Maintenance training manual Boeing 737-600/700/800/900(CFM56)

05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

ATA-05
TIME LIMITS/ MAINTENANCE CHECKS

Revision 2/January 2016

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

For training purposes only.

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

TABLE OF CONTENTS

00 GENERAL 4
20 SCHEDULED MAINTENANCE TASKS 9
40 ZONAL INSPECTION PROGRAM 12
50 UNSCHEDULED MAINTENANCE CHECKS 14
• UNSCHEDULED MAINTENANCE
CHECKS
• HIRF/LIGHTNING PROCEDURES
• RESISTANCE

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

05-00
GENERAL

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Maintenance training manual
05 – Time limits/maintenance checks
INTRODUCTION
This procedure has these tasks:
(1) Airworthiness Limitation Precautions.
(2) Enhanced Zonal Inspection Program (EZAP)
precautions.
Airworthiness Limitation Precautions
(1) Critical Design Configuration Control Limitations
(CDCCLs)
(a) All occurrences of CDCCLs found in this chapter of the
AMM are identified by this note after each applicable
CDCCL design feature:
(b) Design features that are CDCCLs are defined and
controlled by Special Federal Aviation Regulation (SFAR)
88, and can be found in Section 9 of the Maintenance
Planning Data (MPD) document. CDCCLs are a means of
identifying certain design configuration features intended to
preclude a fuel tank ignition source for the operational life of
the airplane. CDCCLs are mandatory and cannot be
changed or deleted without the approval of the FAA office
that is responsible for the airplane model Type Certificate, or
applicable regulatory agency. A critical fuel tank ignition
source prevention feature may exist in the fuel system and
its related installation or in systems that, if a failure condition
were to develop, could interact with the fuel system in such
FOR TRAINING PURPOSES ONLY
Boeing 737-600/700/800/900(CFM56)
ATA 104 – T1/T2 – Level 1
a way that an unsafe condition would develop without this
limitation. Strict adherence to configuration, methods,
techniques, and practices as prescribed is required to
ensure the CDCCL is complied with. Any use of parts,
methods, techniques or practices not contained in the
applicable CDCCL must be approved by the FAA office that
is responsible for the airplane model Type Certificate, or
applicable regulatory agency.
(2) Airworthiness Limitation Instructions (ALIs)
(a) All occurrences of fuel tank system ALIs found in this
chapter of the AMM are identified by this step after the
General section in the applicable ALI inspection task:
(b) Inspection tasks that are ALIs are defined and
controlled by Special Federal Aviation Regulation (SFAR)
88, and can be found in Section 9 of the Maintenance
Planning Data (MPD) document. These ALIs identify
inspection tasks related to fuel tank ignition source
prevention which must be done to maintain the design level
of safety for the operational life of the airplane. These ALIs
are mandatory and cannot be changed or deleted without
the approval of the FAA office that is responsible for the
airplane model Type Certificate, or applicable regulatory
agency. 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 FAA
office that is responsible for the airplane model Type
Certificate, or applicable regulatory agency.
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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

Enhanced Zonal Inspection Program (EZAP) inspection is not intended as a quality assurance after
Precautions maintenance check for determining proper reassembly of
systems, components, structures, or powerplants. The
(1) Enhanced Zonal Analysis Procedure (EZAP) and zonal program packages a number of General Visual (GV)
associated Electrical Wiring Interconnection System (EWIS) Inspections into one or more zonal inspections.
(a) Enhanced Zonal Analysis Procedure (EZAP) is an The program includes any GV inspection tasks required to
analytical procedure required by Part 25, Appendix H, assure security of attachment and general condition of any
Section H25.5(a)(1) that identifies the physical and system or structural items within the zone.
environmental conditions contained in each zone of an
airplane, analyzes the effects of these conditions on (2) Equivalent Tools, Fixtures, Test Equipment, and
electrical wiring and components, and assesses the Consumable Materials
possibilities for smoke and fire. The end result of the (a) When the procedures in this manual identify tools,
analysis are inspection and restoration tasks in the form of equipment, and consumable materials, you can use
EWIS ICA. equivalent alternatives. If you use alternative tools,
(b) Electrical Wiring Interconnection System (EWIS): means equipment, or consumable materials, make sure that they
any wire, power feeder, wiring device, or combination of give the same results and are as safe to the parts and
these, including termination devices, installed in any area of personnel as the tools, equipment, or consumable
the airplane for the purpose of transmitting electrical energy, materials specified in the procedure.
including data and signals, between two or more intended
termination points. EWIS is defined in full by 14 CFR section
25.1701.
(c) The Zonal Inspection Program includes a general visual
and, if required, physical check of the general condition and
security of attachment of the accessible systems and
structures items contained in defined zones. This includes
checks for degradation such as chafing of tubing, loose duct
supports, damage to wiring and connected EWIS, cable and
pulley wear, fluid leaks, electrical bonding, general condition
of fasteners, inadequate drainage, etc., and general
corrosion, not covered in the MSG-3 analysis. The zonal

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

The types of conditional inspections are as follows: • Nacelle/Strut Pressure Relief Doors Open Condition
• Hard Landing or High Drag/Side Load Landing (Ref (Ref 05−51−44)
05−51−01) • Landing-Gear-Down Overspeed Condition (Ref
• Severe or Unusual Turbulence, Buffet, or Speeds More 05−51−47)
than the Design Limits (Ref 05−51−04) • Tire Treat Loss or Tire Burst (Ref 05−51−54)
• High Energy Stop/Heat Damage (Ref 05−51−07) • Acid Spillage Condition (Ref 05−51−57)
• Flap/Slat Down Overspeed Condition (Ref 05 −51−08) • Airframe Vibration Condition (Ref 05 −51−67)
• Dragged Engine Nacelle/Engine Seizure/Engine and • Main Landing Gear Shimmy Vibration Condition (Ref
Strut Damage Condition (Ref 05 −51−10) 05−51−68)
• Mercury Spillage Condition (Ref 05−51−14) • Conditioned Air Pack Outlet Duct System Failure
• Brake Seizure (Ref 05−51−15) (Ref 05−51−80)
• Flat Spotted Tires (Ref 05−51−16) • Cabin Depressurization Condition (Ref 05 −51−81)
• Wheel Bearing Failure/Damage Condition (Ref • Excessive Cabin Pressure Leakage (Ref
05−51−17) 05−51−91)
• Bird/Hail Strike Condition (Ref 05−51−18) • Non-Environmental Wing Icing (Ref 05 −51−92)
• Lightning Strike Condition (Ref 05 −51−19)
• Fire Resistant Hydraulic Fluid Reaction with Titanium
(Ref 05−51−22)
• Excessive Cabin Pressure Leakage (Ref 05 −51−24)
• Extreme Dust Condition (Ref 05−51−27)
• Ice or Snow Condition (Ref 05−51−28)
• Exceeding Maximum Nose Landing Gear Towing Angle
or Maximum Towing Load (Ref 05−51−29)
• Volcanic Ash (Ref 05−51−31) T
• ail/Tail Skid Drag (Ref 05−51−32)
• Overweight Landing (Ref 05−51−35)
• Damage due to Engine Blade out (Ref 05 −51−42)
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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

TIME LIMITS/MAINTENANCE CHECKS

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

05-20
SCHEDULED MAINTENANCE
CHECKS

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Maintenance training manual
05 – Time limits/maintenance checks
INTRODUCTION
The airline industry has categorized airplane "minor"
maintenance tasks using terminology such as Preflight,
Transit, Through Service, Overnight Service, Turnaround,
Station Check, Line Check, Daily Inspection, etc. Boeing has
elected to use the terms "Transit" and "24 Hour" in this
document to designate those minor maintenance checks
performed at time intervals less than the "A" Check.
NOTE: "Transit," "24 Hour," and "A" Checks as shown
herein are recommended minimum maintenance
requirements and may be augmented or revised accordingly
by the operator.
Transit Check
The "Transit" Check requires minor maintenance/servicing,
and is intended to assure continuous serviceability of a
transiting aircraft. This check is planned for use at an
enroute stop and is basically a "walk-around" inspection
which requires a check of the aircraft interior and exterior for
obvious damage, leaks, proper operating equipment,
security of attachment, required servicing, etc.
24 Hour Check
The "24 Hour" (Elapsed Clock Hours - ECH) Check, more
comprehensive than the "Transit" Check, is intended for use
FOR TRAINING PURPOSES ONLY
Boeing 737-600/700/800/900(CFM56)
ATA 104 – T1/T2 – Level 1
at a route terminus. A "24 Hour” Check should be
performed before the first flight of the day. The "24 Hour"
Check also requires accomplishment of all items contained
in the Transit Check, unless they are obviously redundant.
"A" Check
The "A" Check is considered a primary inspection and is
intended to disclose the general condition of the aircraft.
The "A" Check may be done at specified hourly, flight
cycle, or calendar time intervals.
Multiple "A" Checks (2A, 4A, 8A)
Multiple "A" Checks are considered intermediate checks
which require a more extensive examination of the airplane
to determine its condition for assuring sustained
airworthiness. These checks include selected operational
checks, filter servicing, lubrication and require the opening
of specific access doors and panels. Multiple "A" Checks
also require accomplishment of all lesser "A" Checks.
"C" Check
The "C" (Periodic Check) requires a greater depth of
inspection throughout the airplane to ensure continued
airworthiness. This task involves selected
Operational/Functional Checks and requires removal of
access doors and panels, etc., to facilitate the inspection. If
performing Block Checks, performance of the "C" Check
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Maintenance training manual
05 – Time limits/maintenance checks
also requires accomplishment of all items in the lesser
checks unless they are obviously redundant.
NOTE: As cited earlier in this document, letter checks may
be scheduled independently. In particular, phase checks
may be accomplished independently of heavier checks.
Some entries in the Interval column may indicate check
multiples. For instance, 2A indicates that the task is
recommended for accomplishment every second A Check
as opposed to 1A which denotes each A Check.
General
Any scheduled task outlined in this section may be
considered to have been accomplished if an equivalent
check/test is performed by the operator's flight or ground
crew during transit/24 hour procedures. However, an
operator should be careful not to compromise their dispatch
reliability in an effort to save maintenance man-hours. In
some cases, finding a problem during a routine maintenance
check allows ample time to remedy the situation prior to a
scheduled departure. Detection of a problem by the flight
crew is more likely to cause a delay. TR and 24 Hour
Checks in this MPD consider this aspect.
The terms "check" and "inspection" are not intended to imply
a level of skill required to accomplish a task.
FOR TRAINING PURPOSES ONLY
Boeing 737-600/700/800/900(CFM56)
ATA 104 – T1/T2 – Level 1
In cases where the MPD Item Number and APL/ENG
applicability are identical to the previous entry (e.g., left and
right engine tasks), only the zone, access, manhours and
task description are repeated for that task. In this way, the
number of times each MPD Item Number appears is kept
to a minimum.
Fuel System Maintenance - Fuel tank sumping task
intervals should be determined by operators and based
upon their operating environment, fuel management
resources and in-service experience. Fuel sampling checks
for microbial contamination task intervals should be based
on the airplane operating environment, fuel source
reliability, and operator in-service experience with incidents
of fuel tank microbial growth and/or resulting tank structural
corrosion. Each operator should assess their fleet for the
possibility of microbial growth corrosion and then plan and
perform preventative maintenance to avoid costly corrosion
damage.
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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

05-40
ZONAL INSPECTION PROGRAM

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

Location Zones

Zone Area
100 Lower Half of Fuselage
200 Upper Half of Fuselage
500 Left Wing
600 Right Wing

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

05-50
UNSCHEDULED MAINTENANCE
CHECKS

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

UNSCHEDULED MAINTENANCE CHECKS

Some of the unscheduled maintenance checks may include:

•Hard landing
•High energy stop
•Flap overspeed condition
•Galley spill
•Flat spotted tires
•Wheel bearing failure
•Ice or snow condition…

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

HIRF/ LIGHTNING PROCEDURE

This procedure has eight tasks:

(1) General Visual inspection of the bond strap between the
rudder and the vertical stabilizer.
(2) General Visual inspection of the bond straps between the
aileron and the wing.
(3) General Visual inspection of the bond straps between the
leading edge flap and the wing.
(4) General Visual inspection of the bond straps between the
spoiler and the wing.
(5) General Visual inspection of the bond straps between the
elevator and the horizontal stabilizer.
(6) General Visual inspection of the bond straps between the
strut and the wing.
(7) General Visual inspection of the bond straps between the
air conditioning pack compartment
door and the airplane structure.
(8) General Visual inspection of the bond straps between the
main landing gear door and the
airplane structure.

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Maintenance training manual Boeing 737-600/700/800/900(CFM56)
05 – Time limits/maintenance checks ATA 104 – T1/T2 – Level 1

RESISTANCE

LOOP RESISTANCE TESTER

Introduction

General

The Loop Resistance Tester (LRT) is a specialized piece of

test equipment which is used to make non-intrusive wire
bundle and coax cable shield resistance measurements.
The LRT can also be used to make resistance
measurements across a built-up joint or individual electrical
connections/ joints.

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