SPM 20-00-01

COMPONENT MAINTENANCE MANUAL
PART No. STANDARD PRACTICES MANUAL
TRANSMITTAL SHEET
-TO:
HOLDERS OF COMPONENT MAINTENANCE MANUAL 20-00-01, Revision No. 1 dated Nov 29/12 is
attached.
FILING INSTRUCTIONS
Affected pages are listed on the 'LIST OF EFFECTIVE PAGES' and designated as follows
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D = Deleted (to be removed)
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Make sure that the content of the manual agrees with the LIST OF EFFECTIVE PAGES.
File the TRANSMITTAL SHEET separately.
Remove and destroy the pages that are affected by this revision.
Highlights
This revision updates the standard practices manual and changes some cleaning and repair procedures.
New repair procedures have been added. It also updates the consumable materials list. Please replace
the complete existing manual with this issue.
-Title, Logo updated. Statement of initial certification removed. Address updated.
-ROR, Revision No. updated.
-LEP, Changed to show revised and new pages.
-TOC, Updated and corrected.
-INTRO 1, Internet and e-mail links added. Company name updated.
-INTRO 2, Abbreviations updated.
-4001, Warnings updated. Special tools table 4001 added.
-4002, Consumables Table renumbered 4002 updated. Material Ref No.s updated. Cleaning procedures
updated
-4003, Cleaning procedures updated. Material Ref No.s updated.
-4004, Cleaning procedures updated. Material Ref No.s updated.
-Repair No.1, 6001, Repair description changed. Repair procedure updated.
-Repair No. 1, 6002, Blank.
-Repair No. 1, 6003, Deleted.
-Repair No. 1, 6004, Deleted
-Repair No. 2, 6001, Table 6001 and Table 6002 updated. Procedure updated.
-Repair No. 2, 6002, Material Ref No.s updated. Procedure updated.
-Repair No. 3, 6001, Table 6001 and Table 6002 updated.
-Repair No. 3, 6002, Notes added. Material Ref No.s updated.
-Repair No. 3, 6003, Material Ref No.s updated.
TRANSMITTAL
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-Repair No. 3, 6004, Text run-on.
-Repair No. 4, 6001 to 6003, Repair procedure added.
-9001, Table 9001 updated.
-9002, Table 9002 updated.
-9003, Text run-on.
-9004, Text run-on.
TRANSMITTAL
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(K2523)
STANDARD PRACTICES MANUAL
© EATON, AEROSPACE GROUP

Abbey Park, Southampton Road, Titchfield, Fareham, Hampshire, PO14 4QA, U.K.
Tel: +44 (0)1329 853000 - Fax: +44 (0)1329 853714
REVISION No. 1
ISSUE: Sep 30/2004 20-00-01 20040
930
TP 1
Nov 29/12
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RECORD OF REVISIONS
REV. ISSUE INSERTED REV. ISSUE INSERTED

No. DATE No. DATE
DATE BY DATE BY
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1 Nov 11/04 Incorporated
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LIST OF EFFECTIVE PAGES
TITLE PAGE 1 Nov 29/12 REPAIR NO. 4 6001 Nov 29/12

2 Blank 6002 Nov 29/12
6003 Nov 29/12
RECORD OF REVISIONS 1 Nov 29/12 6004 Blank
2 Blank
REPAIR NO. 5 6001 Nov 29/12
RECORD OF TEMPORARY 6002 Nov 29/12
REVISIONS 1 Sep 30/04 6003 Nov 29/12
2 Blank 6004 Blank
SERVICE BULLETIN LIST 1 Sep 30/04 REPAIR NO. 6 6001 Nov 29/12
2 Blank 6002 Nov 29/12
6003 Nov 29/12
LIST OF EFFECTIVE PAGES 1 Nov 29/12 6004 Nov 29/12
2 Blank
TABLE OF CONTENTS 1 Nov 29/12 6002 Nov 29/12
2 Nov 29/12
3 Nov 29/12 REPAIR NO. 8 6001 Nov 29/12
4 Blank 6002 Nov 29/12
6003 Nov 29/12
INTRODUCTION 1 Nov 29/12 6004 Blank
2 Nov 29/12
CLEANING 4001 Nov 29/12 6002 Nov 29/12
4002 Nov 29/12 6003 Nov 29/12
4003 Nov 29/12 6004 Blank
4004 Nov 29/12
4005 Nov 29/12 REPAIR - NO. 10 1 Nov 29/12
4006 Blank 2 Nov 29/12
3 Nov 29/12
REPAIR NO. 1 6001 Nov 29/12 4 Blank
6002 Blank
REPAIR NO. 2 6001 Nov 29/12 2 Nov 29/12
6002 Nov 29/12
SPECIAL TOOLS, FIXTURES,
REPAIR NO. 3 6001 Nov 29/12 EQUIPMENT AND
6002 Nov 29/12 CONSUMABLES 9001 Nov 29/12
6003 Nov 29/12 9002 Nov 29/12
6004 Nov 29/12 9003 Nov 29/12
9004 Nov 29/12
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TABLE OF CONTENTS
Page
INTRODUCTION
1. Introduction INTRO 1
A. General INTRO 1
B. Verification INTRO 1
C. Customer Support INTRO 1
2. Abbreviations INTRO 2
CLEANING
1. Job Set-up Information 4001
A. Tools, Fixtures and Equipment 4001
B. Consumables 4001
C. Referenced Information 4002
2. Procedure 4002
A. All Metal Parts 4002
B. Adhesive and Jointing Compound 4002
C. Carbon Bearings 4003
D. Shaft and Rotor Assemblies 4003
E. Stator Assemblies 4003
F. Lacquer from bonding surface joints 4004
G. Aluminium alloy bonding surfaces 4005
REPAIR No. 1
1. Removal of corrosion and lifted metal 6001
A. Job Set-up Information 6001
B. Job Set-up 6001
C. Repair the surface 6001
REPAIR No. 2
1. Replace Damaged Label 6001
B. Job Set-up 6001
C. Prepare the Label 6002
D. Prepare and Apply the Adhesive 6002
REPAIR No. 3
1. Replace Damaged Threaded Inserts 6001
B. Job Set-up 6001
C. Remove the Insert 6001
D. Cleaning 6002
E. Install the Tanged Insert 6002
F. Install the Tangless Insert 6003
TOC
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TABLE OF CONTENTS (Cont’d)
Page
REPAIR No. 4
1. Stator Assembly - Repair Lacquer 6001
A. Job set-up information 6001
B. Job set-up 6001
C. Procedure 6002
REPAIR No. 5
1. Shaft and Rotor Assembly - Repair Lacquer 6001
B. Job set-up 6001
C. Procedure 6002
Repair No. 6
1. Replace or Repair Epoxy Paint 6001
B. Job Set-up - Repair Existing Epoxy Paint 6001
C. Job Set-up - Replace Existing Epoxy Paint 6003
REPAIR No. 7
1. Deoxidize aluminium alloy surfaces 6001
B. Job Set-up 6001
C. Solvent and Abrasive Pad Method 6001
D. Deoxidant Solution 6002
REPAIR No. 8
1. Repair Damaged Class 1A Aluminium Alloy Surfaces (Standard Anodized Finish) 6001
B. Job Set-up 6001
REPAIR No. 9
1. Repair Damaged Class 3 Aluminium Alloy Surfaces (Bonding Surfaces) 6001
B. Job Set-up 6001
REPAIR - No. 10
1. Replace the Bonding Surface Lacquer
2. 6001
B. Job set-up 6001
C. Procedure 6001
REPAIR No. 11
1. Replace damage to corrosion resistant finish
2. 6001
B. Job set-up 6001
C. Procedure 6001
TOC
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TABLE OF CONTENTS (Cont’d)
Page
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES

1. Special Tools, Fixtures and Equipment 9001
A. General 9001
2. Consumables 9001
A. List of Materials 9001
ILLUSTRATED PARTS LIST NOT APPLICABLE
LIST OF ILLUSTRATIONS
Figure
6001 Threaded Insert Removal Tool and Tang Break-off Tool 6002
6002 Installation of Tanged Threaded Inserts 6003
6003 Tangless Threaded Insert, Insertion Tool 6004
LIST OF TABLES
Table
4001 Special tools, Fixtures and Equipment 4001

4002 Consumables 4002
6001 Tools, Fixtures and Equipment 6001
6001 Tools, Fixtures and equipment 6001
6003 Epoxy primer curing times 6002
6004 Epoxy paint curing times 6002
6005 Epoxy primer curing times 6003
6006 Epoxy paint curing times 6004
6001 Tools, Fixtures and equipment 6001
6002 Lacquer minimum cure times 6002
9001 Special tools, fixtures and equipment 9001
TOC
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INTRODUCTION
TASK 20-00-01-99F-814-A01
1. Introduction
A. General
(1) This publication is a Standard Practices Manual written to specification ATA 2200 in
Simplified English. It contains standard procedures for the maintenance of components
when removed from the aircraft or equipment. The procedures are those approved by
Eaton’s, Aerospace Group but you can use different procedures if you get the same results.
(2) All measurements in this manual are given in SI (metric) units with British units given after
(in parenthesis).
(3) So that our revision distribution database can be kept up to date, please tell us if you
change your address. Before you use this manual you must make sure the revision status is
correct. Use the URL given here:
www.eaton.com/EatonCom/Markets/Aerospace/CustomerServices/
IndexofCMMsandServiceBulletins/index.htm
(4) Maintenance Task Orientation Support System (MTOSS) task and sub-task identification is
used in this manual.This is for Electronic Data Processing (EDP) and the MTOSS numbers
can be ignored by the users of this manual.
WARNING: HEALTH AND SAFETY. ALL THE MATERIALS AND CONSUMABLES

IDENTIFIED IN THIS MANUAL MUST BE USED IN ACCORDANCE WITH THE
ORIGINAL MANUFACTURERS PRODUCT HEALTH AND SAFETY DATA, IN
CONJUNCTION WITH APPLICABLE LOCAL AND NATIONAL REGULATIONS,
TO ENSURE SAFE WORKING PRACTICE.
B. Verification
(1) All procedures have been verified by actual performance of these tasks at Eaton’s,
Aerospace Group.
C. Customer support
(1) Eaton’s Aerospace Group Customer Support Department supplies Customer Support at the
address given below:
Eaton, Aerospace Group
Abbey Park
Titchfield, Fareham
Hampshire, PO14 4QA, U.K.
Tel: +44(0)1329 853000 Fax: 01329 853797
Fax (Customer Support direct): 01329 853714
E-mail: TechPubsFPG-TITUK@Eaton.com
INTRO
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TASK 20-00-01-99F-815-A01
2. Abbreviations
C Celsius
Deg Degree
F Fahrenheit
Fig. Figure
g Gram
IPL Illustrated Parts List
mm Millimeter
No. Number
oz Ounce
psi Pounds per square inch
Ref. Reference
UNC Unified National Coarse
UNF Unified National Fine
INTRO
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CLEANING
TASK 20-00-01-99F-804-A01
1. Job Set-up Information
SUBTASK 20-00-01-94C-002-A01
A. Tools, Fixtures and Equipment
NOTE: Refer to SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES for full
details of listed items.
Table 4001 Special tools, Fixtures and Equipment
REFERENCE NAME
Local Supply Ultrasonic Tank
SUBTASK 20-00-01-94A-002-A01
B. Consumables
WARNING: ALL THE MATERIALS AND CONSUMABLES IDENTIFIED IN THIS MANUAL

MUST BE USED IN ACCORDANCE WITH THE ORIGINAL MANUFACTURERS
PRODUCT HEALTH AND SAFETY DATA, IN CONJUNCTION WITH APPLICABLE
LOCAL AND NATIONAL REGULATIONS, TO ENSURE SAFE WORKING
PRACTICE.
WARNING: MAKE SURE THAT YOU USE THE CLEANING SOLVENTS CORRECTLY. THE
CLEANING SOLVENT MATERIALS ARE FLAMMABLE, SKIN IRRITANTS AND A
MILD POISON. THEY CAN CAUSE INJURY TO PERSONNEL. IF YOU GET
CLEANING SOLVENT ON YOUR SKIN REMOVE IT WITH SOAP AND WATER. IF
IT GETS IN YOUR EYES FLUSH THEM WITH CLEAN WATER AND GET
MEDICAL AID.
WARNING: DO NOT USE CLEANING SOLVENTS NEAR A NAKED FLAME. CLEANING

SOLVENT IS FLAMMABLE AND EXPLOSIVE. IT CAN CAUSE INJURY TO
PERSONNEL AND DAMAGE TO EQUIPMENT.
WARNING: THE CLEANING AREA MUST BE VENTED TO MAKE SURE THAT THERE IS
SUFFICIENT AIRFLOW TO KEEP THE FUMES BELOW THE LEVEL INDICATED
IN THE MATERIAL SAFETY DATA SHEET.
WARNING: BEFORE YOU USE THE CLEANING SOLVENTS PUT ON ACID RESISTANT
GLOVES (MATERIAL NO. 9) AND EYESHIELDS (MATERIAL NO. 10). DO NOT
LET THE CLEANING SOLVENT TOUCH THE SKIN, MOUTH OR EYES.
CAUTION: USE ONLY SPECIFIED CLEANING MATERIALS AND SOLUTIONS OR THEIR

EQUIVALENTS. THE SURFACE PROTECTION COULD BE DAMAGED IF
UNSPECIFIED MATERIALS ARE USED.
CAUTION: DO NOT LET CLEANING SOLVENTS TOUCH RUBBER PARTS.
details of listed items.
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Table 4002 Consumables
REFERENCE NAME
Material No. 1 Cleaning solvent - ultrasonic tank

Material No. 2 Absorbent material
Material No.6 Bag, polythene
Material No. 7 Cleaning solvent - general purpose and de-
greasing
Material No. 8 Cleaning fluid - heavy duty
Material No.9 Gloves, acid resistant
Material No. 10 Eye shields
Material No.11 Brush, soft
Material No. 16 Gloves, heat resistant
Material No.24 Abrasive pad
Material No. 33 Mechanical remover
SUBTASK 20-00-01-99E-002-A01
C. Referenced Information
(1) None.
TASK 20-00-01-100-801-A01
2. Procedure
SUBTASK 20-00-01-110-009-A01
A. All Metal Parts
(1) Make sure all mating faces, all grooves for sealing rings and all keyways are clean.
(2) Clean all-metal parts with absorbent material (Material No. 2) and general purpose cleaning
solvent (Material No. 7). Make sure that you flush all holes and openings with clean running
water.
(3) Dry all parts with absorbent material (Material No. 2) or clean, dry, low pressure air 6.90 bar
(100 psi max).
(4) Put all parts in a clean polythene bag (Material No. 6) if you cannot complete the
maintenance procedure immediately.
SUBTASK 20-00-01-110-010-A01
B. Adhesive and Jointing Compound
(1) Use absorbent material (Material No. 2), made moist with solvent (Material No. 8), and apply
to the surface to be cleaned, let it stay for 2 minutes.
(2) Use an abrasive pad (Material No. 24), clean all surfaces that have a layer of jointing
compound or unwanted adhesive.
(3) If necessary do step B. (1) and B. (2) again until all jointing compound or adhesive has been
removed.
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(100 psi max).
SUBTASK 20-00-01-110-011-A01
C. Carbon Bearings
(1) Use a brush (Material No. 11) and general purpose cleaning solvent (Material No. 7) to
clean the bearings.
(100 psi max).
SUBTASK 20-00-01-110-012-A01
D. Shaft and Rotor Assemblies
NOTE: If there is an interval after cleaning and before you apply the varnish, examine the shaft
and rotor assembly for corrosion. If corrosion has occurred, refer to repair No.5 and
remove the corrosion, then clean the shaft and rotor again.
NOTE: For standard cleaning, use an ultrasonic cleaner that can operate at a frequency of 45
KHZ.
For a component with heavy scaling or contamination, use an ultrasonic cleaner that can
operate at a frequency of 25 KHZ.
NOTE: Refer to the manufacturers instructions for the operating temperature of the solvent
(Material No. 1).
(1) Put the shaft and rotor assembly into an ultrasonic tank of solvent (Material No. 1), make
sure the shaft and rotor assembly is fully covered with solvent.
(2) Set the ultrasonic cleaner to ON and operate it for a maximum of 10 minutes.
(3) Set the ultrasonic cleaner to OFF and remove the shaft and rotor assembly from the tank.
(4) Examine the shaft and rotor assembly for surface or trapped contamination. If there is
contamination, do steps D. (1) to D. (4) again.
(5) Let the shaft and rotor assembly air dry for 30 +/- 2 minutes at room temperature.
(6) Dry the shaft and rotor assembly in an air circulating oven for 120 +/- 5 minutes at 170 to 180
deg C (338 to 356 deg F).
WARNING: PUT ON HEAT RESISTANT GLOVES (MATERIAL NO. 16) BEFORE YOU
REMOVE HOT COMPONENTS.
(7) Remove the shaft and rotor assembly from the oven.
(8) Let the temperature of the shaft and rotor assembly decrease to room temperature.
(9) Examine the shaft and rotor assembly for surface or trapped contamination. If there is
contamination, do steps D. (1) to D. (4) again.
SUBTASK 20-00-01-110-013-A01
E. Stator Assemblies
WARNING: ONLY DO THIS PROCEDURE IN THIS MANUAL IF THE CMM REFERS TO THE
STANDARD PRACTICES MANUAL.
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NOTE: If there is an interval after cleaning and before you apply the varnish, examine the stator
assembly for corrosion. If corrosion has occurred, refer to repair No.4 and remove the
corrosion, then clean the shaft and rotor again.
NOTE: For standard cleaning, use an ultrasonic cleaner that can operate at a frequency of 45
KHZ.
For a component with heavy scaling or contamination, use an ultrasonic cleaner that can
operate at a frequency of 25 KHZ.
NOTE: Refer to the manufacturers instructions for the operating temperature of the solvent
(Material No. 1).
(1) Put the stator assembly into an ultrasonic tank of solvent (Material No. 1), make sure the
stator assembly is fully covered with solvent.
(2) Set the ultrasonic cleaner to ON and operate it for a maximum of 10 minutes.
(3) Set the ultrasonic cleaner to OFF and remove the stator assembly from the tank.
(4) Examine the stator assembly for surface or trapped contamination. If there is contamination,
do steps E. (1) to E. (4) again.
(5) Let the stator assembly air dry for 30 +/- 2 minutes at room temperature
CAUTION: DO NOT LET THE OVEN TEMPERATURE BE MORE THAN 180 DEG C (356 DEG
F). THE STATOR ASSEMBLY AND THE FUSES WILL BE DAMAGED.
(6) Dry the stator assembly in an air circulating oven for 120 +/- 5 minutes at 170 to 180 deg C
(338 to 356 deg F).
(7) Remove the stator from the oven and let it to cool to room temperature.
(8) Examine the stator assembly for surface or trapped contamination. If there is contamination,
do steps E. (1) to E. (4) again.
SUBTASK 20-00-01-110-018-A01
F. Lacquer from bonding surface joints
(1) Use an applicable mechanical remover (Material No. 33) to remove the old lacquer from
between 2 and 3 mm from the fay surface.
NOTE: If you damage the chromate surface, refer to REPAIR and do the Chromate
Conversion repair procedures.
(2) Use clean dry air to remove all particles.
(3) Use a lint-free cloth (Material No.2) dampened with iso-propyl-alcohol (IPA) solvent (Material
No. 7) to fully clean the surface where you removed the old lacquer.
(4) Dry the surface with a lint-free cloth.
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SUBTASK 20-00-01-110-019-A01
G. Aluminium alloy bonding surfaces
(1) Abrasive Clean
(a) Use a n abrasive pad or abrasive paper (Material No. 33) to remove the surface finish.
You must use a smooth, continuous, circular motion.
(b) You must see a bright aluminium bonding surface.
(c) Do not remove more aluminium than is necessary.
(d) Use a lint-free cloth (Material No.2) dampened with iso-propyl-alcohol (IPA) solvent
(Material No. 7) to fully clean the bonding surface.
(e) Dry the surface with a lint-free cloth.
(2) Solvent clean
(a) Use a lint-free cloth (Material No.2) dampened with iso-propyl-alcohol (IPA) solvent
(Material No. 7) to fully clean the bonding surface.
(b) Dry the surface with a lint-free cloth.
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REPAIR No. 1
TASK 20-00-01-380-805-A01
1. Removal of corrosion and lifted metal
SUBTASK 20-00-01-380-012-A01
WARNING: DO NOT USE THIS PROCEDURE FOR DAMAGE TO INTERNAL SURFACES TO

O-RING GROOVES. THE PUMP OR AFFECTED COMPONENT MUST BE
REPLACED.
(1) This procedure is to repair the component surface where the surface is:
- Corrosion that can be removed with abrasive paper.
- Has lifted metal on the surface.
SUBTASK 20-00-01-380-013-A01
A. Job Set-up Information
(1) Tools, Fixtures and Equipment
(a) None
(2) Consumables
NOTE: You can use equivalent alternatives.
REFERENCE NAME
Material No. 12 Fine grade abrasive paper
SUBTASK 20-00-01-110-014-A01
B. Job Set-up
(1) Clean the surface where you must repair the surface. (Ref CLEANING).
SUBTASK 20-00-01-120-005-A01
C. Repair the surface
(1) With a fine grade abrasive paper (Material No. 12) and a light hand polish, remove light
corrosion and all lifted metal from burrs and scores. If this procedure does not remove the
defective material, the component must be replaced.
REPAIR NO. 1
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REPAIR No. 2
TASK 20-00-01-300-802-A01
1. Replace Damaged Label
SUBTASK 20-00-01-360-005-A01
(1) Use this procedure to replace a damaged label or when a new label must be attached to a
new body.
SUBTASK 20-00-01-380-005-A01
Table 6001 Tools, Fixtures and Equipment
REFERENCE NAME
Local supply Ventilated oven

Local supply Vibro-etch machine
(2) Consumables
REFERENCE NAME

Material No. 3 Adhesive
Material No. 12 Abrasive paper
Material No. 17 Tape, adhesive, heat resistant
Material No. 18 Spatula
Material No. 24 Abrasive pad
SUBTASK 20-00-01-360-006-A01
B. Job Set-up
(1) Use the vibro-etch machine to make a copy of the old label data on the new label.
(2) If necessary, remove the damaged label.
(a) Place in an oven and heat to a temperature 150L CL (302L FL) maximum, for 5 minutes
+/- 1 minute.
REPAIR NO. 2
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(b) Put on heat resistant gloves (Material NO. 16) and remove component from the oven.
(c) Use an applicable tool, remove the damaged label.
(d) Let the component become cool.
(3) Remove all remaining adhesive from the component (Ref, CLEANING).
(4) If necessary, repair damaged surfaces (Ref. REPAIR No. 1).
NOTE: After surface preparation, you must not wait more than 16 hours to attach the new
label.
SUBTASK 20-00-01-360-007-A01
C. Prepare the Label
(1) Prepare the back of the label as follows:.
(a) Use an abrasive pad (Material No. 24) or abrasive paper (Material No. 12) to provide a
suitable surface for the adhesive. Do this in two different directions until you can see
new aluminium alloy.
(b) Flush the surface with clean water.
(c) If necessary, do para 1.C.(1) again until you see a water-break free surface.
(d) Use clean absorbent material (Material No. 2) and dry the surface.
(2) Protect the rear of the label.
(a) Do repair No. 8, Paragraphs 1.B.(2) or 1.B.(3).
(3) If necessary, bend the label to agree with the shape of the body.
SUBTASK 20-00-01-360-008-A01
D. Prepare and Apply the Adhesive
WARNING: REFER TO THE MANUFACTURER’S PRODUCT, HEALTH AND SAFETY DATA

SHEETS AND YOUR APPICABLE LOCAL AND NATIONAL REGULATIONS
WHEN YOU USE SCOTCH-WELD 1838 B/A.
(1) Refer to the appropriate CMM and prepare the adhesive (Material No. 3).
(2) Use a spatula (Material No. 18) to apply a layer of adhesive (Material No. 3) to the label.
(3) Put the label into the correct position, if required, refer to appropriate CMM for label
positioning tool, and lightly push it.
(4) Remove unwanted adhesive with a lint-free cloth (Material No. 2).
(5) Use tape (Material No. 17) or appropriate label positioning tool to keep the label in position.
(6) Refer to the appropriate CMM and cure the adhesive (Material No. 3).
(7) Make sure that the label is attached correctly.
(8) Remove the adhesive tape or label positioning tool (if used), and clean the component (Ref.
CLEANING).
REPAIR NO. 2
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REPAIR No. 3
TASK 20-00-01-300-803-A01
1. Replace Damaged Threaded Inserts
SUBTASK 20-00-01-350-013-A01
NOTE:. Only do this procedure in this manual if the CMM refers to the standard Practices Manual.
(1) Use this procedure to replace damaged threaded inserts. Use the procedure at 1.D. to install
threaded inserts with tangs. Use the procedure at 1.E. to install threaded inserts without
tangs (tangless).
SUBTASK 20-00-01-350-014-A01
NOTE: Refer to PGBLK-20-00-01-9000 for full details of listed items.
REFERENCE QUANTITY NAME
Local supply For complete list of insert

tools, refer to Table 9001
(2) Consumables
REFERENCE NAME
Material No. 4 Jointing material
SUBTASK 20-00-01-350-016-A01
B. Job Set-up
(1) Not applicable.
SUBTASK 20-00-01-350-017-A01
C. Remove the Insert
(1) Refer to Fig. 6001. Put the blade of the applicable extraction tool in the insert.
(2) Turn the extraction tool counterclockwise until the insert is removed.
(3) Visually examine the hole for damage.
(4) Do a check of the threads with the applicable plug gauge.
REPAIR NO. 3
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NOTE:. You can use an alternative method if you get the same results.
NOTE: Minor damage to the threads in the holes can be removed by cutting the thread
again.
NOTE: If the thread damage cannot be repaired by re-cutting the thread, replace the
component.
NOTE: If the threads are too large, replace the component.

Insert Removal Tool & Tang Break-off Tool Fig. Sheet 1
Threaded Insert Removal Tool and Tang Break-off Tool

Figure 6001 /GRAPHIC 20-00-01-991-604-A01
SUBTASK 20-00-01-350-020-A01
D. Cleaning
(1) Refer to CLEANING to remove the jointing compound.
SUBTASK 20-00-01-350-019-A01
E. Install the Tanged Insert
(1) Refer to applicable CMM, if necessary, apply the jointing compound (Material No. 4) to the
new insert.
(2) Put the new insert in the applicable insertion tool.
(a) Refer to Fig. 6002, illustration A. Wind the mandrel away from the nozzle.
(b) Put the insert in the chamber of the tool with the tang against the nozzle end.
(c) Wind the mandrel into the insert until it engages the tang of the insert.
(d) Refer to Fig. 6002, illustration B. Continue to wind the mandrel clockwise until the tang
is in line with the end of the nozzle.
REPAIR NO. 3
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Installation of Tanged Threaded Inserts Fig. Sheet 1
Installation of Tanged Threaded Inserts

Figure 6002 /GRAPHIC 20-00-01-991-605-A01
(3) Install the insert to the component.
(a) Refer to Fig. 6002, illustration C. Put the insertion tool at 90 degrees to the surface of
the component.
CAUTION: MAKE SURE THAT YOU DO NOT TRY TO PUSH THE INSERT INTO THE
HOLE. TOO MUCH FORWARD PRESSURE CAN CAUSE DAMAGE TO THE
COMPONENT THREAD.
(b) Carefully wind the insert into the hole until the top is between one and one and a half
threads below the surface.
(c) Remove the insertion tool.
(4) Remove the Tang.
NOTE: This procedure is for use with notched tanged inserts only.
(a) Refer to Fig. 6001. Put the applicable break-off tool on the tang of the insert.
(b) Hit the striker to break the tang.
(c) Remove the tool and the tang.
(5) Remove all unwanted jointing compound (Ref. PGBLK-20-00-01-4000).
(6) Refer to applicable CMM, if necessary, cure the jointing compound (Material No. 4) as
specified.
SUBTASK 20-00-01-350-021-A01
F. Install the Tangless Insert
(1) Refer to applicable CMM, if necessary, apply the jointing material (Material No. 4) to the new
insert.
REPAIR NO. 3
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(2) Adjust the stop collar (if present) on the applicable insertion tool.
(a) Refer to Fig. 6003. Loosen the stop collar with an applicable hexagonal wrench.
(b) Wind the mandrel out of the insert tool. Continue until the thread length is equal to the
length of the insert plus half a thread.
(c) Tighten the collar into position against the pre-winder body.
Tangless Threaded Insert, Insertion tool Fig. Sheet 1
Tangless Threaded Insert, Insertion Tool

Figure 6003 /GRAPHIC 20-00-01-991-606-A01
(3) Wind the mandrel into the pre-winder body until it is loose.
(4) Put an applicable tangless insert into the pre-winder body.
(5) Turn the mandrel until the pawl engages with the notch in the threaded insert.
(6) Wind the mandrel out of the tool until between one and two threads are out of the body.
(7) Put the insertion tool at 90 degrees to the surface of the component.
(8) Carefully wind the insert into the hole until the stop collar is against the tool body (or until the
insert is between one and one and a half threads below the surface, if the tool does not have
a stop collar).
(9) Wind the insertion tool out of the threaded insert.
(10) Remove all unwanted jointing compound (Ref. PGBLK-20-00-01-4000).
(11) Refer to applicable CMM, if necessary, cure the jointing compound (Material No. 4) as
specified.
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REPAIR No. 4
TASK 20-00-01-001-802-A01
1. Stator Assembly - Repair Lacquer
SUBTASK 20-00-01-350-022-A01
(1) Use this procedure to remove and replace the damaged lacquer on the bore of the stator
assembly.
SUBTASK 20-00-01-350-023-A01
A. Job set-up information
NOTE: Refer to PGBLK-20-00-01-9000 for full details of listed items
(2) Consumables
NOTE: You can use equivalent alternatives unless indicated *.
REFERENCE NAME
Material No. 6 Polythene bag

Material No. 9 Gloves, acid resistent
Material No. 11 Brush, soft
Material No. 16 Gloves, heat resistent
* Material No. 20 Lacquer, epoxy, CV115, DTD 5562 or
Rockhard 576-450-002
Material No. 21 Glass PTFE tape
Material No. 22 Grease proof paper
SUBTASK 20-00-01-350-024-A01
B. Job set-up
(1) Not applicable
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SUBTASK 20-00-01-350-025-A01
C. Procedure
(1) Use abrasive paper (Material No. 12) to remove all the lacquer from the bore of the stator
assembly.
(2) Make sure there is no corrosion on the bore of the stator assembly.
NOTE: If you cannot remove the corrosion, replace the stator assembly.
(3) Use clean, dry, low pressure air to remove all abrasive dust on the stator assembly.
(4) Refer to CLEANING and clean the stator assembly.
WARNING: MAKE SURE THAT YOU USE THE LACQUER CORRECTLY. BEFORE YOU USE
THE LACQUER YOU MUST:
- READ THE MANUFACTURER/SUPPLIER MATERIAL SAFETY DATA SHEET.
- PUT ON PROTECTIVE OVERALLS.
- PUT ON CHEMICAL SAFETY GOGGLES (MATERIAL NO. 11).
- PUT ON ACID RESISTANT GLOVES (MATERIAL NO. 9).
- MAKE SURE THAT THERE IS SUFFICIENT AIRFLOW TO KEEP THE FUMES

BELOW THE LEVEL INDICATED IN THE MATERIAL SAFETY DATA SHEET.
LACQUER (MATERIAL NO. 20) IS FLAMMABLE AND A MILD POISON.

LACQUER CAN CAUSE INJURY TO PERSONNEL.
(5) Apply two layers of lacquer (Material No. 20) to the bore of the stator assembly.
(a) Attach the stator leads to the stator stack with glass PTFE tape (Material No. 21).
(b) Use a brush (Material No. 11) to apply a layer of lacquer (Material No. 20) to the bore
of the stator assembly.
(c) Let the lacquer air dry for a minimum of 30 minutes at room temperature.
(d) Use a brush (Material No. 11) to apply a second layer of lacquer (Material No. 20) to
the bore of the stator assembly.
(e) Let the lacquer air dry for a minimum of 30 minutes at room temperature.
CAUTION: DO NOT LET THE OVEN TEMPERATURE EXCEED 180 DEG C (360 DEG
F). THE STATOR ASSEMBLY AND THE FUSES CAN BE DAMAGED.
(f) Cure the lacquer on the stator assembly in an electric fan oven for between 115 and
125 minutes at a temperature between 170 and 180 deg C (338 and 356 deg F).
(6) Remove the stator assembly from the oven.
(7) Let the temperature of the stator assembly decrease to room temperature.
(a) Remove all glass PTFE tape (Material 21).
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(b) Examine the bore. The lacquer must be smooth with no holes, bubbles or cracks.
(c) If it does not agree with these conditions, do steps 1 to 7 again.
(8) Wind grease proof paper (Material No. 22) around the stator assembly.
(9) Put the stator assembly into a clean polythene bag (Material No. 6) to prevent damage,
corrosion or contamination.
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INTENTIONALLY BLANK
REPAIR No. 5
TASK 20-00-01-018-801-A01
1. Shaft and Rotor Assembly - Repair Lacquer
SUBTASK 20-00-01-018-002-A01
(1) Use this procedure to remove and replace the damaged lacquer on the rotor stack of the
rotor assembly.
SUBTASK 20-00-01-350-026-A01
NOTE: Refer to PGBLK-20-00-01-9000 for full details of listed items
(2) Consumables
REFERENCE NAME
Material No. 6 Polythene bag

Material No. 9 Gloves, acid resistant
Material No. 10 Eyeshields
Material no. 17 Adhesive tape, heat resistent
* Material No. 20 Lacquer, epoxy, CV115, DTD 5562 or
Rockhard 576-450-002
Material No. 22 Grease proof paper
Material No. 23 Tape, Polyimide Sil. Adh 0.025 x 12 mm
SUBTASK 20-00-01-018-010-A01
B. Job set-up
(1) Not applicable
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SUBTASK 20-00-01-018-011-A01
C. Procedure
(1) Wind the polymide tape (Material No. 23) around the shaft and rotor assembly, but not the
rotor stack.
(2) Bead or grit blast the rotor stack in accordance with Defence Standard 03-2 to remove
lacquer and corrosion. You must not damage the substrate.
NOTE: If you cannot remove the corrosion, replace the shaft and rotor assembly.
(3) Remove all polymide tape (Material 23).
(4) Use clean, dry, low pressure air to remove all abrasive dust on the shaft and rotor assembly.
(5) Refer to CLEANING and clean the shaft and rotor assembly.
- MAKE SURE THAT THERE IS SUFFICIENT AIRFLOW TO KEEP THE FUMES

BELOW THE LEVEL INDICATED IN THE MATERIAL SAFETY DATA SHEET.
LACQUER (MATERIAL NO. 20) IS FLAMMABLE AND A MILD POISON.

LACQUER CAN CAUSE INJURY TO PERSONNEL.
(6) Apply two layers of lacquer (Material No. 20) to the rotor stack of the rotor assembly.
(a) Wind heat resistant tape (Material No. 17) around the shaft and rotor assembly, but
not the rotor stack.
(b) Use clean, dry, low pressure air to remove all abrasive dust on the shaft and rotor
assembly.
(c) Apply a layer of lacquer (Material No. 20) as a spray, on to the rotor stack of the shaft
and rotor assembly.
(d) Let the lacquer air dry for 15 to 20 minutes at room temperature.
(e) Apply a second layer of lacquer (Material No. 20) as a spray, on to the rotor stack of
the shaft and rotor assembly.
(f) Let the lacquer air dry for 15 to 20 minutes at room temperature.
(g) Cure the lacquer on the shaft and rotor assembly in an electric fan oven for between
115 and 125 minutes at a temperature between 170 and 180 deg C (338 and 356 deg
F).
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(7) Remove the shaft and rotor assembly from the oven.
(8) Let the temperature of the shaft and rotor assembly decrease to room temperature.
(a) Remove all heat resistant tape (Material No. 17).
(b) Examine the shaft and rotor assembly. The lacquer must be smooth with no holes,
bubbles or cracks.
(c) If the lacquer does not agree with these conditions, do steps 1.C.(1) to 1.C.(8)(a)
again.
(9) Wind grease proof paper (Material No. 22) around the shaft and rotor assembly.
(10) Put the shaft and rotor assembly into a clean polythene bag (Material no. 6) to prevent
damage, corrosion or contamination.
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INTENTIONALLY BLANK
Repair No. 6
TASK 20-00-01-350-801-01
1. Replace or Repair Epoxy Paint
SUBTASK 20-00-01-350-027-A01
(1) Use these procedures to repair or remove and replace the worn epoxy paint on the surface of
aluminium components.
SUBTASK 20-00-01-350-028-A01
Table 6001 Tools, Fixtures and equipment
REFERENCE NAME
(2) Consumables
REFERENCE NAME

Material No. 15 Nylon bristle brush
Material No. 18 Spatula
Material No. 26 Epoxy primer
Material No. 27 Etch primer
Material No. 28 Black paint
Material No. 29 White paint
Material No. 31 Container, acid resistant
SUBTASK 20-00-01-350-029-A01
B. Job Set-up - Repair Existing Epoxy Paint
(1) Prepare the existing paint surface.
(a) Make the surface rough with wet and dry fine grade abrasive paper (Material No. 12).
(b) Dry with absorbent material (Material No. 2).
(2) Clean the areas to be repaired with general purpose cleaning solvent, refer to CLEANING.
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(3) Dry with absorbent material (Material No. 2).
(4) Prepare the epoxy primer (Material No. 26).
NOTE: The pot life of the mixed materials is 8 hours.
(a) Mix together epoxy primer (material No. 26), two parts base, one part activator and
one part thinner.
(5) Make sure the room temperature is between 12 and 25 deg. C (53.6 and 77.0 Deg. F),
(6) Use an applicable brush (Material No. 15) and apply one smooth layer of epoxy primer
(Material No. 26).
(7) Cure the epoxy at room temperature or in a ventilated oven. Refer to Table 6003 for curing
times.
Table 6003 Epoxy primer curing times
TEMPERATURE CURING TIME
Room temperature Not less than 240 minutes

70 Deg C (158 Deg. F) 180 minutes
(8) If necessary, use heat resistant gloves (Material No. 16) and remove the pump from the
oven.
(9) Examine the surface. The epoxy primer must be smooth with no holes, bubbles or cracks.
(10) If the epoxy primer does not agree with these conditions, do steps B.(1) to B.(9) again.
(11) Prepare the epoxy paint (Material No. 28 or Material No. 29)
(a) With a container (material No. 31) and a spatula (Material No. 18), mix the epoxy paint
(Material No. 28 or Material No. 29) (Matt or Gloss), ten parts paint, ten parts activator,
three parts thinners.
(b) Apply one smooth layer of epoxy paint (Material No. 28 or Material No. 29) (Matt or
Gloss) with a brush (Material 15).
(12) Cure the epoxy paint in a ventilated oven. Refer to Table 6004 for curing times.
CAUTION: DO NOT CURE THE EPOXY PAINT AT TEMPERATURES MORE THAN 120 DEG
C (248 DEG F) AS THE HIGH TEMPERATURE WILL DAMAGE THE PUMP.
Table 6004 Epoxy paint curing times

(13) Use heat resistant gloves (Material No. 16) and remove the pump from the oven.
(14) Examine the surface. The epoxy paint must be smooth with no holes, bubbles or cracks.
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(15) If the epoxy paint does not agree with these conditions, do steps B.(1) to B.(14) again.
SUBTASK 20-00-01-350-030-A01
C. Job Set-up - Replace Existing Epoxy Paint
(1) Remove the epoxy paint with fine grade abrasive paper (Material No. 12).
(2) Make sure the surface is smooth with wet and dry fine grade abrasive paper (Material No.
12).
(3) Dry with absorbent material (Material 2).
(4) Clean the prepared areas with general purpose cleaning solvent, refer to CLEANING.
(5) Repair damaged aluminium surface, refer to REPAIR No. 7 and REPAIR No. 8.
(6) Prepare the etch primer (Material No. 27)
NOTE: The pot life of the mixed materials is 4 hours at 15 to 35 Deg C (59 to 95 deg F).
Discard all unused materials after this period.
(a) Mix together etch primer (material No. 27), ten parts base, ten parts activator and one
part thinner.
(7) Use an applicable brush (Material No. 15) and apply one smooth layer of etch primer
(Material No. 27).
(8) Cure the etch primer at room temperature for 60 minutes.
(9) Examine the surface. The etch primer must be smooth with no holes, bubbles or cracks.
(10) If the etch primer does not agree with these conditions, do steps C.(1) to C.(9) again.
(11) Prepare the Epoxy primer (Material No. 26).
NOTE: The pot life of the mixed materials is 8 hours.
(a) Mix together epoxy primer (material No. 26), two parts base, one part activator and
one part thinner.
(12) Make sure the room temperature is between 12 and 25 deg. C (53.6 and 77.0 Deg. F),
(13) Use an applicable brush (Material No. 15) and apply one smooth layer of epoxy primer
(Material No. 26)
(14) Cure the epoxy primer. The epoxy primer can be cured at room temperature or in a ventilated
oven. Refer to Table 6005 for curing times.
Table 6005 Epoxy primer curing times
Room temperature Not less than 240 minutes

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(15) If necessary, use heat resistant gloves (Material No. 16) and remove the pump from the
oven.
(17) If the epoxy primer does not agree with these conditions, do steps C.(1) to C.(13) again.
(18) Prepare the epoxy paint (Material No. 28 or Material No. 29)
(a) Mix the epoxy paint (Material No. 28 or Material No. 29) (Matt or Gloss), ten parts
paint, ten parts activator, three parts thinners, in a container (material No. 31) and a
spatula (Material No. 18),
(b) Apply one smooth layer of epoxy paint (Material No. 28 or Material No. 29) (Matt or
Gloss) with a brush (Material 15).
(19) Cure the epoxy paint in a ventilated oven. Refer to Table 6006 for curing times
CAUTION: DO NOT CURE THE EPOXY PAINT AT TEMPERATURES MORE THAN 120 DEG
C (248 DEG F) AS THE HIGH TEMPERATURE WILL DAMAGE THE PUMP.
Table 6006 Epoxy paint curing times

(20) Use heat resistant gloves (Material No. 16) and remove the pump from the oven.
(22) If the epoxy primer does not agree with these conditions, do steps C.(1) to C.(21) again.
REPAIR NO. 6
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REPAIR No. 7
TASK 20-00-01-380-806-A01
1. Deoxidize aluminium alloy surfaces
SUBTASK 20-00-01-380-014-A01
(1) You can do different procedures when you deoxidize the surfaces. Select from the
procedures that follow.
SUBTASK 20-00-01-380-015-A01
(a) None
(2) Consumables
REFERENCE NAME

Material No. 12 Abrasive paper
Material No. 14 De-oxidizing solution
Material No. 24 Abrasive pad
SUBTASK 20-00-01-110-015-A01
B. Job Set-up
(1) Not Applicable.
SUBTASK 20-00-01-120-006-A01
C. Solvent and Abrasive Pad Method
(1) Refer to CLEANING and clean the surface with an applicable solvent (for example Iso-Propyl
Alcohol (IPA) (Material No. 7) or Acetone (Material No. 8)).
NOTE: You can use alternative solvents if they give a water-break free surface (when you
pour water on such a surface, it will be smooth and continuous with no holes in the
layer).
(2) If necessary, use an abrasive pad (Material No. 24) or abrasive paper (Material No. 12) to
remove oxides and other unwanted material. Do this in two different directions until you can
see new aluminium alloy.
(a) Flush the surface with clean water.
(b) If necessary, do para 1.C.(2) again until you see a water-break free surface.
(c) Use clean absorbent material (Material No. 2) and dry the surface.
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SUBTASK 20-00-01-120-007-A01
D. Deoxidant Solution
(1) Refer to the manufacturer’s instructions and apply deoxidant solution (Material No. 14) to the
surface. Make sure that you do not apply it to areas that are not applicable to this repair.
(2) Let the deoxidant solution (Material No. 14) stay on the surface as recommended by the
manufacturer.
(3) Flush the surface with clean water.
(a) If necessary, do para 1.D.(1) again until you see a water-break free surface (when you
pour water on such a surface, it will be smooth and continuous with no holes in the
layer).
(4) Use clean absorbent material (Material No. 2) and dry the surface.
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REPAIR No. 8
TASK 20-00-01-380-807-A01
1. Repair Damaged Class 1A Aluminium Alloy Surfaces (Standard Anodized Finish)
SUBTASK 20-00-01-380-016-A01
(1) Use this procedure to repair the anodic protection of the aluminium alloy surfaces.
SUBTASK 20-00-01-380-017-A01
REFERENCE NAME

Local supply Thermal hot air gun
(2) Consumables
REFERENCE NAME
Material No. 5 Pressure-sensitive transparent tape

Material No. 13 Powder, Alocrom 1200
Material No.19 Sponge
Material No. 25 Sur Tec 650 chromitAL pen
Material No. 31 Container, acid resistant
Material No. 32 Demineralized water
SUBTASK 20-00-01-110-016-A01
B. Job Set-up
(1) Deoxidize the surface to be repaired, Refer to REPAIR No. 7.
(2) Apply Chromate Conversion – Brush (or Swab) Method
WARNING: DO NOT BREATHE IN THE FUMES FROM THE ALOCROM SOLUTION.

DO NOT LET THE SOLUTION TOUCH THE SKIN OR EYES. YOU MUST
PUT ON ACID RESISTANT GLOVES AND EYESHIELDS. IF THE
SOLUTION TOUCHES THE EYES, FLUSH THEM IMMEDIATELY WITH A
LARGE VOLUME OF WATER. IF THE SOLUTION TOUCHES THE SKIN,
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CLEAN IT IMMEDIATELY WITH SOAP AND WATER. YOU MUST APPLY
THE SOLUTION IN AN AREA WITH A GOOD THROUGH FLOW OF
CLEAN AIR. THE SOLUTION IS POISONOUS. IT CAN DAMAGE YOUR
HEALTH.
WARNING: THE ALOCROM SOLUTION IS HIGHLY FLAMMABLE. KEEP THE

ALOCROM SOLUTION AWAY FROM OPEN FLAMES OR OTHER
SOURCES OF IGNITION. DO NOT LET RAGS, SPONGES OR ANY
ORGANIC MATERIALS WHICH ARE WET WITH ALOCROM TO BECOME
DRY BECAUSE THEY WILL BECOME A FIRE HAZARD. YOU MUST
FLUSH ALL MATERIALS USED TO APPLY THE SOLUTION IN A GOOD
FLOW OF CLEAN WATER THEN DISCARD THEM IN ACCORDANCE
WITH LOCAL ENVIRONMENTAL REGULATIONS.
WARNING: WHEN BRUSH ALOCROM 1200, PARTS A AND B ARE MIXED THE
SOLUTION CONTAINS POTASSIUM FERRICYANIDE. DO NOT STORE
THE MIXTURE FOR MORE THAN 24 HOURS BECAUSE SMALL
QUANTITIES OF TOXIC CYANIDE GAS CAN BE MADE. DISCARD
UNUSED SOLUTION IN ACCORDANCE WITH LOCAL ENVIRONMENTAL
REGULATIONS.
(a) Put on protective clothing:
- Acid resistant gloves (Material No. 9)
- Goggles (Material No. 10)
(b) Refer to the manufacturer’s instructions and put equal volumes of parts A and B of the
solution (material No. 13) in a plastic container (material No. 31).
(c) Fully mix the solutions together.
(d) Apply a large quantity of the mixed solution to the deoxidized surface with a brush
(Material No. 15) or a sponge (Material No. 19). Apply the solution equally over the
prepared surface.
NOTE: If the surface is vertical, apply the solution from the bottom to the top.
(e) Examine the applied layer. If it is not continuous and has holes in it, then do steps (b)
to (d) again.
NOTE: Holes in the layer is an indication that the surface was not deoxidized
correctly.
(f) When the color of the applied solution becomes yellow to golden yellow, remove
unwanted solution:
NOTE: The Alocrom 1200 is soft. Be careful not to damage it when you rinse and
dry the component.
1 Flush the surface with clean water (or carefully clean with a soft sponge or
cloth).
2 Flush with demineralized water (Material No. 32).
(g) Dry the solution. Select and do one of the procedures that follows:
1 Apply clean, dry air.
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2 Carefully use a clean cloth.
3 Put the component into an oven for approximately 10 minutes at 120 deg C
(248 deg F).
(h) Do a check and make sure the anodic protection is fully bonded.
NOTE: If you break the layer of anodic protection, you must do the repair
procedure again.
1 With a light force, apply a piece of tape (material no. 5) to the anodic protection.
2 Remove the tape (material No. 5), the layer must not break when the tape is
removed.
(i) Remove the gloves and eyeshields.
(3) Apply Chromate Conversion –Pen Applicator Method.
(a) Prepare the pen applicator (Material No. 25) to use.
1 Remove the cap.
2 Put the tip on the surface and push it (this will open the valve and let the tip
absorb fluid). Stop immediately the tip becomes wet.
NOTE: This will be between 15 and 30 seconds for a new pen.
(b) Apply lines of the chromate conversion smoothly to the metal surface. Make an
overlap of 50% with each new line.
CAUTION: DO NOT CLEAN OR FLUSH THE SURFACE WHEN YOU APPLY THE NEW
LAYER.
(c) Examine the applied layer. If it is not smooth and continuous or has holes in it, then
refer to REPAIR No. 7 and deoxidize the surface again.
(d) Let the layer become dry and immediately do steps 2.(b) and 2.(c) again. Make these
lines at 90 degrees to the lines that you applied before.
NOTE: Do not wait more than five minutes before you apply this layer.
CAUTION: DO NOT CLEAN OR FLUSH THE SURFACE. DO NOT APPLY TOO MUCH
CHROMATE CONVERSION.
(e) Let the layer become dry.
(f) Do steps 3.(b) to 3.(e) again. You must apply a total of four layers.
(g) Let the layer become dry. Do not touch the layer before it is dry.
NOTE: To dry the layer quickly you can use heat (the maximum temperature is 60
deg. C (140 deg. F)).
1 Clean, dry, warm air (Thermal hot air gun).
or
2 A radiant heat source (Ventilated oven).
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INTENTIONALLY BLANK
REPAIR No. 9
TASK 20-00-01-380-808-A01
1. Repair Damaged Class 3 Aluminium Alloy Surfaces (Bonding Surfaces)
SUBTASK 20-00-01-380-003-A01
(1) Use this procedure to repair the anodic protection of aluminium alloy surfaces.
SUBTASK 20-00-01-380-018-A01
Table 6001 Tools, Fixtures and equipment
REFERENCE NAME
Local supply Thermal hot air gun

(2) Consumables
REFERENCE NAME
Material No. 5 Pressure-sensitive transparent tape

Material No.19 Sponge
Material No. 25 Sur Tec 650 chromitAL pen
Material No. 30 Anodic solution, Alocrom 1000
Material No. 32 Demineralized water
SUBTASK 20-00-01-110-017-A01
B. Job Set-up
(1) Deoxidize the surface to be repaired, Refer to REPAIR No. 7.
(2) Apply the chromate conversion - Brush (or swab) method
WARNING: DO NOT BREATHE IN THE FUMES FROM THE ALOCROM SOLUTION.

DO NOT LET THE SOLUTION TOUCH THE SKIN OR EYES. YOU MUST
PUT ON ACID RESISTANT GLOVES AND EYESHIELDS. IF THE
SOLUTION TOUCHES THE EYES, FLUSH THEM IMMEDIATELY WITH A
LARGE VOLUME OF WATER. IF THE SOLUTION TOUCHES THE SKIN,
CLEAN IT IMMEDIATELY WITH SOAP AND WATER. YOU MUST APPLY
REPAIR NO. 9
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THE SOLUTION IN AN AREA WITH A GOOD THROUGH FLOW OF
CLEAN AIR. THE SOLUTION IS POISONOUS. IT CAN DAMAGE YOUR
HEALTH.
(a) Put on protective clothing.
1 Acid resistant gloves (Material No. 9).
2 Goggles (Material No. 10).
(b) Apply a large quantity of the liquid alocrom1000 (Material No. 30) to the deoxidized
surface with a brush (Material no. 15) or a sponge (Material No. 19). Apply the
solution equally over the prepared surface.
NOTE: If the surface is vertical, apply the solution from the bottom to the top.
(c) Examine the applied layer. If it is not continuous and has holes in it, then do step (c)
again.
NOTE: Holes in the layer is an indication that the surface was not deoxidized
correctly.
(d) When the color of the applied solution becomes yellow to golden yellow, remove
unwanted solution:
1 Flush the surface with clean water (or carefully clean with a soft sponge or
cloth).
2 Flush with demineralized water (Material No. 32).
(e) Dry the solution. Select and do one of the procedures that follow:
1 Apply clean, dry air.
2 Carefully use a clean cloth.
3 Put the component into an oven for approximately 10 minutes at 120 deg. C
(248 deg F).
(f) Do a check and make sure the Alocrom 1000 is fully bonded to the surface.
NOTE: If you break the layer of anodic protection, you must do the repair
procedure again.
1 With a light force, apply a piece of tape (Material No. 5) to the anodic
protection.
2 Remove the tape (Material no. 5), the layer must not break when the tape is
removed.
(g) Remove the gloves and eyeshields
(3) Apply Anodic protection (Material No. 25) - Pen Applicator Method.
(a) Prepare the pen applicator (Material No. 25) to use.
1 Remove the cap.
2 Put the tip on the surface and push it (this will open the valve and let the tip
absorb fluid). Stop immediately the tip becomes wet.
REPAIR NO. 9
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Nov 29/12
NOTE: This will be between 15 and 20 seconds for a new pen.
(b) Apply lines of the chromate conversion smoothly to the metal surface. Make an
overlap of 50% with each new line.
CAUTION: DO NOT CLEAN OR FLUSH THE SURFACE WHEN YOU APPLY THE NEW
LAYER.
(c) Examine the applied layer. If it is not smooth and continuous or has holes in it, then
refer to REPAIR No. 7 and deoxidize the surface again.
(d) Let the layer become dry and immediately do steps 3. (b) and 3. (c) again. Make these
lines at 90 degrees to the lines that you applied before.
NOTE: Do not wait more than five minutes before you apply this layer.
CAUTION: DO NOT CLEAN OR FLUSH THE SURFACE. DO NOT APPLY TOO MUCH
CHROMATE CONVERSION.
(e) Let the layer become dry. Do not touch the layer before it is dry.
NOTE: To dry the layer quickly, you can use heat (the maximum temperature is 60
deg. C (140 deg. F)).
1 Clean, dry, warm air (Thermal hot air gun).
or
2 A radiant heat source (Ventilated oven).
REPAIR NO. 9
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INTENTIONALLY BLANK
REPAIR - No. 10
TASK 20-00-01-018-802-A01
1. Replace the Bonding Surface Lacquer
SUBTASK 20-00-01-018-012-A01
NOTE: Only do this procedure if it is specified in the relevant CMM.
(1) Use this procedure to replace the bonding surface lacquer.
SUBTASK 20-00-01-018-013-A01
details of the listed items.
(a) Refer to relevant CMM.
(2) Consumables
REFERENCE NAME

Material No. 34 Lacquer
Material No. 35 Activator
SUBTASK 20-00-01-018-016-A01
B. Job set-up
(1) Not applicable
SUBTASK 20-00-01-018-017-A01
C. Procedure
(1) Refer to CLEANING and remove the lacquer from the bonding faces.
(2) Refer to CLEANING and do a solvent clean of the bonding surfaces.
(3) Refer to the relevant CMM and assemble the bonding surfaces together.
(4) Refer to the relevant CMM and do the TESTING and do the bonding test.
(5) If the measured value is not to the specified limits, Refer to the relevant CMM, disassemble
the bonding surfaces.
REPAIR NO. 10
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(a) Refer to CLEANING and do the solvent clean procedure again.
(6) Prepare the lacquer
NOTE: Do not use thinners. If the lacquer is too thin it is possible that it will get between
the bonding surfaces.
NOTE: The pot-life of the mixed lacquer is 8 hours. Discard it after this time.
(a) Mix the Lacquer (Material No. 34) and the Activator (Material No. 35) in the ratio 2:1.
Fully mix the two materials together to make a smooth, continuous material.
(7) Apply the lacquer
NOTE: Do not wait more than 60 minutes after you have cleaned the bonding surfaces
before you apply the lacquer.
NOTE: Stir the lacquer before and during application.
(a) Use a brush (Material No.11) and apply a layer of the lacquer to the applicable
bonding surfaces and areas.
(b) Make sure that you apply the lacquer between 2 and 3mm (0.08 and 0.12 in) each
side of the bonding surface joints (and the heads of nuts and bolts that are included in
those areas).
(c) Wait until the lacquer is dry (You can put the unit into an oven at a maximum of 80
deg. C (176 deg. F) to decrease this time) and apply a second layer of lacquer.
(8) Cure the lacquer
(a) Let the lacquer cure at ambient temperature for a minimum of 16 hours.
(b) You can put the unit into an oven to decrease the cure time as given in Table 6001.
Table 6002 Lacquer minimum cure times
TEMPERTAURE Minimum Time in Hours
60 - 65 deg. C (140 - 149 deg. F) 4

70 - 75 deg. C (158 - 167 deg. F) 3
80 - 85 deg. C (176 - 185 deg. F) 2
REPAIR NO. 10
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Nov 29/12
(c) Remove the component from the oven.
REPAIR NO. 10
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INTENTIONALLY BLANK
REPAIR No. 11
TASK 20-00-01-018-803-A01
1. Replace damage to corrosion resistant finish
SUBTASK 20-00-01-018-018-A01
NOTE: Only do this procedure if it is specified in the relevant CMM.
(1) Use this procedure to replace the damaged corrosion resistant finish.
SUBTASK 20-00-01-018-019-A01
details of the listed items.
(1) Tools, Fixtures and equipment
(a) Refer to relevant CMM.
(2) Consumables
REFERENCE NAME

Material No. 36 Epoxy resin
Material No. 37 Curing agent
SUBTASK 20-00-01-018-021-A01
B. Job set-up
(1) Not applicable
SUBTASK 20-00-01-018-022-A01
C. Procedure
(1) Mix the epoxy resin (Material No. 36) and the curing agent (Material No. 37) in the ratio of
3:1.
REPAIR NO. 11
20-00-01 20041
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Page 6001
Nov 29/12
(a) Pour the resin (Material No. 36) into a solvent resistant container. Stir the resin and at
the same time, add the curing agent (Material No. 37).
NOTE: The pot life of the mixture is 8 hours. Discard the mixture after this time.
(b) Wait 60 minutes before you use the mixture.
(2) Apply the corrosion resistant finish.
(a) Do this in an environment that is:
- Between 10 and 38 deg. C (50 to 100 deg.F)
- Relative humidity is less than 85 percent.
(3) Use a brush and evenly apply the mixture to 12.7 mm (0.5 in.) each side of the damaged
area.
(4) Wait 30 minutes and apply a second layer of the mixture.
(5) Wait 15 minutes.
(6) Put the component into an oven set between 60 and 90 deg. C (140 and 194 deg. F) for 60
minutes.
(7) Remove the component from the oven.
REPAIR NO. 11
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Page 6002
Nov 29/12
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES
TASK 20-00-01-940-801-A01
1. Special Tools, Fixtures and Equipment
SUBTASK 20-00-01-99F-008-A01
A. General
(1) The special equipment given in Table 9001 is necessary to service the component.
NOTE: Equivalent alternatives can be used.
Table 9001 Special tools, fixtures and equipment
PART NUMBER DESCRIPTION SUPPLIER
Ventilated oven - To be heated up to 180 deg. C (356 Local supply

deg. F)
Vibro-etch machine Local supply
Ultrasonic Tank, frequency 45 and/or 25 KHz Local supply
Thermal hot air gun Local supply
1227-06 Extraction tool, Threaded insert, 0.164-32 UNC K1012
1227-06 Extraction tool, Threaded insert, 0.138-32 UNC K1012
1227-6 Extraction tool, Threaded insert (tanged), 0.190-32 K1012
UNF
1440-2 Plug gauge, 0.164-32 UNC K1012
1440-06 Plug gauge, 0.138-32 UNC K1012
1694-3 Plug gauge, 0.190-32 UNF K1012
3551-2 Insertion tool, Threaded insert (tanged), 0.164-32 UNC K1012
3551-06 Insertion tool, Threaded insert (tanged), 0.138-32 UNC K1012
9863-3 Insertion tool, Threaded insert (tanged), 0.190-32 UNF K1012
3580-2 Break-off tool, Threaded insert (tanged), 0.164-32 UNC K1012
3580-06 Break-off tool, Threaded insert (tanged), 0.138-32 UNC K1012
3581-3 Break-off tool, Threaded insert (tanged), 0.190-32 UNF K1012
TCIF-3 Insertion tool, Threaded insert (tangless), 0.190-32 0YC40
UNF
CT16003R-3 Extraction tool, Threaded insert (tangless), 0.190-32 0YC40
UNF
TASK 20-00-01-940-802-A01
2. Consumables
SUBTASK 20-00-01-99F-011-A01
A. List of Materials
WARNING: GET THE SAFETY INFORMATION SHEETS APPLICABLE TO THE MATERIALS

RECOMMENDED IN THIS MANUAL (OR THE EQUIVALENT ALTERNATIVE
MATERIALS) AND OBEY THEIR INSTRUCTIONS.
20-00-01 20040
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Page 9001
Nov 29/12
(1) The consumables given in Table 9002 are necessary to service the component.
NOTE: Equivalent alternatives can be used unless identified thus *.
MATERIAL DESIGNATION AND SUPPLIERS CODE OR PAGE BLOCK WHERE

NO. SPECIFICATION NAME AND ADDRESS USED
1 Cleaning tank solvent Cleaning

Arklone P, BS4849, K6413 or 13992
MIL-C-81302D or
Lotoxane or Local supply
Metalkleanse LF (at 2% Local supply
solution -
approximately) or
Safety Kleen Premium Local supply
or
Kernet or Local supply
Topclean MC1007 Local supply
2 Cloth, lint-free or Local supply Cleaning, Repair No. 2,
Repair No. 6, Repair No. 7
Absorbent paper towel Local supply
3 Adhesive, Scotchweld K8767 or 76381 Repair No. 2
1838 Parts A and B
4 Jointing compound, K3237 Repair No. 3
PL32M
5 Tape, transparent, Local supply Repair No. 8, Repair No. 9
pressure-sensitive
6 Polythene bag Local supply Cleaning, Repair No. 4,
Repair No. 5
7 Cleaning solvent - Cleaning
general purpose and
de-greasing
Evolve 110 or K6413
PF-QD (quick dry) MIL- Haas TCM
PRF-680 Type I or
PF AquaForte (wipes) Haas TCM
Rolls-Royce OMAT 1/
303C or
Iso-Propyl-Alcohol Local supply
(IPA) or
Industrial Methylated Local supply
Spirits (IMS) or
Sky Wipes Local supply
8 Cleaning fluid - heavy Cleaning
duty
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Page 9002
Nov 29/12
Methyl Lactate Purac Biochem (UK)
(Purasolv ML) or
Acetone or Local supply
PF-SR (Sealant Hass TCM
removal) Boeing D6-
17487 rev L. -BMI
9 Gloves, acid resistant Local supply Cleaning, Repair No. 4,
Repair No. 5, Repair No. 8,
Repair No. 9
10 Eyeshields Local supply Cleaning, Repair No. 5,
Repair No. 8, Repair No. 9
11 Brush, soft Local supply Cleaning, Repair No. 4
12 Fine grade abrasive Local supply Repair No. 1, Repair No. 2,
paper, min grade 280 Repair No. 4, Repair No. 6,
grit repair No. 7
13 Powder, Alocrom 1200 Local supply Repair No. 8
DEF Stan 03-18
14 Deoxidine 624 Local supply Repair No. 7
DTD900/4627
15 Brush, nylon Local supply Repair No. 6, Repair No. 8,
Repair No. 9
16 Gloves, heat resistant Local supply Cleaning, Repair No. 2,
Repair No. 4, Repair No. 5,
Repair No. 6
17 Tape adhesive heat Local supply Repair No. 2, Repair No. 5
resistant
18 Spatula Local supply Repair No. 2, Repair No.6
19 Sponge Local supply Repair No. 8, Repair No. 9
*20 Lacquer, epoxy, CV115, K5635 or 00BB6 Repair No. 4, Repair No. 5
DTD 5562 or Rockhard
576-450-002
21 Glass PTFE tape Local supply Repair No. 4
22 Grease proof paper Local supply Repair No. 4, Repair No. 5
23 Tape, Polymide Sil. Adh Local supply Repair No. 5
0.025 x 12 mm
24 Abrasive pad Local supply Cleaning, Repair No. 2,
Repair No. 7
25 Sur Tec 650 chromitAL Local supply Repair No. 8, Repair No. 9
pen
26 Epoxy primer K5635 Repair No. 6
base PR143
Activator ACT 143
Thinner T187
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Page 9003
Nov 29/12
27 Etch primer (Def Stan K5635 Repair No. 6
80-161)
Base PR30B
Activator TH 34B
Thinner TH 107
28 Black paint, EC75/801 K5635 Repair No. 6
Activator ACT 68
Thinner T 17
29 White paint, EC75/802 K5635 Repair No. 6
Activator ACT 68
Thinner T 17
30 Liquid, Alocrom 1000 Local supply Repair No. 9
MIL-DTL-5541
31 Container, acid Local supply Repair No. 6, repair No. 8
resistant
32 Demineralized water Local supply Repair No. 8, repair No. 9
33 Mechanical remover Local supply Repair No. 10
Scalpel
Plastic scraper
Abrasive pad
Fine grade abrasive
paper
34 Lacquer K2523 Repair No. 10
35 Activator K2523 Repair No. 10
36 Epoxy Primer, BMS10- Local supply Repair No. 11
20, Type II, Class A,
Grade A, Yellow
37 Curing Agent Local supply Repair No. 11
20-00-01 20040
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Page 9004
Nov 29/12

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COMPONENT MAINTENANCE MANUAL

PART No. STANDARD PRACTICES MANUAL

-Title, Logo updated. Statement of initial certification removed. Address updated.

-ROR, Revision No. updated.

-LEP, Changed to show revised and new pages.

-TOC, Updated and corrected.

-INTRO 1, Internet and e-mail links added. Company name updated.

-INTRO 2, Abbreviations updated.

-4001, Warnings updated. Special tools table 4001 added.

-4003, Cleaning procedures updated. Material Ref No.s updated.

-4004, Cleaning procedures updated. Material Ref No.s updated.

-Repair No.1, 6001, Repair description changed. Repair procedure updated.

-Repair No. 1, 6002, Blank.

-Repair No. 1, 6003, Deleted.

-Repair No. 1, 6004, Deleted

-Repair No. 2, 6002, Material Ref No.s updated. Procedure updated.

-Repair No. 3, 6001, Table 6001 and Table 6002 updated.

-Repair No. 3, 6002, Notes added. Material Ref No.s updated.

-Repair No. 3, 6003, Material Ref No.s updated.

-Repair No. 4, 6001 to 6003, Repair procedure added.

-Repair No. 5, 6001 to 6003, Repair procedure added.

-Repair No. 6, 6001 to 6003, Repair procedure added.

-Repair No. 7, 6001 to 6002, Repair procedure added.

-Repair No. 8, 6001 to 6004, Repair procedure added.

-Repair No. 9, 6001 to 6003, Repair procedure added.

-Repair No. 10, 6001 to 6003, Repair procedure added.

-Repair No. 11, 6001 to 6002, Repair procedure added.

-9001, Table 9001 updated.

-9002, Table 9002 updated.

-9003, Text run-on.

-9004, Text run-on.

© EATON, AEROSPACE GROUP

REV. ISSUE INSERTED REV. ISSUE INSERTED

1 Nov 11/04 Incorporated

RECORD OF TEMPORARY REVISIONS

TEMP INSERTED REMOVED

SERVICE BULLETIN LIST

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

TITLE PAGE 1 Nov 29/12 REPAIR NO. 4 6001 Nov 29/12

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES

ILLUSTRATED PARTS LIST NOT APPLICABLE

4001 Special tools, Fixtures and Equipment 4001

WARNING: HEALTH AND SAFETY. ALL THE MATERIALS AND CONSUMABLES

Eaton, Aerospace Group

Hampshire, PO14 4QA, U.K.

Tel: +44(0)1329 853000 Fax: 01329 853797

Fax (Customer Support direct): 01329 853714

IPL Illustrated Parts List

psi Pounds per square inch

UNC Unified National Coarse

UNF Unified National Fine

Table 4001 Special tools, Fixtures and Equipment

Local Supply Ultrasonic Tank

WARNING: ALL THE MATERIALS AND CONSUMABLES IDENTIFIED IN THIS MANUAL

WARNING: DO NOT USE CLEANING SOLVENTS NEAR A NAKED FLAME. CLEANING

CAUTION: USE ONLY SPECIFIED CLEANING MATERIALS AND SOLUTIONS OR THEIR

CAUTION: DO NOT LET CLEANING SOLVENTS TOUCH RUBBER PARTS.

Material No. 1 Cleaning solvent - ultrasonic tank

(2) Use clean dry air to remove all particles.

(4) Dry the surface with a lint-free cloth.

(1) Abrasive Clean

(b) You must see a bright aluminium bonding surface.

(c) Do not remove more aluminium than is necessary.