Q3 & Q4 2015-DHL B757 With PW 2000 Changes

European Air Transport Leipzig
B757 200 PCF Familiarization Information
Source:
Precision Conversions LLC Anrca International LLC
Vision Safe Corporation Aviation Partners Boeing
Innovative Solutions & Support AIM Aviation Inc.
Rolls Royce PLC Telair SLC
Pratt & Whitney Rockwell Collins
UNCONTROLLED COPY *** UNCONTROLLED COPY *** UNCONTROLLED COPY

Name
HR Training
of the presenter
1 HR Training | B757 200 PCF Familiarization Information | Leipzig | Rev.: 01 October 2015
CONTENTS
0. Airplane Changes Overview 9. ATA 27 Flight Controls
1. ATA 21 Air Conditioning 10. ATA 28 Fuel
2. ATA 25 Flight Deck Wall 11. ATA 31 Indication and Recording systems
3. ATA 25 Cargo Barrier 12. ATA 38 Water and Waste
4. ATA 25 Lavatory 13. ATA 52 Doors
5. ATA 25 Galley 14. ATA 56 Windows
6. ATA 25 Cargo Compartment 15. ATA 57 Wings
7. ATA 25 Cargo Handling System 16. ATA 70 Engines
8. ATA 26 Fire Protection

0) AIRPLANE CHANGE OVERVIEW
NEW LAVATORY WINGLETS
INSTALLED RIGHT DOOR (COMING WITH A/C #3)
DELETED
EMERGENCY VISION
ASSURANCE SYSTEM
9G RIGID CARGO PASSENGER OVERWING EMERGENCY EXITS
BARRIER ADDED DOORS DEACTIVATED (IF INSTALLED)
DEACTIVATED
PASSENGER PASSENGER
WINDOWS DOORS
PLUGGED DELETED
MAIN DECK CARGO

INTIGRATED DOOR ADDED
STANDBY FRAMES MODIFIED
UNIT FOR CARGO CLEARANCE
NEW CREW
FLAT PANEL ENTRY DOOR
DISPLAY SYSTEM ANCRA CARGO
LOADING SYSTEM
FLIGHT DECK DOOR AND

PORTION OF WALL REMOVED

Boeing 757-200 PCF Manual Supplements
Various B757-200PCF Precision PtoF Supplements PC-0118-06 Supplemental Maintenance Manual Rev. M: 24.11.2014
PC-0118-06 Supplemental Maintenance Manual TR40 Rev. 40: 04.09.2015
PC-0118-04 Supplemental Illustrated Parts Catalog Rev. M: 29.12.2014
PC-0118-04 Supplemental Illustrated Parts Catalog TR 33 Rev. 33: 04.09.2015
PC-0118-11 Supplemental Structural Repair Manual Rev. 16: 15.10.2014
PC-0118-11 Supplemental Structural Repair Manual TR 20 Rev. 20: 04.09.2015
Various MSN 30046 Aviation Partners Boeing Blended Winglet Aircraft Maintenance Manual Part I Rev. H: Oct 2010
Program Aircraft Maintenance Manual Part II Rev. H: Oct 2010
Supplement 757-200 Structural Repair Manual Rev. July 2012
Supplement to Non Destructive Test Manual Rev. C: Nov 2012
Supplement to Fault Isolation Manual Rev. B: Oct 2008
Supplement Aircraft Illustrated Parts Catalog Rev. N: Sep 2011
Supplement Wiring Diagram Manual Rev. E: Mar 2014
Fuel Quantity Measuring Stick Data Stick 4 & 5 (KG&KG) Rev. IR: 24.01.2006
Fuel Quantity Measuring Stick Data Stick 2 & 3 (KG&KG Rev. IR: 24.01.2006
Aviation Partners Winglets related CMMs
Stand 01. October 2015

23-12-00 B757-200PCF Rockwell Collins VHF Transceiver Wiring Diagram 992-7914 Rev. G: 17.04.2013
23-22-00 B757-200PCF ARCAS Maintenance Manual Supplement TBA

TBA TBA
25-31-01 B757-200PCF B757 Cargo Floor Modification Aircraft Manual Supplement MMS/748-012 Rev. 1: 28.07.2015
25-40-00 B757-200PCF AIM Aviation INC. Lavatory AIM Maintenance Manual AA14485-1 Rev. 3: 05.05.2008
AIM Illustrated Parts Catalog AA14485-1 Rev. 3: 05.05.2008
AIM Lavatory related CMMs
25-50-00 B757-200PCF Sliding Carpet FWD Cargo Compartment Telair SLC Manual B757-200 FWD Rev. 15: 20.11.2014
25-50-01 B757-200PCF Sliding Carpet AFT Cargo Compartment Telair SLC Manual B757-200 FWD Rev. 16: 20.11.2014
25-56-00 B757-200PCF ANCRA Cargo Loading System 83680-13 ANCRA B757-200 Cargo Handling System 25-51-10 Part I Rev. 1: 04.07.2015
ANCRA B757-200 Cargo Handling System 25-51-10 Part I Rev. 1: 04.07.2015

25-60-00 B757-200PCF Installation of Emergency Vision Assurance (EVAS) Precision Engineering Authorisation EA 15-1032 Rev. IR: 04.06.2015
28-20-00 TBA TDG Universal Fault Interrupter UFI TDG 20-3200-0001, AMM Supplement Rev. H: 27.05.2015
TDG 20-3200-0006, Illustrated Hardware Diagram Rev. A: 01.03.2007
TDG 20-3200-0007, Troubleshooting + Fault Isolation Rev. A: 06.11.2007
TDG 20-3200-0005, WDM Supplement Rev. D: 28.06.2010
31-35-03 B757-200PCF WQAR Installed on B757 Series Aircrafts TBA TBA
34-22-09 B757-200PCF Flat Panel Display System AMM Flat Panel Display System Rev. IR: 01.06.2012
34-24-00 B757-200PCF Integrated Standby Unit Operation and Installation Manual for ISU Rev. 11: 09.07.2015
46-20-00 B757-200PCF Portable Electronic Flight Bag (EFB) Mounting and TBA TBA
Power Supply System TBA TBA
56-21-00 B757-200PCF Lightweight Window Plug Installation Lightweight Window Plug Installation LAP2006 Rev. B: 18.01.2005

1) ATA 21 AIR CONDITIONING
Sidewall air distribution system deleted
Main overhead distribution duct modified
Two of four rise ducts deleted
Relocation of flight deck air distribution riser
Right recirculation system deactivated
Portion of lavatory/galley vent system deleted
Mix manifold retained
Shut-off system added

Riser Ducts
DELETED RIGHT
RISER DUCT
FWD ZONE DUCT:

(RELOCATED FROM DELETED LEFT RISER DUCT)
1) AIR TEMPERATURE SENSOR

2) TEMPERATURE BULB
3) OVERHEAT SWITCH
FWD ZONE RIGHT

RISER DUCT
AFT ZONE LEFT

RISER DUCT
UP
AFT ZONE DUCT
1) AIR TEMPERATURE SENSOR

CAPPED PASSENGER 2) TEMPERATURE BULB
SIDEWALL AIR OUTLETS 3) OVERHEAT SWITCH
DELETED LEFT
RISER DUCT

Flight deck air distribution riser between BS 297 and BS 310 relocated to accommodate new crew
entry door.
S 3L SUPPORT BRACKET
REDUCER
OEM DUCT
P 11 PANEL
VIEW
LOOKING FWD
OUTBOARD
FLEX HOSE
(3 DIA)
SLEEVE
OEM DUCT
STA 302.5
DOOR JAMB, FWD

Overhead duct


Riser Shutoff Valves

Air Distribution Schematic
LAV
FLGHT DECK
MAIN DECK MAIN DECK
TO FLIGHT DECK
CONDITION AIR
DISTRIBUTION
AIR CONDITIONING MIX BAY
RISER SHUTOFF VALVES
FWD LOWER DECK CARGO TRIM AIR ALTERNATE AIR AFT LOWER DECK CARGO
MODULATING SHUTOFF VALVE
VALVES
ALTERNATE MAIN E/E
MIX
EQUIPMENT COOLING
MANIFOLD
FROM R PACK
FROM
TRIM AIR PRESS L PACK
REGULATING VALVE
FROM L RECIRC SYS

ZONE TRIM AIR
CONDITIONED AIR AIR GROUND

CONNECTOR
COLD AIR
HOT AIR
ADDED FOR B757 - 200 PCF CARGO CONVERSION
Alternate Air shutoff valve (electrically actuated butterfly valve):

System is added to include an alternate source of air in the event of main cargo compartment fire.

Relocated from the stowage bins (BS 517) to Relocated from BS 1177 to BS 1170:
the ceiling panels (BS 505):
ZONE TEMP SENSOR SENSOR

MODULE FAN MODULE FAN
ZONE TEMP SENSOR ZONE TEMP SENSOR
ZONE TEMP ZONE TEMP

BULB (REF) BULB (REF)
CABIN AIR CABIN AIR

Equipment Cooling Simplified Flow Diagram
FLGHT DECK
FWD LAV FWD MAIN DECK AFT MAIN DECK

MAIN OVERHEAD
PANELS PANELS PURGE LINE
EQUIP COOLING
AUXILIARY FAN
FWD EQUIP COOLING
SUPPLY SMOKE SENSORS
CENTER AISLE 1 AND 2
STAND
PURGE LINE E/E

EQPT
RACK
FWD EQPT SUPPLY
LOW FLOW SENSOR
FROM MIX
MANIFOLD CLEAN
WEATHER (ALTERNATE AIR) EQUIPMENT AIR
RADAR COOLING
FANS
E/E
EQUIPMENT
FWD EQPT EXHAUST
LOW FLOW SENSOR
RACK E/E COMPARTMENT
AFT EQPT
VENT FANS
EQPT COOLING
SMOKE SENSOR
TO MIX MANIFOLD
A/C MIX BAY
RECIRCULATION OVERBOARD
OUTFLOW
FAN EXHAUST
VALVE
VALVE
MODIFIED FOR B757 - 200 PCF CARGO CONVERSION
Overboard exhaust valve controls have been modified to command the valve to open when suppressing a main
cargo compartment fire.

Flow Control Valve
STA 860
STA 839
STA 820
2x FLEX HOSE
SHUTOFF VALVE
OUTBD
FWD
MIX
MANIFOLD OEM FLOOR BEAM
CLAMP
The pack flow control system has been modified to prevent the flow control and shutoff valves from switching to high flow mode,
when on a/c pack is shut off during main cargo compartment fire suppression.

2) ATA 25 FLIGHT DECK WALL
Coming with A/C #4:

Bin and stowage for trolleys in front of the partition liner.

2) ATA 25 FLIGHT DECK WALL
The passenger configuration flight deck wall and
the flight deck door will be removed.
The existing crew and observer seats in the

flight compartment will be retained.
Observer Seat in front of the partition liner is not

installed.
ELT will be installed below the emergency torch.

3)ATA 25 CARGO BARRIER
To protect the crew if there is an emergency

landing, a rigid 9g cargo barrier will be installed.

3)ATA 25 CARGO BARRIER
The rigid cargo barrier will have a sliding
doorway for entry into the main deck cargo
compartment.

4) ATA 25 LAVATORY
The lavatory is installed on the RH side.
Re-circulating
External servicing
Potable Water Dispenser (coming with A/C #4)
Lavatory with Potable Water Dispenser

4) ATA 25 LAVATORY
The lavatory will retain external servicing
capabilities on right hand side of the aircraft.
Lavatory Service Panel

(Relocated RHS)

5) ATA 25 GALLEY
Crew Galley
A crew galley will be added in the flight

compartment, aft and outboard of the copilot.
Hot/cold liquid container
Flight compartment, aft and outboard of

copilot

6) ATA 25 CARGO COMPARTMENT
A Class E cargo compartment will be installed in
the airplane main cabin area.
9g cargo barrier acts as smoke barrier
Accessible in flight
Ceiling raised for 82 inch ULDs
Transverse pallet capability
Floor panels sealed and non-slip
Cargo handling system for 15 ULDS

6) ATA 25 CARGO COMPARTMENT
Cargo Compartment (FLA)

7) ATA 25 CARGO HANDLING SYSTEM
Cargo Handling System
An STC-approved cargo handling system

will be installed in the main deck cargo
compartment to load/unload and restrain
ULDs.
The Cargo Handling System is manually

operated

Cargo handling system Basic
CHS 83680-13 accepts ULD arrangements

given below (refer to ANCRA CMM)
15 ULDs 88 x 125 inches (223.5 x 317.5 cm)

or
13 ULDs 96 x 125 inches (243.8 x 317.5 cm)

Cargo handling system Option 1
CHS 83680-14 accepts ULD arrangements give

below (refer to ANCRA CMM)
15 ULDs 88 x 125 inches (223.5 x 317.5 cm)

or
13 ULDs 88 x 108 inches (223.5 x 274.3 cm)

Increased Height Rails

Aft Back Stop Door Sill Protector

Crosstrack (Part Number: 83760) Position 15 Container Guide

Crosstrack (Part Number: 83731-11) Roller Rail (Part Number: 81384)

8) ATA 26 FIRE PROTECTION
A smoke detection system that meets the
one-minute detection requirements will be
installed to monitor the main deck.
The system will alert the flight crew on the

flight deck by both aural and visual alerts.
This system will provide detection and

alerting only; no fire-extinguishing agents will
be provided for main deck fire suppression.
CARGO BARRIER
CARGOBARRIER
LAVATORY
LAVATORY
A
A
CREW
CREW ENTRY
ENTRY DOOR MAIN DECK
MAINCARGO
DECK DOOR DOOR #2
DOOR #2 DDOOR #3
DOOR #3
INOPERATIVE
BS
( DOOR
317.5) BS
( 550)DOOR
CARGO INOPERATIVE
INOPERATIVE INOPERATIVE
BS 1335
BS 550 BS 710
BS 317.5 BS
( 710) BS
( 1335)
SLIDING DOOR
SLIDINGDOOR

Smoke Detector
The Cargo Fire Maintenance Units (CFMU) are
installed in the E/E bay
CFMUs monitor main cargo smoke detectors
CFMUs connected to CFFU in flight

compartment

The flight deck unit will not only provide
smoke detection system status.
As a part of the Class E firefighting

procedures, the flight crew will shut off the
airflow to the cargo compartment by pushing
a switch on this panel.
Annunciator lights will indicate if the shutoff

valves are open or closed.

8) ATA 26 EVAS
EVAS (Emergency Vision Assurance System) EVAS RIGHT

INSTALLATION ZONE
For Major Inflight Cockpit Smoke events
EVAS LEFT
INSTALLATION ZONE

8) ATA 26 EVAS

8) ATA 26 EVAS
The deployment location is critical to

the operation and functionality of EVAS

9) ATA 27 FLIGHT CONTROLS
The captains elevator control cable system
will be modified to allow for increased main
cargo compartment ceiling height.
Two sets of aft pulleys will be modified to

allow for ceiling and cargo clearance.

9) ATA 27 FLIGHT CONTROLS
Pre-mod Pulleys Post-mod Pulleys

10) ATA 28 FUEL
Universal Fault Interrupter (UFI), designed to
protect center tank fuel override pumps from:
1. Electrical faults (line-to-ground, line-to-

line,open phases, out-of-range conditions)
2. Extended operation with uncovered inlet
3. Un-commanded operation (via control of

redundant control relays)
The UFI device detects the following electrical

and operational fault conditions:
Low Fuel Auto-Shutoff

Relay Failure
Undercurrent
Differential Current
Over Current

10) ATA 28 FUEL

11) ATA 31 INDICATION/RECORDING SYSTEMS
Cargo fire flight Aural warning
deck unit panel
Crew warning
control panel

MAIN VALVE VALVE

FIRE CLOSED CLOSED
FWD AFT
FAULT
MAIN AIRFLOW
VALVES
T
CARGO FIRE Aural Warning Panel
E
S CLOSE
T
CARGO
Cargo fire flight deck unit

Crew warning control panel

(Post-mod)
Crew warning control panel

(Pre-mod)

The flight data recorder has been relocated
Moved from the aft passenger cabin ceiling

Installed below the main cargo compartment floor, aft of the lower aft bulk cargo compartment;
Access is through the aft lower cargo compartment
Maintenance Practices
Maintenance procedures have not changed

See OEM Maintenance Manual 31-31-00
MAIN DECK FLOOR

SECTION 46
E6 RACK
AFT, LOWER CARGO
STA 1640 STA 1200
CARGO DOOR
VOICE AND FLIGHT DATA RECORDER RACK

11) ATA 31 COCKPIT FLAT PANEL DISPLAY
The B757 PCF is equipped with an Innovative

Solutions & Support Flat Panel Display
System.
The FPDS consists of:
Primary Flight Displays (PFD)
Navigation Displays (ND)

Navigation Display and Primary Flight Display

FPDS Component Locations
DCP DCP
E2 - RACK

FPDS Component Locations

ISU Connector location
Integrated Standby Unit (ISU)

11) ATA 31 FMCS
B757/767 PEGASUS 2009 Flight
Management Computer System is installed in
the B757 PCF
Control Display Unit

12) ATA 38 WATER AND WASTE
The water/waste systems will be modified to
accommodate deletion of existing lavatories and
galleys and installation of a new lavatory.
Modification will include the following:
Retain forward and aft drain masts
Delete existing lavatory and galley waste

systems
Install waste system for new lavatory.
Delete existing water supply
Deactivate internal plumbing components of

unused service panels and seal penetrations
Install main deck floor drain

Aft Cabin Waste Water Drain
Aft Cabin Waste Water Drain

The existing fresh water storage and delivery
system components will be removed.
A potable water system for the lavatory will

be added.
The potable water tank will be filled from an

exterior service panel and drained through
the sink faucet.
Potable Water Service Panel

13) ATA 52 DOORS CREW ENTRY DOOR
Crew Entry Door
STA 328.90
AFT EDGE
STA 306.11 OF DOOR SKIN
FWD EDGE
OF DOOR SKIN

Only one crew entry door.
Opens inward to fully open position
Moves under its own weight
Stops against the cargo barrier
Weighs approximately 75 lbs

NO 6 DOOR STOP
P-SEAL INTERIOR LINER SUPPORT

DOOR SEAL
SEAL RETAINER
UPPER CONTROL ROD
NO 1 DOOR STOP
NO 1 DOOR STOP
UPPER LATCH ROD
INNER HANDLE
NO 1 LATCH CAM NO 1 LATCH CAM
NO 3 LATCH CAM INNER HANDLE
IN OPEN POSITION
NO 3 DOOR STOP
LOWER CONTROL ROD

SWING ASSY
NO 2 LATCH CAM
NO 3 LATCH CAM
NO 4 LATCH CAM
NO 5 DOOR STOP
INTERIOR LINER NO 10 DOOR STOP
SCREWS
INTERIOR LINER SUPPORT
NO 10 DOOR STOP

Swing Hinge
REMOVE THE 2 BOLTS SECURING THE AFT HINGE TO THE
SWING HINGE ASSEMBLY. THE SWEING HINGE SHALL
REMAIN ATTACHED TO THE DOOR FRAME HINGE.
NOTE:
SPACERS SUPPORT THE DOOR ON THE AFT
HINGE FRAME ASSEMBLY, THESE WILL FALL
OUT ONCE THE SECUREING BOLT IS REMOVED.

CREW ENTRY DOOR FRAME
NO 1 LATCH CAM
FWD JAMB FRAME
LATCH ROLLER

13) ATA 52 DOORS
Door 2 - Deactivation
No. 1 entry door, right, deleted

13)ATA 52 DOORS L-4 & R-4 DOOR
No. 4 entry doors deleted

13) ATA 52 DOORS MAIN DECK CARGO DOOR
The Main Cargo Door is controlled from a
door control panel located on the partition
forward and adjacent to the L1 crew entry
door.
Mounted to the back of the first observer

seat
MAIN CARGO DOOR

CONTROL PANEL

Main deck cargo door
Hydraulic system completely independent of

the existing airplane hydraulic systems
Main Cargo Door is located on the left hand

side of the airplane at BS 480.3 and
extends to BS 619.7
Main deck cargo door

The MCD Hydraulic System is:
Electrically powered
Independent of the airplane main systems
Manual Operation:
Hydraulic hand pump in forward baggage

compartment, on the right sidewall just aft of
the cargo pit door.
Two hydraulic actuators, at the forward and

aft edge of the door, will raise and lower the
door.

MCD Hydraulic Pump and Reservoir Forward

Hold, RHS, Aft of door
Pump Handle for Manual Operation

Main Cargo Door Vents

Door Latch and Lock System:
Latched by means of eight hydraulically

operated over-center hooktype latches
A single hydraulic cylinder actuates the

latching mechanism
Locking is provided by eight pins
Gang bar will not translate to the unlocked

position as long as the vent doors are in the
closed position
The vent door cannot be closed until the

latches are locked

Main Cargo Door Locking Mechanism

PIN, LOCK

GANG BAR

Main Cargo Door Main Cargo Door Latch

Door Sill Protector (retracted)
Door Sill Protector (extended)

An Aural Warning Panel is installed in the

overhead P5 panel, it provides aural warning to
the flight crew in the event Main Cargo Door is
in unsafe condition.

14) ATA 56 WINDOWS
No. 2 RHS window modified for external opening
LATCH STUD PIN
LINK ASSEMBLY
NO 2 RHS WINDOW OPEN
LOWER SILL NO 2 RHS WINDOW
OUTER RELEASE HANDLE BOLT
BOEING
HANDLE
GEAR
HOUSING
ROD GEAR
BOEING
INNER HANDLE GEAR BOX ASSEMBLY
Inner Handle
SUPPORT STRUCTURE INNER MECHANISM BOLTS
AIRFRAME STRUCTURE

14) ATA 56 WINDOWS
No. 2 RHS Window Handle Modification
SHAFT RELEASE HANDLE

MAIN EXTERIOR HANDLE
SHOWN PULLED OUT
NO 2 RHS WINDOW
AND BROKEN OPEN
OML SKIN

13) ATA 56 WINDOWS
Passenger windows plugged with STC

approved window plugs.

15) ATA 57 WINGS
Coming with A/C #3 some of the B757 PCF will

have Aviation Partners Boeing winglets
installed.
Warning:
The span of the aircraft with winglets
installed will increase about 3m!

15) ATA 57 WINGS
757 APB Winglet
Equipment like Anti collision lights, Strobe lights

and the Rear position light will be figured out in
the associated Aviation Partners Winglets
related CMMs not in the AMM.

16) ATA 70 ENGINES
B757 PCF with German Registration B757 PCF with British Registration
will be powered by PW2000 engines will be powered by RR RB211-535 engines

Thank you for your Attention !

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Q3 & Q4 2015-DHL B757 With PW 2000 Changes

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European Air Transport Leipzig

B757 200 PCF Familiarization Information

UNCONTROLLED COPY *** UNCONTROLLED COPY *** UNCONTROLLED COPY

0. Airplane Changes Overview 9. ATA 27 Flight Controls

1. ATA 21 Air Conditioning 10. ATA 28 Fuel

3. ATA 25 Cargo Barrier 12. ATA 38 Water and Waste

4. ATA 25 Lavatory 13. ATA 52 Doors

5. ATA 25 Galley 14. ATA 56 Windows

6. ATA 25 Cargo Compartment 15. ATA 57 Wings

7. ATA 25 Cargo Handling System 16. ATA 70 Engines

8. ATA 26 Fire Protection

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MAIN DECK CARGO

FLIGHT DECK DOOR AND

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Stand 01. October 2015

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23-22-00 B757-200PCF ARCAS Maintenance Manual Supplement TBA

Stand 01. October 2015

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31-35-03 B757-200PCF WQAR Installed on B757 Series Aircrafts TBA TBA

Stand 01. October 2015

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Main overhead distribution duct modified

Two of four rise ducts deleted

Relocation of flight deck air distribution riser

Right recirculation system deactivated

Portion of lavatory/galley vent system deleted

Mix manifold retained

Shut-off system added

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FWD ZONE DUCT:

1) AIR TEMPERATURE SENSOR

FWD ZONE RIGHT

AFT ZONE LEFT

AFT ZONE DUCT

1) AIR TEMPERATURE SENSOR

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Riser Shutoff Valves

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MAIN DECK MAIN DECK

AIR CONDITIONING MIX BAY

RISER SHUTOFF VALVES

FROM L RECIRC SYS

CONDITIONED AIR AIR GROUND

ADDED FOR B757 - 200 PCF CARGO CONVERSION

Alternate Air shutoff valve (electrically actuated butterfly valve):

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ZONE TEMP SENSOR SENSOR

ZONE TEMP SENSOR ZONE TEMP SENSOR

ZONE TEMP ZONE TEMP

CABIN AIR CABIN AIR

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FWD LAV FWD MAIN DECK AFT MAIN DECK

PURGE LINE E/E

MODIFIED FOR B757 - 200 PCF CARGO CONVERSION

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Coming with A/C #4:

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