Nammwzza 000031

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CHAPTER 51
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STANDARD PRACTICES AND STRUCTURES - GENERAL
TABLE OF CONTENTS
_________________
_______
SUBJECT
STANDARDS PRACTICES AND STRUCTURES ____________________________________
_______
GENERAL
DESCRIPTION AND OPERATION
General
Description
Aircraft Zoning and Dimensions
Restricted Areas
Access - Door and Panel
Identification
Abbreviations
________
CH/SE/SU
51-00-00
PROTECTIVE TREATMENT
General
Description
Unpainted Areas
Aircraft Internal Areas
Types of Protective Treatments
Pretreatments
Paint Coatings
Special Coatings
51-21-00
PROTECTIVE TREATMENT
CLEANING/PAINTING
Wax and Polish Protection on
Unpainted Light Alloy Areas
51-21-00
CORROSION PREVENTION
General
Description
Corrosion Protection
Surface Treatments (Galvanic or
Chemical)
Protection of Mating Surfaces
51-22-00
COATINGS APPLICATION - GENERAL

General
Description
Aluminum Alloy Structure
Exposed Areas
Composite Components
Corrosion-Resistant Steel
Components
51-23-00
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CHAPTER 51
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TABLE OF CONTENTS
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SUBJECT
_______
CH/SE/SU
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SEALING - GENERAL
General
Description
Use of Sealants
Sealed Areas
51-24-00
_______
REPAIRS
General
Description
Minor Damage
Corrosion
Protective Treatments
Sealants
Composite Materials
51-70-00
REPAIRS OF MINOR DAMAGE

General
51-73-00
REPAIRS OF MINOR DAMAGE

INSPECTION/CHECK
Inspection of Minor Damage to
Aluminum Cladding
REPAIR OF MINOR DAMAGE
REPAIRS
Repair of Minor Damage on Aluminum
Clad Components
Repair of Minor Damage on Unclad
Components
Repair of Minor Damage on
Titanium, Forged Aluminum, or
Steel Components
Repair of Dents in Skin Panels
REPAIRS OF CORRODED AREAS
General
Description
REPAIR OF CORRODED AREAS
REPAIRS
Repair of Corroded Areas
Removal of the Corrosion on
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CHAPTER 51
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TABLE OF CONTENTS
_________________
_______
SUBJECT
Unpainted Light Alloy
Removal of the Corrosion on Window
Frames
CH/SE/SU
________
PAINT REPAIRS
General
STRIPPING/PAINT REMOVAL
CLEANING/PAINTING
Removal of Paint by the
Application of Chemical Paint
Strippers
Removal of Paint by Abrasion
REPAIR OF PAINT COATINGS
REPAIRS
Repair of Major Paint Damage on
Light Alloy and Composite Material
Repair of Major Paint Damage on
Steel Component
Repair of Minor Paint Damage
(Topcoat Only)
REPAIR OF SPECIAL COATINGS
REPAIRS
Repair to a layer of
Moisture-Removing Oil
Repair to a layer of Corrosion
Preventive Compound
Repair to a layer of Cold
Phosphate
51-75-00
SEALING REPAIRS
General
Description
Terms and Definitions
Sealant Preparation
Mixing the Sealant
REPAIR OF SEALING EXCLUDING FUEL TANK
REPAIRS
Repair of the Sealing
REPAIR OF FUEL TANK SEALING
REPAIRS
Local Repair of the Fuel Tank
Sealant
Repair of the Fuel Tank Fillet
Temporary External Repair of the
51-76-00
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CHAPTER 51
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TABLE OF CONTENTS
_________________
_______
SUBJECT
Fuel Tank
CH/SE/SU
________
STANDARD COMPOSITE REPAIRS

General
Description
Types of Structure
MATERIAL HANDLING AND PREPARATION
MAINTENANCE PRACTICES
Preparation of Composite Material
Surfaces for Repair (Damage of not
more than 1 Layer)
Water Break Test
Preparation of a
Corrosion-Resistant Steel Doubler
COMPOSITE REPAIRS - SKIN DAMAGE ALL
STRUCTURES
REPAIRS
Temporary Skin Repair with
High-Speed Tape
Permanent Skin Repair - One Ply
Depth
51-77-00
CLEANING PROCESSES
General
Description
Type of Contamination
51-78-00
CLEANING PROCESSES
CLEANING/PAINTING
Aircraft Cleaning after a Sewage
Leakage
Aircraft Cleaning after a
Hydraulic Fluid Leakage
Aircraft Cleaning after Leakage
from a Fish Shipment
Aircraft Cleaning after an Acid or
Alkali Leakage
Inspection after Mercury Spillage
Removal of Corrosion Preventive
Compound
Application of Temporary
Protection System (TPS)
Cleaning of the Door Entry Drains
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STANDARDS PRACTICES AND STRUCTURES - GENERAL - DESCRIPTION AND OPERATION

________________________________________________________________________
1. General
_______
This chapter provides the instructions related to the standard practices
applicable to the airframe, doors, wings, engine pylons and stabilizers.
These practices include:
- Protective Treatment (Ref. AMM 51-21-00)
- Corrosion Prevention (Ref. AMM 51-22-00)
- Coatings Application (Ref. AMM 51-23-00)
- Sealing - General (Ref. AMM 51-24-00)
- Repairs (Ref. AMM 51-70-00)
- Repair of Minor Damage (Ref. AMM 51-73-00)
- Repair of Corroded Areas (Ref. AMM 51-74-00)
- Paint Repair (Ref. AMM 51-75-00)
- Sealing Repairs (Ref. AMM 51-76-00)
- Standard Composite Repairs (Ref. AMM 51-77-00)
- Cleaning Processes (Ref. AMM 51-78-00)
2. Description
___________
A. Aircraft Zoning and Dimensions
(Ref. AMM 06-00-00)
B. Restricted Areas
(Ref. AMM 12-11-28) (Ref. AMM 09-20-00)
C. Access - Door and Panel Identification
(Ref. AMM 06-40-00)

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D. Abbreviations
Abbreviations used in this chapter include:
AFRP
= Aramidfiber Reinforced Plastic
CFRP
= Carbonfiber Reinforced Plastic
CL
= Center Line
FD
= Fuselage Datum
Fig
= Figure
FR
= Frame
FWD
= Forward
GFRP
= Glassfiber Reinforced Plastic
LH
= Left-Hand (side)
LONGN
= Longeron
MAX
= Maximum
MID
= Middle
MIN
= Minimum
RH
= Right-Hand (side)
REF
= Reference
RPM
= Revolutions Per Minute
STA
= Station
STD
= Standard
STGR
= Stringer
THS
= Trimmable Horizontal Stabilizer
VERT
= Vertical

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Aircraft Structure
Figure 001

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PROTECTIVE TREATMENT - DESCRIPTION AND OPERATION

________________________________________________
1. General
_______
The aircraft structure is given protection against corrosion and fluids.
Special attention is given to areas of high contamination, high condensation
and areas where different materials touch.
On metal structure, the protective treatment protects against corrosion and
damage by corrosive fluids and prevents erosion.
Composite structures have a protective treatment to protect against the
effects of lightning, ultra violet rays and erosion.
The material, the function and the location of a component have an effect
upon the type of protective treatment applied to a component.
When a repair or cleaning procedure removes the original surface protection
the protective treatment must be renewed.
2. ___________
Description
(Ref. Fig. 001, 002)
A. Unpainted Areas
The protective treatment build-up is not the same for all aircraft
structures. The areas that are made of corrosion resistant material, or
areas where the performance of the component would change, are not
painted. These areas include:
- the leading edges of the slats and the engine inlet cowl,
- the external surfaces of the engine pylon that are made of corrosion
resistant materials,
- passenger and cargo-compartment door scuff-plates,
- APU exhaust,
- angle of attack sensors and static ports.

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Protective Treatment Zones - Fuselage and Stabilizers

Figure 001

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Protective Treatment Zones - Wing

Figure 002

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B. Aircraft Internal Areas

The internal areas of the aircraft are divided into four categories.
These categories, which have different protection requirements, are as
follows:
(1) Category A:
- Areas which have contact with air and water.
(2) Category B:
- Fuel tanks.
(3) Catagory C1:
- Areas where water/condensation is possible.
(4) Catagory C2:
- The area below STGR32 and the floor structure around the doors,
galleys and toilets. Areas where contact with hydraulic fluid,
lubricants and/or waste water is possible and inaccessible areas.
3. ______________________________
Types of Protective Treatments
A. Pretreatments
The pretreatment of a material increases the corrosion resistant
properties of the material and provides a good surface for the adhesion
of the paint coatings.
The chemical or galvanic applied film passivates the surface and prevents
corrosion.
B. Paint Coatings
A layer of primer paint is applied to all of the general structure to
protect it against corrosion.
The primer contains corrosion inhibitant to prevent a chemical attack
from corrosive materials.
A polyurethane top layer is applied to protect the structure from
chemical and mechanical damage.
C. Special Coatings
A water repellant coating is applied in areas where water or condensation
may collect.
A corrosion preventive compound is applied in areas where the structure
may be effected by corrosion.

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PROTECTIVE TREATMENT - CLEANING/PAINTING

________________________________________
TASK 51-21-00-916-001
Wax and Polish Protection on Unpainted Light Alloy Areas
WARNING : USE SOLVENTS/CLEANING AGENTS, SEALANTS AND OTHER SPECIAL MATERIALS
_______
ONLY WITH A GOOD SUPPLY OF AIR.
OBEY THE MANUFACTURERS INSTRUCTIONS.
PUT ON PROTECTIVE CLOTHING.
DO NOT GET THEM IN YOUR MOUTH.
DO NOT SMOKE.
DO NOT BREATHE THE GAS.
THESE MATERIALS ARE POISONOUS, FLAMMABLE AND SKIN IRRITANT.
GET MEDICAL HELP IF YOUR SKIN OR EYES BECOME IRRITATED.
WARNING : DO NOT GET THE FLUID ON YOUR SKIN OR IN YOUR EYES. IF YOU DO:
_______
- FLUSH IT AWAY WITH CLEAN WATER
- GET MEDICAL AID.
NOTE : Do not polish or wax the slats in the unpainted areas of the leading
____
edge.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
access platform
lint-free cloth

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B. Consumable Materials
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
Material No. 05-025

Material No. 11-001
USA A-A-59318
POLISH METAL ALUMINUM (Ref. 20-31-00)
USA MIL-D-16791
TYPE I
NO LONGER AVAILABLE (Ref. 20-31-00)
3. __________
Job Set-up
Subtask 51-21-00-941-050
A. If necessary, put an access platform in position.
4. Procedure
_________
Subtask 51-21-00-110-050
A. Wax and polish.
WARNING : USE SOLVENTS/CLEANING AGENTS, SEALANTS AND OTHER SPECIAL
_______
MATERIALS ONLY WITH A GOOD SUPPLY OF AIR.
DO NOT SMOKE.
NOTE : Do not polish or wax the slats in the unpainted areas of the
____
leading edge.
(1) Clean the area with CLEANING AGENTS (Material No. 11-001) and a lintfree cloth.
(2) If necessary, repair the corrosion damage (Ref SRM 51-74-00).
(3) Wax and polish the area with SPECIAL MATERIALS (Material No. 05-025)
and a lint-free cloth.

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5. Close-up
________
Subtask 51-21-00-942-050
A. Close-up
(1) Make sure that the work area is clean and clear of tool(s) and other
items.
(2) Remove the access platform(s).

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CORROSION PREVENTION - DESCRIPTION AND OPERATION

________________________________________________
1. _______
General
Corrosion, the removal of corrosion and subsequent maintenance have a direct
effect on the operational safety and the in-service capability of the
aircraft.
2. ___________
Description
Corrosion-resistant materials and protective coatings are applied at the
construction stage to obtain the maximum possible resistance to corrosion.
3. ____________________
Corrosion Protection
A. Surface Treatments (Galvanic or Chemical)
(1) The surface treatment for aluminum-alloy components are yellow
chromating or chromic acid anodizing.
(2) Aluminum-alloy components that are bonded have a surface treatment of
chromic acid anodizing or pickling and bonding primer.
(3) Steel parts have a surface treatment of cadmium plating, chrome
plating or phosphating.
(4) Titanium or stainless-steel components that are assembled to aluminum
alloy components have a surface treatment of cadmium, zinc, or
aluminum plating.
(5) A paint surface treatment has a polyurethane or epoxy primer to give
protection against corrosion. A polyurethane topcoat is applied to
give protection against a chemical attack.
B. Protection of Mating Surfaces
(1) In addition to the surface treatments already applied, a sealant or
anticorrosion material is applied between components assembled
together.
(2) A chemical conversion coating is applied to rivets installed in light
alloy, anodized titanium and cadmium-plated steel components.
(3) Shafts are assembled installed and coated with grease or
anticorrosion materials.

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(4) An application of paint or soft varnish, after components are

assembled protects the joint seams.
(5) Sealant is applied to protect bonded edges, in areas exposed to
corrosion attack.
(6) Soft varnish is applied to protect fillet seals, in areas exposed to
chemical attack.
For further information (Ref. ASRM 51-22-00).

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COATINGS APPLICATION - GENERAL - DESCRIPTION AND OPERATION

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1. _______
General
This topic gives data about the paint and protective coatings on the
aircraft.
For more information about the coatings Ref. ASRM 51-23-00.
2. Description
___________
A. Aluminum Alloy Structure
NOTE : The abbreviation CAA is used for Chromic Acid Anodizing.

____
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Aluminum alloy structure is CAA prepared and then painted. External

surfaces and some internal surfaces have a primer coating and a coat of
paint.
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B. Exposed Areas
Areas which are exposed to moisture, or possible hydraulic leaks or
galley/toilet leaks also have a moisture removing oil coating.
R
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C. Composite Components
Composite components have a pore filler applied, to make the surface
smooth, and a coat of paint.
Some external composite components have an antistatic paint coating.
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D. Corrosion-Resistant Steel Components

Corrosion-resistant steel components and components where the application
of paint would damage the operation of the component are not painted.

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SEALING - GENERAL - DESCRIPTION AND OPERATION

_____________________________________________
1. _______
General
This topic gives data about the reasons for the use of sealants on the
aircraft and the primary sealing areas.
For sealing repairs (Ref. AMM 51-76-00).
2. ___________
Description
(Ref. Fig. 001)
A. Use of Sealants
(1) The primary uses for sealants on the aircraft are:
- sealing the fuselage structure to make sure that the necessary
internal pressure is kept during the flight,
- sealing the fuel tanks (Ref. AMM 51-76-12 for the repair of fuel
tank sealing),
- sealing the external joints of the aircraft structure to make sure
that water does not go into the structure and to make the structure
smoother,
- sealing riveted and bolted joints to make sure that liquids do not
get into the joints,
- sealing sandwich structures to make sure that moisture does not go
into the structure,
- to prevent corrosion (galvanic action) between different metals,
- to prevent corrosion between different materials, especially
between CFRP and aluminum alloys,
- to prevent fretting corrosion (fatigue stress or vibration between
parts of the structure can cause this),
- to fill cavities,
- to protect the surface on housings, channels, tubes, electrical
cables and electrical components,
- where it is necessary to make sure that any leakage of the aircraft
fluids is kept in the areas from which you can drain them, for
example, under the galleys and lavatories.
(Ref. Fig. 001)
B. Sealed Areas
(1) The aircraft is divided into three primary areas for sealing:
(a) The pressurized area of the fuselage which is from STA350(FR1) to
STA3365(FR70). It includes the cockpit, the cabin and the cargo
compartments.

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Areas of Sealing
Figure 001

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(b) The nonpressurized areas of the aircraft which include:

- the MLG and NLG bay,
- the wing center box,
- the airconditioning and hydraulic compartments,
- the tail section of the rear fuselage aft of FR70,
- the vertical and horizontal stabilizers,
- the wings.
(c) The fuel system

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REPAIRS - DESCRIPTION AND OPERATION

___________________________________
1. _______
General
This topic gives data about the repairs used on the aircraft. For more data
refer to the ASRM 51-70-00.
2. Description
___________
A. Minor Damage
(Ref. AMM 51-73-00).
B. Corrosion
(Ref. AMM 51-74-00).
C. Protective Treatments
(Ref. AMM 51-75-00).
D. Sealants
(Ref. AMM 51-76-00).
E. Composite Materials
(Ref. AMM 51-77-00).

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REPAIRS OF MINOR DAMAGE - DESCRIPTION AND OPERATION

___________________________________________________
1. General
_______
Minor damage such as scratches, dents and marks can cause cracks and
corrosion. Minor damage must be repaired.
Refer to AMM 51-73-11 08 for the repair of:
- minor damage on aluminum clad components
- minor damage on unclad components
- minor damage on titanium, aluminum forged or steel components
- dents in skin panels
Refer to the ASRM 51-73-00 for further data.

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REPAIRS OF MINOR DAMAGE - INSPECTION/CHECK

__________________________________________
TASK 51-73-00-200-001
Inspection of Minor Damage to Aluminum Cladding
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
To find out if the minor damage has gone through the aluminum cladding.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
specific
specific
specific
specific
specific
hot air dryer

lint-free cloth
masking paper
masking tape
pipette
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
No specific
Material No. 11-004
chromic oxide
distilled water
potassium nitrate
sodium hydroxide
USA MIL-T-81533
1.1.1TRICHLOROETHANE (METHYL CHLOROFORM)
(Ref. 20-31-00)

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3. __________
Job Set-up
Subtask 51-73-00-941-050
A. Get access to the area of the damage.
4. Procedure
_________
Subtask 51-73-00-230-050
A. Inspection Procedure of Minor Damage
WARNING : OBEY THE MANUFACTURERS INSTRUCTIONS WHEN YOU USE THE SPECIAL
_______
MATERIAL.
THIS MATERIAL IS DANGEROUS.
R
R
R
R
R
R
R
R
R
R
WARNING : DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS

_______
(STATIC, PITOT, TAT, AOA). USE ONLY THE SPECIFIED TOOLS FOR
THE PROTECTION OF THE AIRCRAFT. THE SPECIFIED TOOLS:
- GIVE THE CORRECT PROTECTION TO THE AIRCRAFT EQUIPMENT,
- ARE EASY TO SEE FROM THE GROUND,
- ARE EASY TO REMOVE.
IF YOU USE TAPE, THERE IS A RISK THAT SOME TAPE, OR
ADHESIVE FROM THE TAPE, WILL STAY ON THE PROBES, DUCTS OR
SENSORS. THIS CAN CAUSE INCORRECT INDICATIONS ON THE
RELATED COCKPIT INSTRUMENTS.
(2) Cover the area adjacent to the minor damage with masking tape and
masking paper.
CAUTION : DO NOT LET THE TEST SOLUTION ENTER JOINTS OR GO BELOW RIVET
_______
HEADS. THE TEST SOLUTION CAN CAUSE CORROSION.
(3) Make a test solution with 20 g (0.70 oz), potassium nitrate, 10 g
(0.35 oz) sodium hydroxide 0.01 l (0.0026 USgal) distilled water.
(4) With a pipette, apply 3 or 4 drops of the test solution to the minor
damage.
(5) Let the solution take effect for 1 to 3 minutes. If the minor damage
has gone through the aluminum cladding, the exposed alloy will go
black/ brown, the cladding will not change color.
(6) Flush the test area with clean water before the solution dries.

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Page 602
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(7) Neutralize the area with a 5 % chromic oxide solution.

(8) Flush the test area with clean water.
(9) Dry the area with a hot air dryer.
5. Close-up
________
Subtask 51-73-00-942-050
R
A. Removal of Equipment
R
R
R
items.
(2) Remove the ground support and maintenance equipment, the special and
standard tools and all other items.
R
R
R
(3) Make an entry in the aircraft logbook and attach a tag on the captain
side stick to tell the crew that:
- Protection covers/devices have been installed.

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Page 603
Feb 01/08
REPAIR OF MINOR DAMAGE - REPAIRS

________________________________
TASK 51-73-11-300-001
Repair of Minor Damage on Aluminum Clad Components
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
specific
specific
specific
specific
specific
abrasive cloth grade 280

abrasive paper grade 400
lint-free cloth
rounded scotch stone
steel roller

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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 04-012
R
Material No. 05-025

Material No. 11-004
Material No. 13-002
USA VV-P-236
PURE MINERALVASELINE OR PETRO- LATUM (Ref. 20-31-00)
USA A-A-59318
USA MIL-T-81533
(Ref. 20-31-00)
USA MIL-C-5541
MIL-C-81706
CLASS I/A
CHEMICAL CONVERSION COATING YELLOW ALUMINUM
(Ref. 20-31-00)
C. Referenced Information
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-73-00-200-001
51-75-12-300-001
Inspection of Minor Damage to Aluminum Cladding

Repair of Major Paint Damage on Light Alloy and
Composite Material
3. __________
Job Set-up
Subtask 51-73-11-941-051
4. Procedure
_________
Subtask 51-73-11-320-050
A. Repair of Minor Damage
(1) Do an inspection of the depth of the minor damage (Ref. TASK 51-7300-200-001).
(2) Refer to the ASRM 51-73-00 and the applicable ASRM-chapter 52 thru 57
for the permitted depth limits.

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(3) Repair the minor damage that has not gone through the aluminum
cladding as follows:
WARNING : OBEY THE MANUFACTURERS INSTRUCTIONS WHEN YOU USE THE
_______
SPECIAL MATERIAL.
(4) Clean the repair area with the CLEANING AGENTS (Material No. 11-004)
and a lint-free cloth.
(5) Apply COMMON GREASE (Material No. 04-012) to the scratch.
(6) Force the aluminum cladding into the scratch with a steel roller.
NOTE : Use the roller along the length of the scratch until the
____
aluminum cladding has sealed the surface.
(7) Repair the minor damage that has gone through the aluminum cladding
as follows:
(8) Measure the depth of the scratch.
(10) Remove the paint from the area of the scratch with abrasive cloth
grade 280 until you can see all of the scratch.
(11) Remove the scratch with a rounded scotch stone and water. Move the
scotch stone along the scratch until the contour is smooth and
rounded.
(12) Rub the roughened area with abrasive paper grade 400. Rub along the
length of the scratch until the surface is smooth.
_______
SPECIAL MATERIAL.
(14) Polish the bare metal with SPECIAL MATERIALS (Material No. 05-025)
and a lint-free cloth:
NOTE : Rub the area in the direction of the scratch. Do not rub with
____
a circular motion. Make sure you remove all the rough surface.

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(15) Clean the area with CLEANING AGENTS (Material No. 11-004) and a clean
cloth.
(16) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) to the metal
surface.
(17) Apply the applicable surface protection (Ref. TASK 51-75-12-300-001).
5. Close-up
________
Subtask 51-73-11-942-051
A. Remove the ground support and maintenance equipment, the special and

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Page 804
Nov 01/06
TASK 51-73-11-300-004
Repair of Minor Damage on Unclad Components
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
specific
specific
specific
specific
specific

abrasive paper grade 400
lint free cloth
lint-free cloth
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
Material No. 05-025

Material No. 11-004
Material No. 13-002
USA A-A-59318
USA MIL-T-81533
(Ref. 20-31-00)
USA MIL-C-5541
MIL-C-81706
CLASS I/A
(Ref. 20-31-00)

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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-74-11-300-001
51-75-12-300-001

Composite Material
3. __________
Job Set-up
Subtask 51-73-11-941-052
4. Procedure
_________
Subtask 51-73-11-320-054
(1) If necessary, remove any corrosion (Ref. TASK 51-74-11-300-001).
(4) Remove the paint from the area of the scratch with abrasive cloth
grade 280 until you can see all of the scratch.
(5) Clean the repair area with CLEANING AGENTS (Material No. 11-004) and
a lint free cloth.
(6) Remove the scratch with a rounded scotch stone and water. Move the
scotch stone along the scratch until the contour is smooth and
rounded.
(7) Rub the roughened area with abrasive paper grade 400. Rub along the
_______
SPECIAL MATERIAL.

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Page 806
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(9) Polish the bare metal with SPECIAL MATERIALS (Material No. 05-025)
and a lint-free cloth:
NOTE : Rub the area in the direction of the scratch. Do not rub with
____
a circular motion. Make sure you remove all the rough surface.
(10) Clean the area with CLEANING AGENTS (Material No. 11-004) and a clean
cloth.
(11) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) to the metal
surface.
5. Close-up
________
Subtask 51-73-11-942-052

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Page 807
Nov 01/06
TASK 51-73-11-300-002
Repair of Minor Damage on Titanium, Forged Aluminum, or Steel Components
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
specific
specific
specific
specific

lint-free cloth
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
Material No. 05-025

Material No. 11-002
Material No. 11-004
USA A-A-59318
USA MIL-PRF-680
DRY CLEANING SOLVENT (VARSOL/WHITE SPIRIT)
(Ref. 20-31-00)
USA MIL-T-81533
(Ref. 20-31-00)

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Page 808
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 13-002
USA MIL-C-5541
MIL-C-81706
CLASS I/A
(Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-74-11-300-001
51-75-12-300-001

Composite Material
3. __________
Job Set-up
Subtask 51-73-11-941-053
4. Procedure
_________
Subtask 51-73-11-320-055
(1) If necessary, remove any corrosion (Ref. TASK 51-74-11-300-001).
a lint-free cloth.
(5) For damage to titanium:
CAUTION : USE WATER WHEN YOU GRIND TITANIUM. TITANIUM DUST IS
_______
FLAMMABLE.
(a) Remove the paint from the area of the damage with abrasive cloth
grade 280.

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Page 809
Nov 01/06
(b) Remove the scratch with a rounded scotch stone and water. Move
the scotch stone along the scratch until the contour is smooth
and rounded.
(c) Rub the roughened area with abrasive cloth grade 400 and CLEANING
AGENTS (Material No. 11-002). Rub along the length of the scratch
until the surface is smooth.
_______
SPECIAL MATERIAL.
(d) Clean the area with CLEANING AGENTS (Material No. 11-004) and a
lint-free cloth.
(e) Polish the bare metal with SPECIAL MATERIALS (Material No. 05025) and a lint-free cloth.
NOTE : Rub the area in the direction of the scratch. Do not rub
____
in a circular motion. Make sure you remove all the rough
surfaces.
(f) Clean the area with CLEANING AGENTS (Material No. 11-004) and a
clean cloth.
(6) For damage to forged aluminum:
grade 280.
(b) Remove the scratch with abrasive cloth grade 400. Rub along the
_______
SPECIAL MATERIAL.
(c) Clean the area with CLEANING AGENTS (Material No. 11-004) and a
lint-free cloth.
(d) Polish the bare metal with SPECIAL MATERIALS (Material No. 05025) and a lint-free cloth.
NOTE : Rub the area in the direction of the scratch. Do not use a
____
circular motion. Make sure you remove all the rough
surfaces.

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Page 810
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(e) Clean the area with CLEANING AGENTS (Material No. 11-004) and a
clean cloth.
(f) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) to the
metal surface.
(7) For damage to steel components:
grade 280.
(b) Remove the scratch with a rounded scotch stone and water. Move
the scotch stone along the scratch until the contour is smooth
and rounded.
(c) Rub the roughened area with abrasive cloth grade 400. Rub along
the length of the scratch until the surface is smooth.
_______
SPECIAL MATERIAL.
(d) Clean the area with CLEANING AGENTS (Material No. 11-004) and a
lint-free cloth.
(e) Polish the bare metal with SPECIAL MATERIALS (Material No. 05025) and a lint-free cloth:
NOTE : Rub the area in the direction of the scratch. Do not rub
____
in a circular motion. Make sure you remove all the rough
surface.
(f) Clean the area with CLEANING AGENTS (Material No. 11-004) and a
clean cloth.
5. Close-up
________
Subtask 51-73-11-942-053

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Page 811
Nov 01/06
TASK 51-73-11-300-003
Repair of Dents in Skin Panels
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------R
R
R
No specific
No specific
No specific
1 CLOTH-EMERY (GRADE 400)

1 CLOTH-EMERY (GRADE 240)
1 SPATULA - NON METALLIC
------------------------------------------------------------------------------REFERENCE
DESIGNATION
-------------------------------------------------------------------------------
R
R
R
R
No specific
No specific
Material No. 08-078
Material No. 11-026
Material No. 19-003
masking paper
masking tape
D
DAN 1196
TWO PART PASTE ADHESIVE (Ref. 20-31-00)
GB DEF-STAN
68-148/1
SOLVENT GENERAL PURPOSE (Ref. 20-31-00)
USA AMS 3819
LINT-FREE COTTON CLOTH (Ref. 20-31-00)

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Page 812
Nov 01/07
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-75-12-300-001
R

Composite Material
ASRM 517300
3. __________
Job Set-up
Subtask 51-73-11-941-054
4. Procedure
_________
Subtask 51-73-11-320-053
A. Repair of Dents
(1) Measure the depth of the dent.
R
R
(2) Refer to the ASRM (Ref. ASRM 517300) and the applicable ASRM-chapter
52 thru 57 for the permitted limits of the dent.
R
R
(3) If a repair of the dent is necessary:
R
R
(a) Remove all of the paint from the area of the dent and 10 mm
(0.3937 in.) around the dent with CLOTH-EMERY (GRADE 240).
R
R
(b) Clean the repair area with the CLEANING AGENTS (Material No. 11026) and a clean lint-free cloth MISCELLANEOUS (Material No. 19003)
R
R
(4) Apply masking paper and masking tape to the area around the dent.
(5) Fill the dent:
R
R
(a) Mix the necessary quantity of the BONDING AND ADHESIVE COMPOUNDS
(Material No. 08-078).

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Page 813
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R
R
R
(b) Apply the BONDING AND ADHESIVE COMPOUNDS (Material No. 08-078) to
the repair area with a SPATULA - NON METALLIC.
R
R
R
(6) Make sure that the area is dry before you continue with the steps
that follow.
R
R
R
(7) Smooth the BONDING AND ADHESIVE COMPOUNDS (Material No. 08-078) to
the contours of the component with CLOTH-EMERY (GRADE 240).
R
R
R
(8) Smooth the BONDING AND ADHESIVE COMPOUNDS (Material No. 08-078) to
the contours of the component with CLOTH-EMERY (GRADE 400).

5. Close-up
________
Subtask 51-73-11-942-054

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Page 814
Nov 01/07
REPAIRS OF CORRODED AREAS - DESCRIPTION AND OPERATION

_____________________________________________________
1. _______
General
Corrosion can seriously effect the safe operation of the aircraft, its
components and structure. When corrosion is found it must be removed as soon
as possible. The area of the corrosion damage must be inspected before the
repair can be started.
It is very important that all corrosion deposits are removed. Any corrosion
remaining can become a starting point for more corrosion.
Refer to ASRM 51-74-00 for more data.
2. ___________
Description
Corrosion usually starts on the material surface. It then goes towards the
material center destroying its solid substance.
Refer to AMM 51-74-11 08 for the removal of:
- corrosion, general,
- corrosion on unpainted alloy,
- corrosion on window frames.

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Page 1
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REPAIR OF CORRODED AREAS - REPAIRS

__________________________________
TASK 51-74-11-300-001
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
abrasive cloth 400 grade

lint-free cloth
magnifying glass
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------No specific
No specific
Material No. 11-001
R
Material No. 11-004
masking paper
masking tape
USA MIL-D-16791
TYPE I
USA MIL-T-81533
(Ref. 20-31-00)

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May 01/07
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-75-12-300-001
51-76-11-300-001

Composite Material
3. __________
Job Set-up
Subtask 51-74-11-941-050
A. Get access to the area of the corrosion.
4. Procedure
_________
Subtask 51-74-11-140-050
A. Repair of Corrosion
_______
MATERIAL.
a lint-free cloth.
R
R
R
R
R
R
R
R
R
R

_______
(2) Cover the area adjacent to the damage with masking paper and masking
tape.
(3) Remove the corrosion with abrasive cloth 400 grade.
NOTE : For limits refer to the related ASRM-chapter.
____

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Page 802
Feb 01/08
a lint-free cloth.
(5) Make a visual inspection with a magnifying glass to make sure that
all the corrosion is removed.
(6) If necessary, repair the damaged sealant (Ref. TASK 51-76-11-300001).
(7) Repair the damaged paint (Ref. TASK 51-75-12-300-001).
5. Close-up
________
Subtask 51-74-11-942-050
R
R
R
R
items.
R
R
R
(3) Make an entry in the aircraft log book and attach a tag on the
captain side stick to tell the crew that:

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Page 803
Feb 01/08
TASK 51-74-11-300-002
Removal of the Corrosion on Unpainted Light Alloy
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
abrasive cloth (grade 400)

lint-free cloth
magnifying glass
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------No specific
No specific
Material No. 11-001
R
Material No. 11-004
masking paper
masking tape
USA MIL-D-16791
TYPE I
USA MIL-T-81533
(Ref. 20-31-00)

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Page 804
May 01/07
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-21-00-916-001
Wax and Polish Protection on Unpainted Light Alloy

Areas
3. __________
Job Set-up
Subtask 51-74-11-941-051
A. Get access to the area of the corrosion.
4. Procedure
_________
Subtask 51-74-11-140-051
A. Remove the Corrosion
_______
MATERIAL.
a lint-free cloth.
R
R
R
R
R
R
R
R
R
R

_______
tape.
(3) Remove the corrosion with abrasive cloth (grade 400).
a lint-free cloth.

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Page 805
Feb 01/08
(5) Make a visual inspection with a magnifying glass to make sure that
all the corrosion is removed.
(6) Wax and polish the repair area (Ref. TASK 51-21-00-916-001).
5. Close-up
________
Subtask 51-74-11-942-051
R
R
R
R
items.
R
R
R
(3) Make an entry in the aircraft log book and attach a tag to the

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Page 806
Feb 01/08
TASK 51-74-11-300-003
Removal of the Corrosion on Window Frames
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
access platform
aluminum oxide (80-120 microns)
light grit blasting equipment
lint-free cloth
magnifying glass
PE-Foil
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------No specific
No specific
Material No. 11-001
R
Material No. 11-004
masking paper
masking tape
USA MIL-D-16791
TYPE I
USA MIL-T-81533
(Ref. 20-31-00)

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Page 807
May 01/07
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-75-12-300-001
51-76-11-300-001
51-74-11-991-001

Composite Material
Fig. 801
3. __________
Job Set-up
Subtask 51-74-11-941-052
A. Put the access platform in position adjacent to the area of the
corrosion.
4. Procedure
_________
(Ref. Fig. 801/TASK 51-74-11-991-001)
Subtask 51-74-11-140-052
A. Removal of the Corrosion
_______
MATERIAL.
a lint-free cloth.
R
R
R
R
R
R
R
R
R
R

_______
(2) Cover the window pane with tape 3M595, PE-Foil and Tesodur tape.

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Page 808
Feb 01/08
Masking of the Windows

Figure 801/TASK 51-74-11-991-001

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Page 809
Nov 01/06
tape.
(4) Remove the corrosion with light grit blasting equipment and aluminum
oxide (80-120 microns) at a pressure of 4 bar (58.0150 psi).
NOTE : For limits refer to the related ASRM-chapter.
____
a lint-free cloth.
(6) Make a visual inspection of the repair area with a magnifying glass
to make sure all the corrosion is removed.
(7) If necessary, repair the damaged sealant (Ref. TASK 51-76-11-300001).
(8) Repair the damaged paint (Ref. TASK 51-75-12-300-001).
5. Close-up
________
Subtask 51-74-11-942-052
R
R
items.
R
R
R
R
R
(3) Make an entry in the aircraft log book and attach a tag on the

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Page 810
Feb 01/08
PAINT REPAIRS - DESCRIPTION AND OPERATION

_________________________________________
1. General
_______
Paint and/or special coatings seal the aircraft structures against
corrosion. The type of protective coating used depends on the location,
function and corrosion resistance of the component.
You must repair any damage to the original protective treatment. Refer to
AMM 51-23-00 and SRM 51-75-00 for the original build up.

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Page 1
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STRIPPING/PAINT REMOVAL - CLEANING/PAINTING

___________________________________________
TASK 51-75-11-100-001
Removal of Paint by the Application of Chemical Paint Strippers
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
polyethylene film
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 08-019
FOIL, PRESSURE SENSITIVE (USE 08-108) (Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
12-21-11-615-002
ASRM 51-75-11
External Cleaning

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3. __________
Job Set-up
Subtask 51-75-11-950-052
A. Protection of the Aircraft
CAUTION : MAKE SURE THAT THE MATERIALS, AREAS AND PARTS WHICH FOLLOW HAVE
_______
THE CORRECT PROTECTION FROM CHEMICAL PAINT STRIPPERS:
- RUBBER, ALL COMPOSITE PARTS, ACRYLIC MATERIALS, AERODYNAMIC
SMOOTHER, METAL BONDED EDGES, PITOT PROBES, SENSORS, STATIC
PORTS, ENGINE AIR INTAKE, PRECOOLER AIR OUTLET SCREEN, ENGINE
EXHAUST DUCT, APU EXHAUST, APU INTAKES AND OUTLETS,
AIR-CONDITIONING RAM AIR INLETS, LANDING GEARS, DOOR SEALS,
ACCESS DOORS, CABIN WINDOW AND WINDSHIELD PANELS AND SEALS,
ELECTRICAL EQUIPMENT AND CABLES, PLASTIC MATERIALS, EXTERNAL
SKIN PANEL JOINTS, HIGH STRENGTH STEEL PARTS, DRAIN HOLES,
VENTS AND ALL ANTENNAS.
(1) Use the polyethylene film and the BONDING AND ADHESIVE COMPOUNDS
(Material No. 08-019) to mask the areas adjacent to the work area.
NOTE : Do not mask
____
tank areas)
- there are
- the total
hours.
the joints of external skin panels (except in fuel

if:
no bonded doublers in the joints
time you apply the stripper is less than four
(2) If necessary, install the correct protection covers/devices to

protect the adjacent aircraft components from damage and
contamination (Ref. TASK 12-21-11-615-002).
4. Procedure
_________
Subtask 51-75-11-150-050
A. Removal of Paint by the Application of Chemical Paint Strippers Metallic Materials Only (Ref. ASRM 51-75-11).
5. Close-up
________
Subtask 51-75-11-942-051
A. Put the aircraft back to the serviceable condition.
(1) If necessary, remove the protection covers/devices you installed on
the aircraft components adjacent to the work area (Ref. TASK 12-2111-615-002).
R
R

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Page 702
May 01/09
items.

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Page 703
Nov 01/06
TASK 51-75-11-100-002
Removal of Paint by Abrasion
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
abrasive paper, grade 220 or 320

masking paper
masking tape
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-004
Material No. 19-003
USA MIL-T-81533
(Ref. 20-31-00)
USA AMS 3819
Material No. 19-011

SCOTCH BRITE PADS (Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
12-21-11-615-002
51-76-11-300-001
External Cleaning

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3. __________
Job Set-up
Subtask 51-75-11-950-053
A. Protection of the Aircraft
(1) Use the masking paper and the masking tape to mask the areas adjacent
to the work area.
(2) If necessary, install the correct protection covers/devices to
protect the adjacent aircraft components from damage and
contamination (Ref. TASK 12-21-11-615-002).
4. Procedure
_________
Subtask 51-75-11-150-052
A. Removal of Paint by Abrasion - Metallic and Composite Materials
_______
DO NOT SMOKE.
CAUTION : DO NOT CAUSE DAMAGE TO THE SURFACE OF THE COMPOSITE MATERIAL
_______
WHEN YOU REMOVE THE PAINT COATING WITH ABRASIVE PAPER.
CAUTION : DO NOT USE A METAL SCRAPER TO REMOVE THE UNWANTED MATERIAL. A
_______
METAL SCRAPER CAN CAUSE DAMAGE TO THE SURFACE OF THE COMPONENT.
NOTE : This procedure gives the data necessary to remove the paint
____
coatings from composite materials. The procedure can also be used
to remove paint coatings from metallic materials, as an
alternative procedure to chemical paint stripping.
NOTE : This procedure gives the data necessary to remove the top coat of
____
the paint system, but not to remove the basic primer.
(1) Lightly abrade the surface of the work area with the abrasive paper,
grade 220 or 320, until the layer of basic primer comes fully into
view.

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Page 705
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(2) Polish the abraded areas with the scotch-brite pad, MISCELLANEOUS
(3) Remove and discard the masking materials.
(4) Clean the work area with a lint-free cloth MISCELLANEOUS (Material
No. 19-003) and the CLEANING AGENTS (Material No. 11-004), and let
the surface dry.
(5) Inspect the areas that were masked for damaged paint.
(6) If necessary, do the steps (1), (2) and (4) again, to remove the
damaged paint.
(7) If applicable, inspect the work area for damage to the sealing beads
of the skin joints.
(8) If necessary, repair the damaged sealing beads at the skin joints
(Ref. TASK 51-76-11-300-001).
5. Close-up
________
Subtask 51-75-11-942-052
A. Put the aircraft back to the serviceable condition.
(1) If necessary, remove the protection covers/devices you installed on
the aircraft components adjacent to the work area (Ref. TASK 12-2111-615-002).
R
R
items.

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Page 706
May 01/09
REPAIR OF PAINT COATINGS - REPAIRS

__________________________________
TASK 51-75-12-300-001
Repair of Major Paint Damage on Light Alloy and Composite Material
_______
DO NOT SMOKE.
NOTE : If the standard certified color, BAC 707, or
____
color is not to be used to restore the paint
upper surfaces of the horizontal tail plane,
spoilers or the flaps, please contact Airbus
the non-standard paint color.
the original certified

or the repainting of the
elevator, ailerons,
Industrie for approval of
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
-------------------------------------------------------------------------------
No specific
No specific
No specific
No specific
98D53103000000

lint-free cloth
masking paper
masking tape
1 COVER-ALPHA PROBE PROTECTIVE

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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-001
R
Material No. 11-004
USA MIL-D-16791
TYPE I
USA MIL-T-81533
(Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-74-11-300-001
3. __________
Job Set-up
Subtask 51-75-12-941-050
A. Get access to the area to be repaired.
4. Procedure
_________
Subtask 51-75-12-350-052
A. Repair the Paint Damage
_______
MATERIAL.

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Page 802
May 01/07
a lint-free cloth.
R
R
R
R
R
R
R
R
R
R

_______
(2) If necessary, repair the corrosion damage (Ref. TASK 51-74-11-300001).
(3) Cover the area adjacent to the damage with the masking paper and
masking tape.
NOTE : If you must repair paint damage adjacent the AOA sensor, you
____
must install COVER-ALPHA PROBE PROTECTIVE (98D53103000000).
(4) Remove the damaged paint and primer coatings with abrasive cloth
grade 280.
(5) Feather the edges of the undamaged paint to give a smooth surface to
the repair area.
a lint-free cloth.
(7) Apply the primer coatings and paint coatings to the repair area.
(8) Remove the masking paper, masking tape and protective covers as
necessary.
5. Close-up
________
Subtask 51-75-12-942-050
R
R
R
R
items.

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Page 803
Feb 01/08
R
R
R

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Feb 01/08
TASK 51-75-12-300-002
Repair of Major Paint Damage on Steel Component
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
specific
specific
specific
specific

lint-free cloth
masking paper
masking tape
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-042
R
Material No. 11-001
Material No. 11-004
USA MIL-C-10578
TYPE II
PHOSPHATIC LIQUID NO LONGER AVAILABLE (Ref. 20-31-00)
USA MIL-D-16791
TYPE I
USA MIL-T-81533
(Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-75-13-916-003
ASRM 512311000
Repair to a layer of Cold Phosphate

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Page 805
Aug 01/08
3. __________
Job Set-up
Subtask 51-75-12-941-051
4. Procedure
_________
Subtask 51-75-12-350-053
_______
MATERIAL.
a lint-free cloth.
R
R
R
R
R
R
R
R
R
R

_______
masking tape.
(3) If necessary, repair the corrosion damage (Ref. SRM 51-74-00).
(4) If necessary repair the minor damage (Ref. SRM 51-73-00).
(5) Remove the damaged paint and primer coatings with abrasive cloth
grade 280.
(6) Feather the edges of the undamaged paint to give a smooth surface to
the repair area.
(7) Clean the repair with CLEANING AGENTS (Material No. 11-004) and a
lint-free cloth.

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(8) Apply a protective treatment of SPECIAL MATERIALS (Material No. 05042) to the repair area. (Ref. TASK 51-75-13-916-003)
(9) Apply the paint coating to the repair area (Ref. ASRM 512311000).
(10) Remove the masking paper/masking tape.
5. Close-up
________
Subtask 51-75-12-942-051
R
R
R
R
items.
R
R
R

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Page 807
Feb 01/08
TASK 51-75-12-300-003
Repair of Minor Paint Damage (Topcoat Only)
_______
DO NOT SMOKE.
NOTE : If the standard certified color, BAC 707, or
____
color is not to be used to restore the paint
upper surfaces of the horizontal tail plane,
spoilers or the flaps, please contact Airbus
the non-standard paint color.
the original certified

or the repainting of the
elevator, ailerons,
Industrie for approval of
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
-------------------------------------------------------------------------------
No specific
No specific
No specific
No specific
98D53103000000

lint-free cloth
masking paper
masking tape
1 COVER-ALPHA PROBE PROTECTIVE

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Page 808
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-001
Material No. 11-004
USA MIL-D-16791
TYPE I
USA MIL-T-81533
(Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------ASRM 512311000
3. __________
Job Set-up
Subtask 51-75-12-941-052
4. Procedure
_________
Subtask 51-75-12-350-054
a lint-free cloth.
R
R
R
R
R
R
R
R
R
R

_______

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Page 809
Feb 01/08
masking tape.
NOTE : If you must repair paint damage adjacent the AOA sensor, you
____
must install COVER-ALPHA PROBE PROTECTIVE (98D53103000000).
(3) Remove the damaged topcoat of paint with abrasive cloth grade 280.
(4) Feather the edges of the undamaged topcoat to give a smooth surface
to the repair area.
a lint-free cloth.
(6) Apply the paint coatings to the repair area (Ref. ASRM 512311000).
(7) Remove the masking paper, masking tape and protective covers as
necessary.
5. Close-up
________
Subtask 51-75-12-942-052
R
R
R
R
items.
R
R
R

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Page 810
Feb 01/08
REPAIR OF SPECIAL COATINGS - REPAIRS

____________________________________
TASK 51-75-13-916-001
Repair to a layer of Moisture-Removing Oil
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
lintfree cloth
masking paper
masking tape
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-027
Material No. 11-004
RUST INHIBITOR(FOR CORROSION USE 15-004)

(Ref. 20-31-00)
USA MIL-T-81533
(Ref. 20-31-00)

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Page 801
Nov 01/06
3. __________
Job Set-up
Subtask 51-75-13-941-050
4. Procedure
_________
Subtask 51-75-13-110-050
A. Repair a layer of Moisture-Removing Oil
R
R
R
R
R
R
R
R
R
R

_______
(STATIC, PITOT, TAT, AOA). USE ONLY THE SPECIFIED TOOLS FOR THE
PROTECTION OF THE AIRCRAFT. THE SPECIFIED TOOLS:
IF YOU USE TAPE, THERE IS A RISK THAT SOME TAPE, OR ADHESIVE
FROM THE TAPE, WILL STAY ON THE PROBES, DUCTS OR SENSORS. THIS
CAN CAUSE INCORRECT INDICATIONS ON THE RELATED COCKPIT
INSTRUMENTS.
(1) Cover the equipment and fittings adjacent to the area with masking
paper and masking tape.
_______
SPECIAL MATERIAL.
(2) Clean the area with CLEANING AGENTS (Material No. 11-004) and a
lintfree cloth.
(3) Apply a layer of SPECIAL MATERIALS (Material No. 05-027) to the area.
(4) Let the moisture-removing oil cure for 1 hour before you apply a
second protective layer.
(5) Remove the masking paper or the masking tape.

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Feb 01/08
5. Close-up
________
Subtask 51-75-13-942-050
R
R
R
R
items.
R
R
R

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Page 803
Feb 01/08
TASK 51-75-13-916-002
Repair to a layer of Corrosion Preventive Compound
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
masking paper
masking tape
1 SCRAPER - NON METALLIC
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-005
Material No. 15-010
USA MIL-C-16173
GRADE II
CORROSION PREVENTIVE (Ref. 20-31-00)
USA MIL-C-11796-C
CLASS 1A
CORROSION PREVENTIVE FILLER COMPOUND (Ref. 20-31-00)

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Page 804
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-75-13-916-001
Repair to a layer of Moisture-Removing Oil
3. __________
Job Set-up
Subtask 51-75-13-941-051
4. Procedure
_________
Subtask 51-75-13-140-050
A. Repair of a layer of Corrosion Preventive Compound
R
R
R
R
R
R
R
R
R
R

_______
INSTRUMENTS.
_______
(1) Apply the masking paper and the masking tape to the equipment
adjacent to the area.
(2) Remove the damaged layer of corrosion-preventive compound with the
SCRAPER - NON METALLIC.
(3) Repair the layer of the moisture-removing oil (Ref. TASK 51-75-13916-001).

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Page 805
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(4) Apply the special materials

(a) Apply the corrosion-preventive compound STORAGE PRESERVATION
(Material No. 15-010) to the area.
_______
SPECIAL MATERIAL.
(b) Apply the SPECIAL MATERIALS (Material No. 05-005) to the area.
(5) Remove the masking paper and the masking tape.
5. Close-up
________
Subtask 51-75-13-942-051
R
R
R
R
items.
R
R
R

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Page 806
Feb 01/08
TASK 51-75-13-916-003
Repair to a layer of Cold Phosphate
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
specific
specific
specific
specific
specific
specific

brush
hot air dryer
lintfree cloth
masking paper
masking tape
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-042
R
Material No. 11-004
USA MIL-C-10578
TYPE II
PHOSPHATIC LIQUID NO LONGER AVAILABLE (Ref. 20-31-00)
USA MIL-T-81533
(Ref. 20-31-00)

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Page 807
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3. __________
Job Set-up
Subtask 51-75-13-941-052
A. Get access to the applicable area.
4. Procedure
_________
Subtask 51-75-13-120-050
A. Repair a layer of Cold Phosphate
R
R
R
R
R
R
R
R
R
R

_______
INSTRUMENTS.
(1) Cover the equipment and fittings adjacent to the area with the
masking paper or masking tape.
(2) Remove the damaged phosphate layer from an area of 20 mm (0.7874 in.)
around the repair with the abrasive cloth grade 400.
_______
SPECIAL MATERIAL.
(3) Clean the area with CLEANING AGENTS (Material No. 11-004) and the
lintfree cloth.
(4) Apply a layer of SPECIAL MATERIALS (Material No. 05-042) with the
brush or a clean lintfree cloth.
(5) Let the phosphatic liquid soak into the metal surface for 5 to 15
minutes.
(6) When the surface of the metal has changed to a grey-white color,
rinse the area with clean water.
(7) Dry the area with a the hot air dryer.

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Page 808
Feb 01/08
(8) Remove the masking paper or the masking tape.

5. Close-up
________
Subtask 51-75-13-942-052
R
R
R
R
items.
R
R
R

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Page 809
Feb 01/08
SEALING REPAIRS - DESCRIPTION AND OPERATION

___________________________________________
1. _______
General
Sealants are used on the aircraft structure to stop pressurization and fuel
leaks. You must repair the sealant when it has been damaged during
maintenance or found damaged on an inspection/check.
For the repair of general sealants Ref. AMM 51-76-11 08.
For the repair of fuel tank sealing Ref. AMM 51-76-12 08.
For more data Ref. ASRM 51-24-00 and ASRM 51-76-00.
2. Description
___________
A. Terms and Definitions
The table below shows some of the terms used in sealant procedures and
their definitions.
----------------------------------------------------------------------------|
TERM
|
DEFINITION
|
|------------------------|----------------------------------------------------|
| Application Life or
| This is the period of time that a sealant remains |
| Pot Life
| suitable for application after it has been mixed. |
|------------------------|----------------------------------------------------|
| Barrier Coating
| A layer of quick-drying sealant that is applied
|
|
| over a layer of slow-drying sealant before it has |
|
| fully cured. This term also applies when a layer
|
|
| of special material is put over the original
|
|
| sealant to protect it.
|
|------------------------|----------------------------------------------------|
| Breakable Joint
| A joint that can be easily disassembled.
|
|------------------------|----------------------------------------------------|
| Cure
| This refers to the change of a sealant from its
|
|
| original mixed condition to its final condition.
|
-----------------------------------------------------------------------------

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----------------------------------------------------------------------------|
TERM
|
DEFINITION
|
|------------------------|----------------------------------------------------|
| Fillet
| This is formed when sealant is applied into gaps
|
| or
| or corners in the structure. The fillet or bead
|
| Bead
| can be formed from sealant that is applied for
|
|
| this purpose, or from the interfay sealant that
|
|
| is squeezed out when a joint is assembled.
|
|------------------------|----------------------------------------------------|
| Initial Cure Time
| This is the minimum period of time required before |
|
| a sealant is cured enough to permit a sealed
|
|
| joint to be pressure tested.
|
|------------------------|----------------------------------------------------|
| Interfay Sealant
| A layer of sealant applied to the contacting
|
|
| (faying) surfaces of repair parts before they are |
|
| assembled.
|
|------------------------|----------------------------------------------------|
| Leak Path
| This is the path along which a fluid can get
|
|
| out of, or into a sealed area.
|
|------------------------|----------------------------------------------------|
| Overcoating
| This term refers to the application of a brushing |
|
| thickness sealant over a joint.
|
|------------------------|----------------------------------------------------|
| Tack Free Time
| This is the period of time measured from when the |
|
| sealant is mixed until its surface should be
|
|
| touch dry.
|
|------------------------|----------------------------------------------------|
| Work Life
| This is the period of time within which a joint
|
|
| that must be sealed, must be riveted, bolted or
|
|
| temporarily fastened, after the sealant has been
|
|
| applied to the contacting surfaces of the joint.
|
----------------------------------------------------------------------------3. ___________________
Sealant Preparation
A. Mixing the Sealant
(1) Refer to the manufacturers instructions for :
- mixing ratios,
- application life,
- tack free time,
- cure time,
- work life.

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(2) Mix the base compound and sealant accelerator slowly until you get an
even consistency and color. If you mix quickly you will cause heat
and air bubbles and shorten the application life of the sealant.
(3) You must mix the sealant as close to the time of application as
possible.

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REPAIR OF SEALING EXCLUDING FUEL TANK - REPAIRS

_______________________________________________
TASK 51-76-11-300-001
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
1 BRUSH - NON METALLIC

------------------------------------------------------------------------------REFERENCE
DESIGNATION
-------------------------------------------------------------------------------
R
R
No specific
No specific
Material No. 09-013
Material No. 11-004
Material No. 16-021
masking paper
masking tape
USA MIL-PRF-81733
SEALANT-BRUSH CONSIS TENCY (OBSOLETE) (Ref. 20-31-00)
USA MIL-T-81533
(Ref. 20-31-00)
F
ASNB70720
FLEXIBLE POLYURETHANE (Ref. 20-31-00)

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Nov 01/08
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 19-003
USA AMS 3819

------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-75-13-916-002
Repair to a layer of Corrosion Preventive Compound
3. __________
Job Set-up
Subtask 51-76-11-941-050
A. Get access to the damaged sealant.
4. Procedure
_________
Subtask 51-76-11-110-050
A. Repair the Sealing
_______
(1) Remove the damaged sealant with a SCRAPER - NON METALLIC.
(2) Make a chamfer on the undamaged sealant to give a repair overlap to a
minimum width of 12.7 mm (0.5000 in.).
(3) Make the surface of the chamfer rough.
_______
SPECIAL MATERIAL.
(4) Clean the repair area.
(a) Clean the repair area with CLEANING AGENTS (Material No. 11-004)
and a lint free-cloth, MISCELLANEOUS (Material No. 19-003) and
let it dry.

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(5) Use a BRUSH - NON METALLIC apply the SEALANTS (Material No. 09-013)
to the repair area with an overlap of the undamaged sealant.
(6) Let the sealant cure for a minimum of 1 hour.
R
R
R
R
R
R
R
R
R
R

_______
(7) Apply masking paper and masking tape to the area adjacent to the
repair.
(8) Apply the STRUCTURE PAINTS (Material No. 16-021) to the repair area
to a width of 25.0 mm (0.9842 in.) around the repair area.
(9) Let the nylon coating cure for a minimum of 1 hour.
(10) If necessary, apply the surface protection (Ref. TASK 51-75-13-916002).
5. Close-up
________
Subtask 51-76-11-942-050
A. Removal or Equipment
R
R
R
items.
R
R
R

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REPAIR OF FUEL TANK SEALING - REPAIRS

_____________________________________
TASK 51-76-12-300-001
Local Repair of the Fuel Tank Sealant
1. __________________
Reason for the Job
General repair of fuel leaks.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------R
No specific
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
R
Material No. 11-026

Material No. 19-003
GB DEF-STAN
68-148/1
USA AMS 3819
------------------------------------------------------------------------------REFERENCE
DESIGNATION
-------------------------------------------------------------------------------
12-11-28-650-001
28-00-00-910-001
28-10-00-910-001
28-10-00-910-002
SRM 517612 P. Block 1
General Refuel/Defuel Safety Procedures

Fuel Safety Procedures
Safety Procedures When You Do Work in a Fuel Tank
Access to the Fuel Tanks and the Work Areas

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3. __________
Job Set-up
Subtask 51-76-12-941-050
A. Obey the fuel safety procedures (Ref. TASK 28-00-00-910-001), (Ref. TASK
28-10-00-910-001) and (Ref. TASK 28-10-00-910-002).
Subtask 51-76-12-650-050
B. Defuel the aircraft. (Ref. TASK 12-11-28-650-001)
Subtask 51-76-12-010-050
C. Get access to the fuel leak area.
4. Procedure
_________
Subtask 51-76-12-160-050
R
A. Preparation for the Repair

_______
R
R
(1) Remove the sealant from around the leak point area for a minimum
distance of 75 mm (2.9527 in.) with a SCRAPER - NON METALLIC.
(2) Chamfer the edges of the sealant that is not damaged.
R
R
R
and a clean lint free-cloth MISCELLANEOUS (Material No. 19-003).
Subtask 51-76-12-914-050
B. Repair
R
R
R
(1) Do the local repair of the fuel tank sealant (Ref. SRM 517612 P.
Block 1).
Subtask 51-76-12-650-051
C. Refuel the aircraft (Ref. TASK 12-11-28-650-001).

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Nov 01/07
Subtask 51-76-12-790-050
D. Examine the repair area for leaks.
NOTE : Leaks are not permitted.
____
(1) If there are leaks, refer to SRM 51-76-12, P. Block 1, for corrective
action.
5. Close-up
________
Subtask 51-76-12-942-050

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TASK 51-76-12-300-002
Repair of the Fuel Tank Fillet
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------R
No specific
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
R
Material No. 11-026

Material No. 19-003
GB DEF-STAN
68-148/1
USA AMS 3819
------------------------------------------------------------------------------REFERENCE
DESIGNATION
-------------------------------------------------------------------------------
12-11-28-650-001
28-00-00-910-001
28-10-00-910-002
SRM 517612 P. Block 1
General Refuel/Defuel Safety Procedures

3. __________
Job Set-up
Subtask 51-76-12-941-051
A. Obey the fuel safety procedures (Ref. TASK 28-00-00-910-001) and
(Ref. TASK 28-10-00-910-002).

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Subtask 51-76-12-650-052
B. Defuel the aircraft (Ref. TASK 12-11-28-650-001).
Subtask 51-76-12-010-051
C. Get access to the fuel leak area.
4. Procedure
_________
Subtask 51-76-12-160-051
R
A. Preparation for the Repair

_______
(1) Remove the sealant from the leak point and up to a distance of 75 mm
(2.9527 in.) from the leak point area with a SCRAPER - NON METALLIC.
R
R
R
R
R
(2) Chamfer the edges of the sealant that is not damaged. Clean the
repair area.
R
R
and a clean lint-free cloth MISCELLANEOUS (Material No. 19-003).
Subtask 51-76-12-914-051
B. Repair
R
R
(1) Do the repair of the fuel tank fillet (Ref. SRM 517612 P. Block 1).
Subtask 51-76-12-650-053
C. Refuel the aircraft. (Ref. TASK 12-11-28-650-001)
Subtask 51-76-12-790-051
D. Examine the repair for leaks.
____
(1) If there are leaks, refer to SRM 51-76-12, P. Block 1, for corrective
action.

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5. Close-up
________
Subtask 51-76-12-942-051

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Page 806
Nov 01/07
TASK 51-76-12-300-003
Temporary External Repair of the Fuel Tank
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 09-008C
R
Material No. 11-026
Material No. 19-003
EARLY QUICK REPAIR F UEL TANK SEALANT (Ref. 20-31-00)

GB DEF-STAN
68-148/1
USA AMS 3819
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------12-11-28-650-004
28-00-00-910-001
28-10-00-910-002
28-11-00-280-002
28-25-00-650-001
Pressure Refuel with Manual Control

Structural Fuel Tank Leaks - General Information
Pressure Defuel

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3. __________
Job Set-up
Subtask 51-76-12-941-052
A. Obey the fuel safety procedures (Ref. TASK 28-00-00-910-001) and
(Ref. TASK 28-10-00-910-002).
Subtask 51-76-12-010-052
B. Get access to the fuel leak area.
Subtask 51-76-12-280-050
C. Calculate the leak rate (Ref. TASK 28-11-00-280-002) and make sure that a
temporary repair is permitted.
4. Procedure
_________
Subtask 51-76-12-110-052
A. Prepare the Repair Area
Subtask 51-76-12-914-052
B. Repair
_______
DO NOT SMOKE.
(1) Apply the SEALANTS (Material No. 09-008C) to the leak area. Push the
sealant into the leak source with a SCRAPER - NON METALLIC until the
leak stops.
(2) If you cannot get a good seal, defuel the aircraft to below the leak
level (Ref. TASK 28-25-00-650-001).

R
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Page 808
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(3) Apply a second coat of the SEALANTS (Material No. 09-008C).

(4) Let the repair cure.
(5) Refuel the aircraft above the level of the repair (Ref. TASK 12-1128-650-004) and examine the fuel tank for leaks.
____
5. Close-up
________
Subtask 51-76-12-942-052

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Page 809
Nov 01/08
STANDARD COMPOSITE REPAIRS - DESCRIPTION AND OPERATION

______________________________________________________
1. General
_______
This topic gives information on minor and temporary repairs to composite
material components. The information is of a general type only. You must
refer to specific repair data, material specifications and manufacturers
instructions. Failure to do so could result in an unauthorised repair.
The composite materials used are Glassfiber Reinforced Plastic (GFRP),
Carbonfiber Reinforced Plastic (CFRP) and Aramidfiber Reinforced Plastic
(AFRP). These materials are used in the construction of composite
structures.
When you do a repair to composite structures, the repair materials are:
- carbonfiber materials to repair carbonfiber structure.
- glassfiber materials to repair glassfiber and aromidfiber structures.
2. Description
___________
A. Types of Structure
(1) Sandwich Structures
Composite material is used for the skin of structures which is then
bonded to a metallic or nonmetallic core. The core is usually a
honeycomb structure (Ref. AMM 51-77-12 08).
(2) Monolithic Structures
These structures have a composite material skin with internal
stringers, ribs and spars to give rigidity and strength (Ref. AMM
51-77-14 08).
(3) Mixed Structures
To follow the aircraft design, some structures are mixed; part
sandwich and part monolithic structure.
NOTE : For more data Ref. ASRM 51-77-00 or the ASRM chapter related
____
to the component you will repair.

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MATERIAL HANDLING AND PREPARATION - MAINTENANCE PRACTICES

_________________________________________________________
TASK 51-77-11-910-006
Preparation of Composite Material Surfaces for Repair (Damage of not more than
1 Layer)
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
demineralized water
emery paper grade 100
light grit blast (400-700) micron walnut grit
lint-free cloth
masking paper
masking tape
vacuum cleaner

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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-004
USA MIL-T-81533
(Ref. 20-31-00)
3. __________
Job Set-up
Subtask 51-77-11-010-052
A. There is no special job set-up for this task.
4. Procedure
_________
Subtask 51-77-11-918-052
A. Prepare the Composite Material Surfaces for Repair
R
R
R
R
R
R
R
R
R
R

_______
INSTRUMENTS.
(1) Cover the area adjacent to the repair area with masking paper and
masking tape.
(2) Remove the surface protection and up to 50 mm (1.9685 in.) around the
repair area with emery paper grade 100 or light grit blast (400-700)
micron walnut grit.
(3) Remove all damaged material but not more than one layer.
(4) Feather the edges of the undamaged area to give a smooth edge to the
repair area.

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(5) Make the repair area smooth with emery paper grade 280 and emery
paper grade 400.
_______
SPECIAL MATERIAL.
a lint-free cloth.
NOTE : Do not pour the vapor degreaser directly on the repair area.
____
Moisten the lint-free cloth with vapor degreaser.
(7) Remove all loose and unwanted material with a vacuum cleaner.
(8) Clean the repair area with demineralized water and a lint-free cloth.
NOTE : Do not pour demineralized water directly on the repair area.
____
Moisten the lint-free cloth with demineralized water.
R
5. Close-up
________
Subtask 51-77-11-942-050
R
R
items.
R
R
R
R
R

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Feb 01/08
TASK 51-77-11-700-001
Water Break Test
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
demineralized water
lint-free cloth
3. __________
Job Set-up
Subtask 51-77-11-010-051
4. Procedure
_________
Subtask 51-77-11-750-050
A. Do the Water Break Test
(1) Dry the repair area with a clean lint-free cloth.
(2) Spray a thin coating of demineralized water on the repair area.
NOTE : A thick coating of demineralized water will not show all the
____
defects on the repair area.
(3) Inspect the wetted surface to make sure the water forms a thin
continuous coating.
(4) A defect is shown when the demineralized water is repelled and forms
into beads of water.
(5) If necessary, rub down the repair area with emery paper grade 400 to
remove the defect.

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(6) If necessary, clean the repair area with demineralized water and a
lint-free cloth.
(7) If necessary, repeat the water-break test until there are no defects
on the repair area surface.
(8) Dry the repair area with a clean lint-free cloth.
NOTE : On completion of the water-break test, do not touch the repair
____
area. Do the repair quickly to prevent contamination.
(9) At the repair area apply new paint as necessary (Ref. SRM 51-75-12).

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TASK 51-77-11-910-008
Preparation of a Corrosion-Resistant Steel Doubler
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
corrosion-resistant steel sheet

lint-free cloth
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-002
USA MIL-PRF-680
DRY CLEANING SOLVENT (VARSOL/WHITE SPIRIT)
(Ref. 20-31-00)
3. __________
Job Set-up
Subtask 51-77-11-010-050

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4. Procedure
_________
Subtask 51-77-11-918-054
A. Prepare a Corrosion-Resistent Steel Doubler
(1) If the specific repair data does not give a doubler thickness, the
doubler thickness is as follows:
(a) For a skin thickness up to 3 mm (0.1181 in.), the doubler
thickness is 1.5 mm (0.0590 in.).
(2) For a skin thickness over 3 mm (0.1181 in.), the doubler thickness is
half of the skin thickness.
(a) Cut the doubler from corrosion-resistant steel sheet to the
necessary dimensions.
(b) Make a chamfer on the edges of the doubler.
(c) If necessary, shape and form the doubler to match the contours of
the composite structure.
NOTE : The gap between the doubler and the composite structure
____
must not exceed 0.3 mm (0.0118 in.).
(3) Clean the doubler
_______
SPECIAL MATERIAL.
(a) Clean the doubler with CLEANING AGENTS (Material No. 11-002) and
a lint-free cloth.

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COMPOSITE REPAIRS - SKIN DAMAGE ALL STRUCTURES - REPAIRS

________________________________________________________
TASK 51-77-12-300-001
Temporary Skin Repair with High-Speed Tape
_______
DO NOT SMOKE.
NOTE : You can use high-speed tape to cover light skin damage when internal
____
damage is not found.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
A. Consumable Materials
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
No specific
No specific
Material No. 11-004
emery paper, grade 100

high-speed tape
lintfree cloth
USA MIL-T-81533
(Ref. 20-31-00)
B. Referenced Information
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-77-12-991-001
Fig. 801

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Nov 01/06
3. __________
Job Set-up
Subtask 51-77-12-941-050
4. Procedure
_________
(Ref. Fig. 801/TASK 51-77-12-991-001)
Subtask 51-77-12-350-050
A. Do the Temporary Skin Repair
(1) Remove frayed fibers.
(2) Make the sharp edges smooth with emery paper, grade 100.
(3) Make the repair area smooth with emery paper, grade 280 and emery
paper, grade 400.
_______
SPECIAL MATERIAL.
a lintfree cloth.
Subtask 51-77-12-560-050
B. Prepare the High-Speed Tape
R
R
R
CAUTION : USE ONLY THE SPECIFIED MATERIALS AND OBEY THE INSTRUCTIONS FROM
_______
THE MANUFACTURERS. OTHER MATERIALS CAN CAUSE DAMAGE TO THE
SURFACE PROTECTION OF THE COMPONENTS AND THE RELATED AREA.
(1) Cut the high-speed tape to the necessary dimensions and round off the
corners.
(2) Apply the high-speed tape to the repair area.
5. Close-up
________
Subtask 51-77-12-942-050

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Page 802
Aug 01/08
Temporary Skin Repair with High-Speed Tape

Figure 801/TASK 51-77-12-991-001

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Nov 01/06
TASK 51-77-12-330-005
Permanent Skin Repair - One Ply Depth
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
A. Consumable Materials
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
Material No. 05-057
emery paper, Grade 280

emery paper, Grade 400
polythene sheet
C
Z-18.903
MICROBALLOONS (Ref. 20-31-00)
Material No. 08-010C

X (Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-75-12-300-001
51-77-11-700-001
51-77-11-910-006
51-77-12-991-003

Composite Material
Water Break Test
Preparation of Composite Material Surfaces for Repair
(Damage of not more than 1 Layer)
Fig. 802
3. __________
Job Set-up
Subtask 51-77-12-941-057
R

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4. Procedure
_________
(Ref. Fig. 802/TASK 51-77-12-991-003)
Subtask 51-77-12-350-051
A. Do the Skin Repair
(1) If necessary, remove the temporary skin repair.
(2) Prepare the repair area (Ref. TASK 51-77-11-910-006).
(3) Do a water-break test on the repair area (Ref. TASK 51-77-11-700001).
_______
SPECIAL MATERIAL.
(4) Mix the necessary amount of adhesive. Use BONDING AND ADHESIVE
COMPOUNDS (Material No. 08-010C), SPECIAL MATERIALS (Material No. 05057).
(5) Apply the adhesive to the repair area.
(6) Put a polythene sheet over the repair area.
(7) Refer to the material specification for the curing time and let the
adhesive cure.
(8) Remove the polythene sheet when the adhesive has cured.
(9) Rub down the adhesive with emery paper, Grade 280 and emery paper,
Grade 400 to the contours of the composite structure.
(10) Apply the protective treatment. (Ref. TASK 51-75-12-300-001)

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Permanent Skin Repair - One Ply Depth

Figure 802/TASK 51-77-12-991-003

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Page 806
Nov 01/06
5. Close-up
________
Subtask 51-77-12-942-057
A. Close up
items.

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Page 807
Nov 01/06
CLEANING PROCESSES - DESCRIPTION AND OPERATION

______________________________________________
1. _______
General
This topic gives information on the cleaning of the aircraft structure after
a spillage or contamination of the structure. A spillage must be removed as
soon as possible to prevent damage to the aircraft structure.
2. Description
___________
A. Type of Contamination
(1) Sewage
Sewage can damage the aircraft metallic components and cause
corrosion.
(2) Hydraulic Fluid
Contamination of the aircraft structure with hydraulic fluid, for a
long time, will damage the corrosion-protection-paint.
(3) Acid and Alkali Spillage
Acids and alkalies can cause corrosion very quickly and damage the
aircraft protective paint finish.
(4) Fish Container Leakage
Contamination of the aircraft structure with fish slime or sea water
can cause corrosion to metal structure and components.

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CLEANING PROCESSES - CLEANING/PAINTING

______________________________________
TASK 51-78-00-615-001
Aircraft Cleaning after a Sewage Leakage
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
1
1
1
1
bicarbonate of soda
potassium bichromate
BRUSH - NON METALLIC
HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F)
SCRAPER - NON METALLIC
VACUUM EQUIPMENT 0 TO 0.4 BAR (6 PSI)

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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-005
USA MIL-C-16173
GRADE II
Material No. 05-027

Material No. 11-001
R
Material No. 19-003

(Ref. 20-31-00)
USA MIL-D-16791
TYPE I
USA AMS 3819
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-74-11-300-001
51-75-12-300-003
51-75-13-916-001
51-75-13-916-002
Repair
Repair
Repair
Repair
of
of
to
to
Corroded Areas
Minor Paint Damage (Topcoat Only)
a layer of Moisture-Removing Oil
a layer of Corrosion Preventive Compound
3. __________
Job Set-up
Subtask 51-78-00-865-050
A. Open, safety and tag the circuit breakers of all electrical components
and systems in the work area.
Subtask 51-78-00-010-050
B. Get Access
(1) Get access to the area of the leakage.
(2) Remove components from the area you will clean to prevent
contamination from water and/or cleaning agents.
NOTE : Make sure that all electrical outlets are covered to protect
____
them from water.

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May 01/07
4. Procedure
_________
Subtask 51-78-00-110-050
A. Cleaning Procedure
_______
(1) Remove the loose materials with a SCRAPER - NON METALLIC, a VACUUM
EQUIPMENT 0 TO 0.4 BAR (6 PSI), or a BRUSH - NON METALLIC.
(2) Flush the area with clean water.
_______
SPECIAL MATERIAL.
(3) Mix water and 10 % of the bicarbonate of soda or the CLEANING AGENTS
(Material No. 11-001) to make a cleaning solution.
(4) Clean the area with the cleaning solution and a lint-free cloth
MISCELLANEOUS (Material No. 19-003).
(6) Prepare one of the cleaning solutions that follow:
- mix water with 5 % potassium bichromate and 0.5 % of the CLEANING
AGENTS (Material No. 11-001)
or
- mix water with 0.5 % of the CLEANING AGENTS (Material No. 11-001).
(7) Clean the area with the cleaning solution and a lint-free cloth
(9) Dry the area with a HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F).
(10) If necessary, repair corrosion damage (Ref. TASK 51-74-11-300-001).
(11) If necessary, repair the paint layers (Ref. TASK 51-75-12-300-003).
(12) If necessary, apply a layer of the SPECIAL MATERIALS (Material No.
05-027) to the area (Ref. TASK 51-75-13-916-001).

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Nov 01/06

5. Close-up
________
Subtask 51-78-00-410-050
A. Close Access
(1) Install all the components that were removed for the cleaning task.
(2) Remove the safety clips(s) and the tag(s) and close the circuit
breaker(s) of all the electrical components and systems in the work
area.

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Page 704
Nov 01/06
TASK 51-78-00-615-002
Aircraft Cleaning after a Hydraulic Fluid Leakage
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
hot air dryer

lint-free cloth
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-005
USA MIL-C-16173
GRADE II
Material No. 05-027

(Ref. 20-31-00)
Material No. 05-038
Material No. 11-001
R
Material No. 11-003
POWDER (REMOVAL OF HYDRAULIC FLUID SPILLAGE)

(Ref. 20-31-00)
USA MIL-D-16791
TYPE I
USA ASTM D 740
METHYL-ETHYL-KETONE (Ref. 20-31-00)

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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-74-11-300-001
51-75-12-300-003
51-75-13-916-001
51-75-13-916-002
51-76-11-300-001
Repair
Repair
Repair
Repair
Repair
of
of
to
to
of
Corroded Areas
the Sealing
3. __________
Job Set-up
Subtask 51-78-00-865-052
A. Open, safety and tag the circuit breakers of all the electrical
components and systems in the work area.
Subtask 51-78-00-010-051
B. Get Access
(2) Remove components from the area you will clean to prevent
____
them from water.
4. Procedure
_________
Subtask 51-78-00-110-051
(1) Remove the hydraulic fluid with a lint-free cloth.
_______
SPECIAL MATERIAL.
(2) Clean the area with CLEANING AGENTS (Material No. 11-003) and a
lint-free cloth.

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(3) Apply SPECIAL MATERIALS (Material No. 05-038) to the area, let it
stay on the area for 30 minutes.
NOTE : The Met-L-chek developer will stay wet if there is unwanted
____
hydraulic fluid.
(4) If necessary, repeat the procedure until the unwanted hydraulic fluid
is removed.
(5) Clean the area with the CLEANING AGENTS (Material No. 11-001) and a
lint-free cloth.
(10) If necessary, repair the filler seals (Ref. TASK 51-76-11-300-001).
(11) If necessary, apply a layer of SPECIAL MATERIALS (Material No. 05027) to the area (Ref. TASK 51-75-13-916-001).
5. Close-up
________
Subtask 51-78-00-410-051
A. Close Access
(2) Remove the safety clip(s) and tag(s) and close the circuit breaker(s)
of all the electrical components and systems in the work area.

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Nov 01/06
TASK 51-78-00-615-003
Aircraft Cleaning after Leakage from a Fish Shipment
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Clean the aircraft structure after a leak from a fish container.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
specific
specific
specific
specific
1
1
1
1
BRUSH - NON METALLIC

HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F)
SCRAPER - NON METALLIC
VACUUM EQUIPMENT 0 TO 0.4 BAR (6 PSI)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-005
USA MIL-C-16173
GRADE II
Material No. 05-027

Material No. 11-001
R
Material No. 19-003

(Ref. 20-31-00)
USA MIL-D-16791
TYPE I
USA AMS 3819

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May 01/07
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-74-11-300-001
51-75-12-300-003
51-75-13-916-001
51-75-13-916-002
51-76-11-300-001
Repair
Repair
Repair
Repair
Repair
of
of
to
to
of
Corroded Areas
the Sealing
3. __________
Job Set-up
Subtask 51-78-00-865-054
A. Open, safety and tag the circuit breakers of all electrical components
Subtask 51-78-00-010-052
B. Get Access
(2) Remove the components from the area you will clean to prevent
____
them from water.
4. Procedure
_________
Subtask 51-78-00-110-052
_______
(1) Remove the loose materials with a SCRAPER - NON METALLIC, a VACUUM
EQUIPMENT 0 TO 0.4 BAR (6 PSI), or a BRUSH - NON METALLIC.
(2) Clean the area with the CLEANING AGENTS (Material No. 11-001).

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Page 709
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(4) Prepare one of the cleaning solution that follow:

- mix water with 5 % potassium bichromate and 0.5 % of the CLEANING
AGENTS (Material No. 11-001)
or
- mix water with 0.5 % of the CLEANING AGENTS (Material No. 11-001).
(5) Clean the area with the cleaning solution.
(6) Remove the solution with a clean lint-free cloth MISCELLANEOUS
(9) If necessary, repair the corrosion damage (Ref. TASK 51-74-11-300001).
(11) If necessary, repair the clear nylon coating to the sealant
(Ref. TASK 51-76-11-300-001).
5. Close-up
________
Subtask 51-78-00-410-052
A. Close Access
(2) Remove the safety clip(s) and tag(s) and close the circuit breaker(s)
of all the electrical components and systems in the work area.

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Page 710
Nov 01/06
TASK 51-78-00-615-004
Aircraft Cleaning after an Acid or Alkali Leakage
_______
DO NOT SMOKE.
WARNING : YOU MUST ALWAYS WEAR RUBBER GLOVES WHEN YOU DO THIS PROCEDURE.
_______
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
boric acid
hot air dryer
lint-free cloth
nonmetallic brush
plastic container
plastic sheets
sodium bicarbonate
soft brush
sponge
universal indicator paper

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Page 711
Nov 01/06
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 05-005
USA MIL-C-16173
GRADE II
Material No. 05-027

(Ref. 20-31-00)
Material No. 05-038
POWDER (REMOVAL OF HYDRAULIC FLUID SPILLAGE)
(Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-74-11-300-001
51-75-12-300-003
51-75-13-916-001
51-75-13-916-002
Repair
Repair
Repair
Repair
of
of
to
to
Corroded Areas
3. __________
Job Set-up
Subtask 51-78-00-865-056
components and the systems in the leakage area.
Subtask 51-78-00-010-053
B. Get Access
(2) Remove the components from the area you will clean, to prevent
____
them from water.
(3) Put plastic sheets over components and areas adjacent to the leakage.

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Page 712
Nov 01/06
(4) Use a plastic container for used cloths and/or sponges.

4. Procedure
_________
Subtask 51-78-00-110-053
(1) Soak up the contamination with a lint-free cloth or a sponge.
(2) In areas that you can not dry with a cloth use SPECIAL MATERIALS
(3) Prepare the necessary solution.
(4) For alkali leakage mix a solution of 5 % boric acid and water. Mix 50
g (1.76 oz) of boric acid with 1 l (0.2641 USgal) of water to get the
necessary solution.
(5) For acid leakage mix a solution of 5 % sodium bicarbonate and water.
Mix 50 g (1.76 oz) of sodium bicarbonate with 1 l (0.2641 USgal) of
water to get the necessary solution.
(6) Apply the solution to the dirty area with a nonmetallic brush and/or
lint-free cloth.
(7) Apply the solution until the chemical reaction stops. Keep the
solution on the surface for 5 min.
(8) Remove the neutralized mixture with a cloth and/or a sponge.
(10) Use a soft brush to remove the clean water.
(11) Do a test to measure the pH-value of the leakage area.
(12) Use universal indicator paper to do the test.
(13) Make sure that the pH-value is not more than 7 and not less than 5.5.
(14) You must do a test on areas where it is not easy to get access.
(15) If the pH-valve is not correct clean the area again.

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Nov 01/06

5. Close-up
________
Subtask 51-78-00-410-053
A. Close Access
(2) Remove the safety clip(s) and tag(s) and close the circuit breakers
of the electrical components and systems in the work area.

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Page 714
Nov 01/06
TASK 51-78-00-200-001
Inspection after Mercury Spillage
WARNING : ALWAYS SUPPLY SUFFICIENT VENTILATION WHILE YOU CLEAN AREAS WHERE
_______
THERE IS MERCURY CONTAMINATION.MERCURY VAPORS ARE TOXIC.
WARNING : DO NOT TRY TO COLLECT MERCURY BY HAND.
_______
WARNING : DO NOT BREATHE MERCURY VAPORS.THE AIR FROM THE VACUUM CLEANER
_______
CONTAINS MERCURY VAPORS COLLECTED DURING CONTACT WITH THE MERCURY
DEPOSITED IN THE GLASS CONTAINER.
WARNING : DO NOT USE THE AIR HOSE TO REMOVE MERCURY FROM THE AIRCRAFT.
_______
1. __________________
Reason for the Job
You must do the inspection when mercury is spilled in the cargo compartment.
Mercury and mercury compounds, are heavily corrosive on a wide range of
metallic materials, especially on aluminum alloys. When mercury is spilled
in the aircraft there is a high risk of serious damage to the structure.
Corrosion caused by spilled mercury can destroy a large area, although only
a small amount of mercury is spilled. Heavy destruction can occur within a
few hours.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
air compressor
battery water rubber-syringe
cardboard
cellulose tape
glass fiber sheets
medicine dropper
mercury sniffer
paper trough
portable X-ray equipment
safety barriers
soap
vacuum cleaner
warning notice
woods

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Page 715
Nov 01/06
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------52-30-00-860-001
52-30-00-860-003
53-22-14-000-001
53-22-14-400-001
53-42-14-000-001
53-42-14-400-001
SRM
SRM
Open the FWD or AFT Cargo-Compartment Door with the

Yellow Electric Pump
Open the FWD or AFT Cargo-Compartment Door with the
Hand Pump
Removal of the FWD Cargo-Compartment Floor-Panels
Installation of the FWD Cargo-Compartment
Floor-Panels
Removal of the AFT Cargo-Compartment Floor-Panels
Zone 150
Installation of the AFT Cargo-Compartment
Floor-Panels Zone 150
51220000
53020002
3. __________
Job Set-up
Subtask 51-78-00-941-055
A. Safety Precautions
(1) Put the safety barriers in position.
(2) On the panel 2020VU put a warning notice to tell persons to keep out
of the work areas.
Subtask 51-78-00-010-054
B. Get Access
(1) Open the cargo compartment doors 825 and 826 (Ref. TASK 52-30-00-860001).
Subtask 51-78-00-869-050
C. Ventilation of the Cargo Compartment
(1) Blow clean filtered air from an air compressor through the cargo
compartment, as follows:
(a) Put the air compressor near the aircraft.

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Page 716
Nov 01/06
(b) Put the end of the air compressor supply hose into the
compartment through the door.
(c) Start the air compressor and make sure that the air flows through
the cargo compartment.
4. Procedure
_________
Subtask 51-78-00-615-050
A. Cleaning of the Contaminated Area
(1) Mark the area that is contaminated by mercury spillage.
(2) Isolate the contaminated area, do not let mercury spread from the
contaminated areas to the clean areas. Do not walk through or move
parts from the contaminated area into the clean areas of the
aircraft.
(3) Do not touch the surfaces that you suspect of contamination. Use
woods and glass fiber sheets to support your body while you work on
the contaminated area.
NOTE : Do not use contaminated protective clothing in clean areas.
____
(4) Remove mercury spillage as follows:
(a) Collect all the visible mercury with a cardboard or a paper
trough.
(b) Collect the mercury with a vacuum cleaner.
(c) To collect small particles of mercury use cellulose tape.
(d) If there is a larger quantity collect the mercury with a medicine
dropper or a battery water rubber-syringe.
(e) To check under floor zones, use a mercury sniffer and a portable
X-ray equipment.

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Page 717
Nov 01/06
Subtask 51-78-00-210-050
B. Inspection of the Cargo Compartment (Ref. TASK 53-22-14-000-001)
(Ref. TASK 53-42-14-000-001) (Ref. SRM 51220000) (Ref. SRM 53020002)
NOTE : When you find mercury on the floor, do not remove
____
access/inspection plates, screws, rivets, bolts, etc., from the
floor. A hole in the contaminated area of the floor may let the
mercury spread to the structure below the floor.
R
R
R
R
R
R
R
R
-----------------------------------------------------------------------------|
|INSP.|
|PHASE|PHASE|PHASE|INSP.|DETAIL|
|ITEM |
| INSP. TASKS TO BE ACCOMPLISHED | 1 | 2 | 3 |SIGN |(FIG) |
|
|CODE |
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
| 1 | 2 |
| 4 | 5 | 6 | 7 | 8
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|1.
|
| Do a visual inspection of the
| X |
|
|
|
|
|
|
| cargo compartment floor, the
|
|
|
|
|
|
|
|
| componemts of the cargo loading |
|
|
|
|
|
|
|
| system and the lowest point of |
|
|
|
|
|
|
|
| the structure:
|
|
|
|
|
|
|
|
| - remove the mercury.
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|2.
|
| Do a visual inspection of the
| X |
|
|
|
|
|
|
| non-visible contamined areas
|
|
|
|
|
|
|
|
| with a mercury sniffer:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|3.
|
| Remove floor panels in the
| X |
|
|
|
|
|
|
| contaminated zones:
|
|
|
|
|
|
|
|
| - FWD cargo compartment floor
|
|
|
|
|
|
|
|
|
(Ref. TASK 53-22-14-000-001), |
|
|
|
|
|
|
|
| - aft cargo compartment floor
|
|
|
|
|
|
|
|
|
(Ref. TASK 53-43-14-00-001). |
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|4.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Do a visual inspection of the

|
bottom of the fuselage.
|
Do an inspection of the skin and|
the internal structure below the|
point of spillage.
|
If mercury spillage has occurred|
in the cargo area, do an
|
inspection of the lowest point |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|

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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Page 718
May 01/09
R
R
R
R
R
R
R
R
-----------------------------------------------------------------------------|
|INSP.|
|PHASE|PHASE|PHASE|INSP.|DETAIL|
|ITEM |
| INSP. TASKS TO BE ACCOMPLISHED | 1 | 2 | 3 |SIGN |(FIG) |
|
|CODE |
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
| 1 | 2 |
| 4 | 5 | 6 | 7 | 8
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|
|
| of the fuselage below the cargo |
|
|
|
|
|
|
|
| compartment floor:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|5.
|
| Do an inspection with a mercury | X |
|
|
|
|
|
|
| sniffer or a portable X-ray
|
|
|
|
|
|
|
|
| equipment of the non-visible
|
|
|
|
|
|
|
|
| contaminated areas between the |
|
|
|
|
|
|
|
| skin, stringer and frames below |
|
|
|
|
|
|
|
| the floor.
|
|
|
|
|
|
|
|
| NOTE
|
|
|
|
|
|
|
|
| Droplets of mercury are shown on|
|
|
|
|
|
|
|
| the X-ray equipment as small
|
|
|
|
|
|
|
|
| white spots.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|6.
|
| Do an inspection of the
| X |
|
|
|
|
|
|
| stucture.
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|
A.|
| Use a portable X-ray
|
|
|
|
|
|
|
|
| equipment to examine the
|
|
|
|
|
|
|
|
| hidden corrosion areas between |
|
|
|
|
|
|
|
| the skin, stringers and frames |
|
|
|
|
|
|
|
| below the floor.
|
|
|
|
|
|
|
|
| If you find damage:
|
|
|
|
|
|
|
|
| - do a repair
|
| X |
|
|
|
|
|
|
(Ref. SRM 51-22-00-00).
|
|
|
|
|
|
|-----|-----|---------------------------------|-----|-----|-----|-----|------|
|7.
|
| Examine all the removable compo-| X |
|
|
|
|
|
|
| nents.
|
|
|
|
|
|
|
|
| If you find damage:
|
|
|
|
|
|
|
|
| - do a repair
|
| X |
|
|
|
|
|
|
(Ref. SRM 53-02-00-02).
|
|
|
|
|
|
------------------------------------------------------------------------------

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Page 719
May 01/09
5. Close-up
________
Subtask 51-78-00-110-055
A. Cleaning of the Tools
(1) Clean all the tools used in the contaminated areas with steam or hot
water and soap.
(2) Discard twist drills and other cutting tools used on the contaminated
structure.
(3) Thoroughly clean all the protective clothing with water and soap
after use in the contaminated areas.
Thoroughly wash your hands with water and soap before you touch your
face.
Subtask 51-78-00-410-054
B. Close Access
(1) Install the floor panels of the cargo compartment (Ref. TASK 53-2214-400-001) (Ref. TASK 53-42-14-400-001).
(2) Close the cargo compartment doors (Ref. TASK 52-30-00-860-003).
Subtask 51-78-00-942-054
C. Put the Aircraft Back to its Initial Configuration
(1) Remove the warning notice(s).
items.

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Page 720
Nov 01/06
TASK 51-78-00-615-005
Removal of Corrosion Preventive Compound
_______
DO NOT SMOKE.
CAUTION : DO NOT POINT THE SPRAY GUN OF THE WATER HIGH-PRESSURE CLEANER AT
_______
ELECTRICAL COMPONENTS, HARNESSES, SENSORS, CONNECTORS, EQUIPMENT AND
ACTUATOR BEARINGS.
WATER CAN CAUSE DAMAGE TO THESE COMPONENTS.
CAUTION : DO NOT APPLY THE CLEANING AGENTS TO THESE PARTS:
_______
- BEARINGS, ACTUATORS, FITTINGS
- ACRYLICS OR POLYCARBONATE MATERIALS
- ELECTRICAL HARNESSES, SENSORS, CONNECTORS.
CLEANING AGENT ON OR IN THESE PARTS CAN CAUSE DAMAGE.
1. __________________
Reason for the Job
This is an alternative method to solvent cleaning for the removal of
corrosion preventive compounds, Material Nos. (15-004, 15-005, 15-006,
15-007, 15-008 and 15-009 from large areas).
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
1 CLEANING EQUIPMENT - HIGH PRESSURE

1 HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F)

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Nov 01/06
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-032
WAX REMOVER (Ref. 20-31-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------ASRM 51-23-12-001
51-74-11-300-001
51-75-12-300-001
51-75-12-300-003
(for corrective action)

Repair of Corroded Areas (for corrective action)
Composite Material (for corrective action)
Repair of Minor Paint Damage (Topcoat Only) (for
corrective action)
3. __________
Job Set-up
Subtask 51-78-00-865-061
components and systems in the work area.
Subtask 51-78-00-941-056
B. Get Access
(1) Get access to the area(s) where you will do the work.
Subtask 51-78-00-010-055
C. Removal and Cleaning of Components
(1) Remove the components from the area where the corrosion preventive
compound must be removed.
(2) Install protective covers on all the electrical outlets to protect
them against contamination.

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Page 722
Nov 01/06
4. Procedure
_________
Subtask 51-78-00-160-051
A. Removal of the Corrosion Preventive Compound
WARNING : OBEY THE MANUFACTURERS INSTRUCTIONS WHEN YOU USE THIS/THESE
_______
MATERIAL/S.
USE PROTECTIVE CLOTHING, RUBBER GLOVES, GOGGLES AND A MASK.
(1) Apply a thin layer of the CLEANING AGENTS (Material No. 11-032) to
the area.
(2) Let the CLEANING AGENTS (Material No. 11-032) soak into the corrosion
preventive compound for a minimum of 20 minutes.
(3) Flush the area with water with a maximum temperature of 50 deg.C
(122.00 deg.F). Use a CLEANING EQUIPMENT - HIGH PRESSURE to do this,
as follows:
(a) Hold the spray gun of the CLEANING EQUIPMENT - HIGH PRESSURE with
an angle of 30 to 45 degrees to the surface.
(b) Make sure that the distance between the nozzle of the CLEANING
EQUIPMENT - HIGH PRESSURE and the surface is more than 250 mm
(9.8425 in.).
(c) Do not apply more than 80 bar (1160.3016 psi) water pressure to
the structure.
(d) Do not apply more than 2 bar (29.0075 psi) water pressure to the
composite materials.
(5) If necessary repair the corroded areas (Ref. TASK 51-74-11-300-001).
(6) If necessary repair the damaged paint on aluminum and/or composite
materials (Ref. TASK 51-75-12-300-001) and (Ref. TASK 51-75-12-300003).
(7) Apply the new corrosion preventive compound as necessary (Ref. ASRM
51-23-12-001).

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Page 723
Nov 01/06
5. Close-up
________
Subtask 51-78-00-410-055
A. Close Access
items.
(2) Install all the components that were removed for the removal of the
corrosion preventive compound.
Subtask 51-78-00-865-062
B. Remove the safety clip(s) and tag(s) and close the circuit breaker(s) of
all the electrical components and systems in the work area.
Subtask 51-78-00-942-055
C. Remove the ground support and maintenance equipment, the special and

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Page 724
Nov 01/06
TASK 51-78-00-916-001
Application of Temporary Protection System (TPS)
CAUTION : DO NOT APPLY THE CLEANING AGENTS TO THESE PARTS:
_______
- BEARINGS, ACTUATORS, FITTINGS
- ACRYLICS OR POLYCARBONATE MATERIALS
- ELECTRICAL HARNESSES, SENSORS, CONNECTORS.
CLEANING AGENT ON OR IN THESE PARTS CAN CAUSE DAMAGE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-026
Material No. 15-005
Material No. 15-006
Material No. 15-007
Material No. 15-008
Material No. 15-009
GB DEF-STAN
68-148/1
AIB TN 10138 TYPE I GRADE 2
CORROSION PREVENTIVE TEMPORARY PROTECTIVE COMPOUND
(Ref. 20-31-00)
AIB TN 10138 TYPE I GRADE 3
(Ref. 20-31-00)
AIB TN 10138
TYPE II GRADE 1
(Ref. 20-31-00)
AIB TN 10138
TYPE II GRADE 2
(Ref. 20-31-00)
F
AIMS 09-08-003 TYPE III
CORROSION PREVENTIVE TEMPORY PROTECTIVE COMPOUND
(Ref. 20-31-00)

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Page 725
Nov 01/06
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 19-003
USA AMS 3819

------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------51-78-00-991-002
Fig. 701
3. __________
Job Set-up
Subtask 51-78-00-865-063
A. Open safety and tag the circuit breakers of all the electrical components
Subtask 51-78-00-941-057
B. Get Access
(1) Get access to the area(s) where you will do the inspection/check.
Subtask 51-78-00-010-056
C. Removal of components
(1) Remove all components necessary from the TPS inspection/check area.
(2) Remove all insulation blankets/material from the inspection/check
area.

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Page 726
Nov 01/06
4. Procedure
_________
(Ref. Fig. 701/TASK 51-78-00-991-002)
Subtask 51-78-00-160-052
A. Cleaning and/or removal of the Temporary Protective System (TPS)
(1) Does the MPD task make the removal of the TPS necessary.
(a) If the TPS does not need to be removed, clean the inspection area
with the CLEANING AGENTS (Material No. 11-026) and a clean
lint-free cloth MISCELLANEOUS (Material No. 19-003).
(b) If the TPS has to be removed, use a SCRAPER - NON METALLIC to
remove the TPS application. Only remove sufficient TPS to allow
for the inspection procedure. Clean the area with the CLEANING
AGENTS (Material No. 11-026) and a clean lint-free cloth
Subtask 51-78-00-210-051
B. Inspection of the Temporary Protection System (TPS)
(1) Inspect the area where the TPS is applied.
(2) If the TPS is in the correct condition, a secondary layer of the same
TPS can be applied over the first layer.
(3) If the TPS is not in the correct condition, remove the TPS, clean the
area and apply a new layer of the correct TPS type.
(4) If the TPS has been removed for an inspection, apply a new layer of
the TPS to the inspection area.

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Page 727
Nov 01/06
Temporary Protection System (TPS)

Figure 701/TASK 51-78-00-991-002

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Page 728
Nov 01/06
Subtask 51-78-00-916-054
C. Application of the Temporary Protection System (TPS)
_______
DO NOT SMOKE.
(1) The three types of TPS are:
- STORAGE PRESERVATION (Material No. 15-005), STORAGE PRESERVATION
(Material No. 15-006), TPS type 1
- STORAGE PRESERVATION (Material No. 15-007), STORAGE PRESERVATION
(Material No. 15-008), TPS type 2
- STORAGE PRESERVATION (Material No. 15-009), TPS type 3.
R
R
R
R
R
(2) Make sure the correct TPS type is applied to the surface.
(3) If TPS type 1 has been removed, apply the same TPS type 1 to the
surface.
(4) If TPS type 1 and TPS type 2 have been applied in an inspection area
and are removed:
- Apply the same TPS type 1 and type 2 or, as an alternative, apply
the TPS type 3 to the inspection area.
(5) Make sure that the TPS is not applied to the insulating
blankets/material.
5. Close-up
________
Subtask 51-78-00-410-056
A. Close Access
items.

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Page 729
May 01/09
Subtask 51-78-00-865-064
B. Remove the safety clip(s) and tag(s) and close the circuit breaker(s) of
all the electrical components and systems in the inspection area.
(1) Install the insulation blankets/material if necessary.
Subtask 51-78-00-942-056
C. Remove the ground support and maintenance equipment, the special and

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Page 730
Nov 01/06
TASK 51-78-00-615-006
Cleaning of the Door Entry Drains
_______
DO NOT SMOKE.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------R
R
No specific
No specific
No specific
1 ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE

1 AIR SOURCE 0,3 TO 0,7 BAR (5 TO 10 PSI)- FILTERED,
DRY
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No. 11-026
Material No. 19-003
GB DEF-STAN
68-148/1
USA AMS 3819

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Page 731
May 01/09
3. __________
Job Set-up
Subtask 51-78-00-010-057
A. Get Access
(1) Put the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE in position at the
applicable passenger door.
(2) Open the applicable passenger door.
(3) Get access to the applicable water drain(s).
(4) Remove the correct forward or aft floor panel(s) at the door entry
position.
4. Procedure
_________
Subtask 51-78-00-110-056
(1) Clean the floor panel with the CLEANING AGENTS (Material No. 11-026)
(2) Make sure that the water drain collector(s) are clean and in the
correct condition.
(3) Remove the sealant/contamination with a SCRAPER - NON METALLIC and a
clean lint-free cloth MISCELLANEOUS (Material No. 19-003)
(4) Examine the condition of the drains:
(a) Put water down the drain collector(s) and let it drain.
(b) Make sure that the water drains away from below the fuselage.
(5) If the water does not drain away from the drain collector(s):
R
R
(a) Use a low pressure AIR SOURCE 0,3 TO 0,7 BAR (5 TO 10 PSI)FILTERED, DRY attached to the drain collector(s) to remove the
contamination.
(b) Put water down the drain collector(s) and make sure that it
drains away from below the fuselage.

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Page 732
May 01/09
5. Close-up
________
Subtask 51-78-00-410-057
A. Close Access
(1) Install the entry-door floor panel(s) in the correct position(s).

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Page 733
Nov 01/06

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__________

L.E.P. 1- 2 REVISED TO REFLECT THIS REVISION INDICATING

COATINGS APPLICATION - GENERAL

REPAIRS OF MINOR DAMAGE

REPAIRS OF MINOR DAMAGE

STANDARD COMPOSITE REPAIRS

STANDARDS PRACTICES AND STRUCTURES - GENERAL - DESCRIPTION AND OPERATION

PROTECTIVE TREATMENT - DESCRIPTION AND OPERATION

Protective Treatment Zones - Fuselage and Stabilizers

Protective Treatment Zones - Wing

B. Aircraft Internal Areas

PROTECTIVE TREATMENT - CLEANING/PAINTING

Material No. 05-025

CORROSION PREVENTION - DESCRIPTION AND OPERATION

(4) An application of paint or soft varnish, after components are

COATINGS APPLICATION - GENERAL - DESCRIPTION AND OPERATION

A. Aluminum Alloy Structure

NOTE : The abbreviation CAA is used for Chromic Acid Anodizing.

Aluminum alloy structure is CAA prepared and then painted. External

D. Corrosion-Resistant Steel Components

SEALING - GENERAL - DESCRIPTION AND OPERATION

(b) The nonpressurized areas of the aircraft which include:

REPAIRS - DESCRIPTION AND OPERATION

REPAIRS OF MINOR DAMAGE - DESCRIPTION AND OPERATION

REPAIRS OF MINOR DAMAGE - INSPECTION/CHECK

hot air dryer

WARNING : DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS

(7) Neutralize the area with a 5 % chromic oxide solution.

REPAIR OF MINOR DAMAGE - REPAIRS

abrasive cloth grade 280

Material No. 05-025

Inspection of Minor Damage to Aluminum Cladding

abrasive cloth grade 280

Material No. 05-025

Repair of Corroded Areas

abrasive cloth grade 280

Material No. 05-025

Repair of Corroded Areas

1 CLOTH-EMERY (GRADE 400)

Repair of Major Paint Damage on Light Alloy and

(1) Measure the depth of the dent.

(3) If a repair of the dent is necessary:

(5) Fill the dent:

(9) Apply the applicable surface protection (Ref. TASK 51-75-12-300-001).

REPAIRS OF CORRODED AREAS - DESCRIPTION AND OPERATION

REPAIR OF CORRODED AREAS - REPAIRS

abrasive cloth 400 grade

Repair of Major Paint Damage on Light Alloy and

WARNING : DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS

abrasive cloth (grade 400)

Wax and Polish Protection on Unpainted Light Alloy

WARNING : DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS

Repair of Major Paint Damage on Light Alloy and

WARNING : DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS

Masking of the Windows

PAINT REPAIRS - DESCRIPTION AND OPERATION

STRIPPING/PAINT REMOVAL - CLEANING/PAINTING

the joints of external skin panels (except in fuel

(2) If necessary, install the correct protection covers/devices to

abrasive paper, grade 220 or 320

Material No. 19-011

REPAIR OF PAINT COATINGS - REPAIRS

the original certified

NOTE : The abbreviation CAA is used for Chromic Acid Anodizing.