOV 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-71**J. PAGE FORMAT: CERTIFICATION MAINTENANCE REQUIREMENTS (CMRs)**COLUMNEXPLANATIONMPD ITEM NUMBER Each task in the MPD is identified with a unique number. The first and second digits are the ATA Number. The rest of the numbers denote theMPD Sequence Number.TASKMSG-3 TASK CATEGORIESLUB = LUBRICATIONSVC = SERVICINGVCK = VISUAL CHECKOPC = OPERATIONAL CHECKFNC = FUNCTIONAL CHECKRST = RESTORATIONDIS = DISCARDAny act of consumable replenishment for the purpose of maintaining inherent design capabilities.Any act of consumable replenishment for the purpose of maintaining inherent design capabilities.A visual failure finding task to determine if an item is fulfilling its intended purpose. Does not requirequantitative tolerances.A failure finding task to determine if an item is fulfilling its intended purposes. Does not require quantitativetolerances.A quantitative check to determine if one or more functions of an item performs within specified limits. This isa potential failure finding task.Reworking, replacement of parts or cleaning necessary to return an item to a specific standard.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, theinterval listed underneath is the repeat interval.ZONEAirplane Zone Number (see Zone Diagrams, MPD Appendix A) where task is performed.ACCESSAccess Panel/Door Number (see Access Panel/Door illustrations, MPD Appendix A) required to be opened to perform the task.NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-72757 MAINTENANCE PLANNING DATAAPPLICABILITYAPL ENGApplicable Airplane Model and Engine. "Note" refers to an explanation under the task description.**APL**ALL = All 757 Airplanes300 = 757-300 AirplanesNOTE = Airplane Applicability Note**ENGINE**ALL = All 757 Engines535 = RR RB211-535C, 535E4535C = RR RB211-535C2000 = Pratt & Whitney PW 2037, PW 2040 & PW2043 EnginesNOTE = Engine Applicability NoteTASK DESCRIPTION Description of the task to be performed.COLUMNEXPLANATIONMAY 2002757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-73**K. CERTIFICATION MAINTENANCE REQUIREMENTS TASKS MPD** **ITEM NUMBER TASK** **CMR INTERVAL ZONE ACCESS** **APPLICABILITY 757** **CERTIFICATION MAINTENANCE REQUIREMENTS APL ENG TASK DESCRIPTION** 26-010-03 OPC 3000 FH 2113133141511313AL822300 2000 Operationally Check Cargo Fire Extinguishing Firing Circuit Integrity and CargoCompartment Isolation (Recirc and Cargo Heating Fans Off, OEV open In Air-mode).26-010-04 OPC 7500 FH 2113133141511313AL822300 535 Operationally Check Cargo Fire Extinguishing Firing Circuit Integrity and CargoCompartment Isolation (Recirc and Cargo Heating Fans Off, OEV open In Air-mode).26-010-05 OPC 7500 FH 211212300 2000 Operationally Check the Smoke Idle Engine Mode with Cargo Fire Armed, Single PackOperation and With Cowl Anti-Ice On and verify High Stage Bleed Air On with Cargo FireArmed.26-015-00 OPC 48 HRSNOTE212ALL ALL Operationally Check the Automatic Fire/Overheat Logic/Test System (AFOLTS) WithEng/APU/Cargo Test Switch (if not checked by crew).Interval Note: Task should not exceed 48 elapsed clock-hours.27-029-01 FNC 6000 FH 212324335345119BL197KL198PR335DB345DBNOTEALL ALL Functionally Check internal leakage of Elevator and Rudder Power Control Actuators(Left, Center, Right) including Monitoring System.Access Note: The following access panels require opening to accomplish this task:434AL and 444AL for the RR Engines and 435 AL and 445 AL for the P&W engines.27-036-00 OPC 600 FH 211ALL ALL Operationally Check the Stall Warning Systems and Auto Slats.27-063-00 OPC 2000 FHNOTE212ALL ALL Operationally Check TE Flap/Slat Alternate (Electric) Drive System.Interval Note: The MSG-3 Frequency of 1C was developed for the original MRB Report.28-41-00-5ADELETEDFNC 4000 FH 212531541542631641642Perform Comparison Check of each channel of the Fuel Quantity Indicating System(FQIS) using Measuring Sticks.(Main Fuel Tanks should contain less than 10,000 LBS each.)(1): SB 757-28A7. Task is applicable to airplanes prior to Line Number 34 which havenot incorporated SB.NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-74757 MAINTENANCE PLANNING DATA29-004-00 FNC 6000 FH 212324335345197KL198PRNOTEALL ALL Functionally Check Gross Internal Leakage of Each Hydraulic System (Left, Center,Right).SB 29-0026. The CMR Classification can be terminated and frequency increasedto 12,000 HRS (task remains an MRB item) provided the following conditionsare satisfied:1. Incorporation of SB 757-29-26 On A/Ps Prior to Line Number 139. Line Numbers 139and on incorporate equivalent.2. Use of BMS 3-11 Hydraulic Fluid Only.Access Note: The following access panels require opening to accomplish this task:434AL and 444AL for the RR engines and 435AL and 445AL for the P&W engines.29-007-00 OPC 12000 FHNOTE143212119BL732ALL ALL Check operation of Hydraulic Power Transfer Unit (PTU) and PTU Control Valve.(Audibly check PTU for Smooth Operation. Cycle flaps to verify Flap/Slat Movement.)Interval Note: MSG-3 Frequency of 1C applies and may be adjusted as any MRB itemuntil the 12000 Hour CMR Developed Frequency is reached.29-013-00 OPC 6000 FH 144198212198MR742ALL ALL Operationally Check Auto and Manual RAT Deployment Systems, RAT Hydraulic Pumpand Drive System.29-017-01 VCK 600 FH 143 732 NOTE ALL Inspect position of Hydraulic Power Transfer Unit (PTU) Case Drain Filter DifferentialPressure Indicator.Airplane Note: SB 757-29-0014. Task applicable to Line Numbers 1 through 30 and 32which have not incorporated this SB.29-018-01 VCK 600 FH 444 444AL ALL ALL Inspect Hydraulic System R EDP Pressure Filter Differential Pressure IndicatorFor Position.29-019-01 OPC 6000 FH 212 ALL ALL Operationally Check Hydraulic Pressure on EICAS Maintenance Page using EngineDriven Pumps (EDP). (This also checks that the EDP Check Valve will open.)31-004-00 OPC 100 FH 212 ALL ALL Operationally check by performing a readout of all EICAS Maintenance Messages bypressing the ECS/MSG Display Select Switch (if not checked by crew).31-006-01 OPC 10800 FH 211 ALL ALL Operationally Check (including L-R switching) of the Right EICAS Computer (if notchecked by crew).**MPD ITEM** **NUMBER TASK CMR** **INTERVAL ZONE ACCESS APPLICABILITY** **757 CERTIFICATION MAINTENANCE REQUIREMENTS** **APL ENG TASK DESCRIPTION**NOV 2010757 MAINTENANCE PLANNING DATAD622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-7552-033-00 FNC 3000 FH 211212NOTE ALL Functionally Check the Locking and Unlocking Latch Bolt Mechanism of the Flight DeckDoor Decompression Panel.Airplane Note: Applicable to Passenger Airplanes L/N 1022 and on.77-008-00 OPC 400 FH 212 ALL 2000 Operationally Check Standby Engine Indicator by actuating Test Switch (if not checkedby crew).78-024-00 OPC 5000 FHNOTE211212411421435AL445AL200 2000 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Auto Restow.Interval Note: If task is performed in conjunction with 78-025-00 the interval is 3000 FH.78-024-00 OPC 5000 FHNOTE211212411421435AL445AL300 2000 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Auto Restow.Interval Note: If task is performed in conjunction with 78-025-00 the Interval Is 3000 FH.78-025-00 OPC 1000 FHNOTE211212411421435AL445AL200 2000 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Sync-locks.Interval Note: If task is performed in conjunction with 78-024-00 the interval is 3000 FH.78-025-00 OPC 1000 FHNOTE211212411421435AL445AL300 2000 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Sync-locks.Interval Note: If task is performed in conjunction with 78-024-00 the interval is 3000 FH.73-110-01 OPC 4000 FH 411421414AR424ARALL 535C Operationally Check by verifying proper operation of the Fuel Flow Governor IdleReset Solenoid.77-110-00 OPC 400 FH 212 ALL 535 Operationally Check Standby Engine Indicator by actuating Test Switch (if not checkedby crew).78-131-00 OPC 1200 FH 415416425426300 535 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Locking Actuators.**MPD ITEM** **NUMBER TASK CMR** **INTERVAL ZONE ACCESS APPLICABILITY** **757 CERTIFICATION MAINTENANCE REQUIREMENTS** **APL ENG TASK DESCRIPTION**NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-76757 MAINTENANCE PLANNING DATA78-133-00 OPC 6000 FH 210415416425426415FL415KL434AL425FL425KL444AL300 535 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Auto Restow System.78-134-00 OPC 1200 FH 415416425426300 535 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Crossover Shaft.78-135-01 OPC 1200 FH 415416425426300 535 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Sync-Locks.78-136-00 OPC 6000 FH 415416425426300 535 Operationally Check the Engine 1 and Engine 2 Thrust Reverser Indication System.**MPD ITEM** **NUMBER TASK CMR** **INTERVAL ZONE ACCESS APPLICABILITY** **757 CERTIFICATION MAINTENANCE REQUIREMENTS** **APL ENG TASK DESCRIPTION**NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-77757 MAINTENANCE PLANNING DATA**L. JAA UNIQUE REQUIREMENTS INTRODUCTION** The scheduled maintenance requirements described in this subsection result from Model 757-300 airplane certification activitieswith the Joint AviationAuthorities (JAA). Accordingly, these JAA Airworthiness Limitations and Certification Maintenance Requirements actions are mandatory for the 757-300.The complete JAA requirements include all of the FAA requirements plus the JAA unique requirements of this subsection.**STRUCTURAL SAFE LIFE LIMITS**Boeing Drawing 161N0006, 757 Main Landing Gear Component Interchangeability List and 162N0006, 757 Nose Landing Gear ComponentInterchangeability List, identify the 757 landing gear and support structure safe-life (life limited) parts. Boeing Document D101N801-45, 757 Rolls RoyceEngine Mount Safe Life Part Numbers, identifies all 757-300 Rolls Royce Engine safe-life (life limited) parts. The Drawings and Document noted aredistributed by Service Letters 757-SL-32-030 and 757-SL-71-019.**ITEM LIFE LIMIT** 757-300 Nose Landing Gear62,000 Landings757-300 Main Landing Gear62,000 Landings757-300 Main Landing Gear Support Structure62,000 Landings757-300 Rolls Royce Engine Forward Mount except P/N FW6296850,000 Landings757-300 Rolls Royce Engine Forward Mount P/N FW6296836,000 Landings(1)757-300 Rolls Royce Engine Aft Mount50,000 Landings(1)Rolls Royce Service Bulletin RB.211-71-AG051 replaces thrust bearing housing P/N LK83059 with P/N FW62968, which will be includedin the Group B Parts Mandatory Inspections section of the RB.211-535 Time Limits Manual, 05-20-02.NOV 2010D622N001-9BOEING PROPRIETARY - Copyright (c) - Unpublished Work - See title page for details Page 9.0-78757 MAINTENANCE PLANNING DATATHIS PAGE INTENTIONALLY LEFT BLANKBLANK