fammsi5a_000032

HIGHLIGHTS __________

REVISION NO. 03 Jan 01/04

Pages which have been revised are outlined below, together with the Highlights of theRevision

--------------------------------------------------------------------------------------CH/SE/SU C REASON FOR CHANGE EFFECTIVITY PAGES--------------------------------------------------------------------------------------

CHAPTER 51__________

L.E.P. 1- 2 Revised to Reflect this revision indicating new,revised, and/or deleted pages51-75-12 CORRECTION/ADDITION/AMPLIFICATION ALL 802- 803 SRM REFERENCE CORRECTED

51-HIGHLIGHTS of 1 REVISION NO. 03 Jan 01/04

SI5

CHAPTER 51 __________

STANDARD PRACTICES - STRUCTURE

LIST OF EFFECTIVE PAGES _______________________ N, R or D indicates pages which are New, Revised or Deleted respectively Remove and insert the affected pages and complete the Record of Revisions and the Record of Temporary Revisions as necessary

CH/SE/SU C PAGE DATE CH/SE/SU C PAGE DATE CH/SE/SU C PAGE DATE

RECORD 51-73-11 809 Apr01/03 51-75-13 810 Apr01/03OF TEMP. 51-73-11 810 Apr01/03 51-75-13 811 Apr01/03REVISION 51-73-11 811 Apr01/03 51-75-13 812 Apr01/03 51-73-11 812 Apr01/03 51-75-13 813 Apr01/03L.E.P. R 1- 2 Jan01/04 51-73-11 813 Apr01/03 51-75-13 814 Apr01/03T. of C. 1 Oct01/03 51-73-11 814 Apr01/03 51-75-13 815 Apr01/03T. of C. 2 Oct01/03 51-73-11 815 Apr01/03T. of C. 3 Oct01/03 51-76-00 1 Apr01/03T. of C. 4 Oct01/03 51-74-00 1 Apr01/03 51-76-00 2 Apr01/03T. of C. 5 Oct01/03 51-74-11 801 Apr01/03 51-76-11 801 Apr01/03 51-74-11 802 Apr01/03 51-76-11 802 Apr01/0351-00-00 1 Apr01/03 51-74-11 803 Apr01/03 51-76-11 803 Apr01/0351-00-00 2 Apr01/03 51-74-11 804 Apr01/03 51-76-11 804 Apr01/03 51-74-11 805 Apr01/03 51-76-11 805 Apr01/0351-10-00 1 Apr01/03 51-74-11 806 Apr01/03 51-76-11 806 Apr01/0351-10-00 2 Apr01/03 51-74-11 807 Apr01/03 51-76-12 801 Apr01/03 51-76-12 802 Apr01/0351-21-00 1 Apr01/03 51-75-00 1 Apr01/03 51-76-12 803 Apr01/0351-21-00 2 Apr01/03 51-75-11 701 Apr01/03 51-76-12 804 Oct01/0351-21-00 701 Oct01/03 51-75-11 702 Apr01/03 51-76-12 805 Oct01/0351-21-00 702 Oct01/03 51-75-11 703 Apr01/03 51-76-12 806 Oct01/03 51-75-11 704 Apr01/03 51-76-12 807 Oct01/0351-22-00 1 Apr01/03 51-75-11 705 Apr01/03 51-76-12 808 Apr01/0351-22-00 2 Apr01/03 51-75-11 706 Apr01/03 51-76-12 809 Apr01/03 51-75-11 707 Apr01/03 51-76-12 810 Apr01/0351-23-00 1 Apr01/03 51-75-12 801 Apr01/03 51-76-12 811 Jul01/03 51-75-12 R 802 Jan01/04 51-76-12 812 Apr01/0351-24-00 1 Apr01/03 51-75-12 R 803 Jan01/04 51-76-12 813 Apr01/0351-24-00 2 Apr01/03 51-75-12 804 Apr01/03 51-76-12 814 Apr01/0351-24-00 3 Apr01/03 51-75-12 805 Apr01/03 51-75-12 806 Apr01/03 51-77-00 1 Apr01/0351-70-00 1 Apr01/03 51-75-12 807 Apr01/03 51-77-11 201 Apr01/03 51-75-12 808 Apr01/03 51-77-11 202 Apr01/0351-73-00 1 Apr01/03 51-75-13 801 Apr01/03 51-77-11 203 Apr01/0351-73-11 801 Apr01/03 51-75-13 802 Apr01/03 51-77-11 204 Apr01/0351-73-11 802 Apr01/03 51-75-13 803 Apr01/03 51-77-11 205 Apr01/0351-73-11 803 Apr01/03 51-75-13 804 Apr01/03 51-77-12 801 Apr01/0351-73-11 804 Apr01/03 51-75-13 805 Apr01/03 51-77-12 802 Apr01/0351-73-11 805 Apr01/03 51-75-13 806 Apr01/03 51-77-12 803 Apr01/0351-73-11 806 Apr01/03 51-75-13 807 Apr01/03 51-77-12 804 Apr01/0351-73-11 807 Apr01/03 51-75-13 808 Apr01/03 51-77-12 805 Apr01/0351-73-11 808 Apr01/03 51-75-13 809 Apr01/03 51-77-12 806 Apr01/03

51-L.E.P. Page 1 Jan 01/04

SI5

CH/SE/SU C PAGE DATE CH/SE/SU C PAGE DATE CH/SE/SU C PAGE DATE

51-77-12 807 Apr01/0351-77-12 808 Apr01/03

51-78-00 1 Apr01/0351-78-00 701 Apr01/0351-78-00 702 Apr01/0351-78-00 703 Apr01/0351-78-00 704 Apr01/0351-78-00 705 Apr01/0351-78-00 706 Apr01/0351-78-00 707 Apr01/0351-78-00 708 Apr01/0351-78-00 709 Apr01/0351-78-00 710 Apr01/0351-78-00 711 Apr01/0351-78-00 712 Apr01/0351-78-00 713 Apr01/0351-78-00 714 Apr01/0351-78-00 715 Apr01/0351-78-00 716 Apr01/0351-78-00 717 Apr01/0351-78-00 718 Apr01/0351-78-00 719 Apr01/0351-78-00 720 Apr01/0351-78-00 721 Apr01/0351-78-00 722 Apr01/0351-78-00 723 Apr01/0351-78-00 724 Apr01/0351-78-00 725 Apr01/0351-78-00 726 Apr01/0351-78-00 727 Apr01/0351-78-00 728 Apr01/0351-78-00 729 Apr01/0351-78-00 730 Apr01/0351-78-00 731 Apr01/0351-78-00 732 Apr01/0351-78-00 733 Apr01/03

51-L.E.P. Page 2 Jan 01/04

SI5

CHAPTER 51 __________


TABLE OF CONTENTS _________________

SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ STANDARD PRACTICES AND STRUCTURES - 51-00-00 ___________________________________ GENERAL _______ DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Aircraft Zoning and Dimensions 1 ALL Restricted Areas 1 ALL Access - Door and Panel 1 ALL Identification

INVESTIGATION, CLEANUP AND AERODYNAMIC 51-10-00 ______________________________________ SMOOTHNESS __________ DESCRIPTION AND OPERATION 1 ALL General 1 ALL For a high aircraft performance 1 ALL it is necessary that the aircraft has an aerodynamically clean shape and a smooth external surface.

PROTECTIVE TREATMENT 51-21-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Protective Treatment Build-up 1 ALL Internal Treatment 1 ALL Types of Protective Treatments 2 ALL Pretreatments 2 ALL Paint Coatings 2 ALL Special Coatings 2 ALL

PROTECTIVE TREATMENT 51-21-00 CLEANING/PAINTING 701 ALL Wax and Polish Protection on 701 ALL Unpainted Light Alloy Areas

CORROSION PREVENTION 51-22-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Corrosion Prevention 1 ALL Corrosion-Resistant Materials 1 ALL and Protective Coatings Corrosion Protection 1 ALL Surface Treatment (Galvanic or 1 ALL Chemical)

51-CONTENTS Page 1 Oct 01/03R SI5

CHAPTER 51 __________



SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ Protection of Mating Surfaces 1 ALL

COATINGS APPLICATION, GENERAL 51-23-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Aluminum Alloy Structure 1 ALL Exposed Areas 1 ALL Composite Components 1 ALL Corrosion-Resistant Steel 1 ALL Components

SEALING - GENERAL 51-24-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Sealants 1 ALL Areas for Sealing 1 ALL

REPAIRS 51-70-00 _______ DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Minor Damage 1 ALL Corrosion 1 ALL Protective Treatments 1 ALL Sealants 1 ALL Composite Materials 1 ALL

REPAIR OF MINOR DAMAGE 51-73-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL INSPECTION OF MINOR DAMAGE 51-73-11 REPAIRS 801 ALL Repair of Minor Damage on Aluminum 801 ALL Clad Components Repair of Minor Damage on Unclad 804 ALL Components Repair of Minor Damage on 808 ALL Titanium, Forged Aluminum, or Steel Components Repair of Dents in Skin Panels 813 ALL

REPAIR OF CORRODED AREAS 51-74-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL


CHAPTER 51 __________



SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ Description 1 ALL REPAIR OF CORRODED AREAS 51-74-11 REPAIRS 801 ALL Repair of Corroded Areas 801 ALL Removal of the Corrosion on Window 804 ALL Frames

PAINT REPAIR 51-75-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL STRIPPING 51-75-11 CLEANING/PAINTING 701 ALL Removal of Paint by the 701 ALL Application of Chemical Paint Strippers Removal of Paint by Abrasion 705 ALL REPAIR OF PAINT COATINGS 51-75-12 REPAIRS 801 ALL Repair of Paint Damage on Aluminum 801 ALL and Composite Material (more than the Topcoat) Repair of Paint Damage on a Steel 804 ALL Component (more than the Topcoat) Repair of Paint Damage (Topcoat 806 ALL Only) REPAIR OF SPECIAL COATINGS 51-75-13 REPAIRS 801 ALL Repair to a layer of 801 ALL Moisture-Removing Oil Repair to a layer of Corrosion 805 ALL Preventive Compound Repair to a layer of Cold 807 ALL Phosphate Application of the Corrosion 810 ALL Preventing Filling Compound in the Seat Track Crowns in the Wet Areas of the Passenger Compartment

SEALING REPAIRS 51-76-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Terms and Definitions 1 ALL Mixing the Sealant 2 ALL REPAIR OF SEALING 51-76-11 REPAIRS 801 ALL Repair of the Sealant 801 ALL


CHAPTER 51 __________



SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ Repair of Sealant to Service Doors 804 ALL REPAIR OF FUEL TANK SEALING 51-76-12 REPAIRS 801 ALL Local Repair of the Fuel Tank 801 ALL Sealant Repair of the Fuel Tank Fillet 804 ALL Temporary External Repair of the 808 ALL Fuel Tank Repair to Formed-in-Place Seal in 811 ALL the Fuel Tank

STANDARD COMPOSITE REPAIRS 51-77-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Types of Structure 1 ALL Sandwich Structures 1 ALL Monolithic Structures 1 ALL Mixed Structures 1 ALL MATERIAL HANDLING AND PREPARATION 51-77-11 MAINTENANCE PRACTICES 201 ALL Preparation of Composite Material 201 ALL Surfaces for Repair (Damage of not more than 1 Layer) Water-Break Test 204 ALL COMPOSITE REPAIRS - SKIN DAMAGE ALL 51-77-12 REPAIRS 801 ALL Temporary Skin Repair with 801 ALL High-Speed Tape Permanent Skin Repair - One Ply 805 ALL Depth

CLEANING PROCESSES 51-78-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL General 1 ALL

CLEANING PROCESSES 51-78-00 CLEANING/PAINTING 701 ALL Aircraft Cleaning after a Sewage 701 ALL Leakage Aircraft Cleaning after a 706 ALL Hydraulic Fluid Leakage Aircraft Cleaning after a Fish 712 ALL Shipment


CHAPTER 51 __________



SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ Aircraft Cleaning after an Acid or 717 ALL Alkali Leakage Aircraft Cleaning after a Fuel 723 ALL Leakage Aircraft Cleaning after a Leakage 727 ALL of Aggressive Media in the Cargo Compartments


STANDARD 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 ___________ (Ref. Fig. 001)

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)

�� EFF : ALL � Page 1�� 51-00-00 � � Apr 01/03 � � � � SI5

Aircraft Structure Figure 001


INVESTIGATION, CLEANUP AND AERODYNAMIC SMOOTHNESS - DESCRIPTION AND OPERATION _____________________________________________________________________________

1. General _______ (Ref. Fig. 001)

A. For a high aircraft performance it is necessary that the aircraft has an aerodynamically clean shape and a smooth external surface. The aerodynamic smoothness of the external surface is divided into three areas: - high aerodynamic smoothness, - good aerodynamic smoothness, - normal aerodynamic smoothness.


Aerodynamic Smoothness - Critical Areas Figure 001


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 the metal structure, the protective treatment gives protection 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 on the type of protective treatment applied to a component.

When a repair or cleaning procedure removes the original surface protection the protective treatment must also be repaired.

2. Description ___________

A. Protective Treatment Build-up The protective treatment build-up is not the same for all of the aircraft structures. The areas that are made of corrosion-resistant material, or areas where the performance of the component would be changed, 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.

B. Internal Treatment 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 the floor structure around the doors, galleys and toilets. In inaccessible areas and areas where contact with hydraulic fluid, lubricants and/or waste water is possible.

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 bond of the paint coatings. The chemical or galvanic coating film is applied to prevent electromechanical corrosion.

B. Paint Coatings A layer of primer paint coating is applied to all of the general structure to protect it against corrosion. The primer paint coating contains a corrosion inhibitor to prevent chemical damage from corrosive materials. A polyurethane top layer paint coating is applied to give protection to the structure from chemical and mechanical damage.

C. Special Coatings A water repellant coating is applied in areas where water or condensation can collect. A corrosion preventive compound is applied in areas where the structure can be effected by corrosion.


PROTECTIVE TREATMENT - CLEANING/PAINTING ________________________________________

TASK 51-21-00-916-801

Wax and Polish Protection on Unpainted Light Alloy Areas

R NOTE : Do not polish or wax the slats in the unpainted areas of the leading ____R 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 access platform No specific lint-free cloth

B. Consumable Materials

------------------------------------------------------------------------------- REFERENCE DESIGNATION -------------------------------------------------------------------------------

Material No. 05-025 USA MIL-P-6888 POLISH METAL ALUMINUM (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00)

C. Referenced Information


51-74-11-300-801 Repair of Corroded Areas (for corrective action)

�� EFF : ALL � Page 701�� 51-21-00 � � Oct 01/03 � � � � SI5

3. Job Set-up __________

Subtask 51-21-00-941-050

A. If necessary, put an access platform in position.

4. Procedure _________

Subtask 51-21-00-916-050

A. Apply the Special Material

R NOTE : Do not polish or wax the slats in the unpainted areas of the ____R leading edge.

(1) Clean the area with CLEANING AGENTS (Material No. 11-001) and a lint- free cloth.

(2) If necessary, repair the corrosion damage (Ref. TASK 51-74-11-300- 801).

(3) Wax and polish the area with SPECIAL MATERIALS (Material No. 05-025) and a lint-free cloth.

5. Close-up ________

Subtask 51-21-00-942-050

A. Remove the Ground Support Equipment

(1) Make sure that the work area is clean and clear of tools and other items.

(2) If necessary, remove the access platform.


CORROSION PREVENTION - DESCRIPTION AND OPERATION ________________________________________________

1. General _______

A. Corrosion Prevention Corrosion prevention, the removal of corrosion, and the subsequent maintenance have a direct effect on the safety and the in-service operation of the aircraft.

B. Corrosion-Resistant Materials and Protective Coatings Corrosion-resistant materials and protective coatings are applied at the construction stage to give protection against corrosion.

2. Corrosion Protection ____________________

A. Surface Treatment (Galvanic or Chemical)

(1) The surface coating for aluminum-alloy components are yellow chromating or chromic acid anodizing.

(2) Aluminum-alloy components that are bonded have a surface coating of chromic acid anodizing or pickling and bonding primer.

(3) Steel parts have a surface coating of cadmium plating, chrome plating or phosphating.

(4) Titanium or stainless-steel components that are assembled together with aluminum-alloy components have a surface coating of cadmium, zinc, or aluminum plating.

(5) The paint surface coating has a polyurethane or epoxy primer to give protection against corrosion. A polyurethane topcoat is applied to give protection against chemical damage.

B. Protection of Mating Surfaces

(1) 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 and installed coated with grease or anticorrosion materials.

(4) An application of paint or soft varnish, after components are assembled, gives protection to the joint seams.


(5) Sealant is applied to give protection to the bonded edges, in areas exposed to corrosion damage.

(6) Soft varnish is applied to to give protection to the fillet seals, in areas exposed to chemical damage.

For further information (Ref. ASRM 51-22-00).


COATINGS APPLICATION, GENERAL - DESCRIPTION AND OPERATION _________________________________________________________

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.


A. Aluminum Alloy Structure

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

Aluminum alloy structure is CAA prepared and then painted. External surfaces and some internal surfaces have a primer coating and a coat of paint.

B. Exposed Areas Areas which are exposed to moisture, or possible hydraulic leaks or galley/toilet leaks also have a moisture removing oil coating.

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.

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.


SEALING - GENERAL - DESCRIPTION AND OPERATION _____________________________________________

1. General _______ This topic gives data about 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. Sealants The primary uses for sealants on the aircraft are: - to seal the fuselage structure to make sure that the necessary internal pressure is kept during the flight, - to seal the fuel tanks (Ref. AMM 51-76-12), - to seal the external joints of the aircraft structure to make sure that water does not go into the structure and to make the structure smoother, - to seal riveted and bolted joints to make sure that liquids do not get into the joints, - to seal 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 leakage of aircraft fluids are kept in the areas from which you can drain them, for example, under the galleys and lavatories.

B. Areas for Sealing The aircraft is divided into three primary areas for sealing:

(1) The pressurized area of the fuselage which is from STA766/FR1 to STA6061/FR80. It includes the cockpit, the avionics compartment, the cabin and the cargo compartments.

(2) The nonpressurized areas of the aircraft which include: - the Main Landing Gear (MLG) bay, - the Centre Landing Gear (CLG) bay, - the Nose Landing Gear (NLG) bay, - the wing center box, - the air conditioning and hydraulic compartments,


Areas of Sealing Figure 001


- the tail section of the rear fuselage aft of STA6061/FR80, - the vertical and horizontal stabilizers, - the wings.

(3) The fuel system.


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.


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)


REPAIR 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 more data.


INSPECTION OF MINOR DAMAGE - REPAIRS ____________________________________

TASK 51-73-11-300-801

Repair of Minor Damage on Aluminum Clad Components


Self Explanatory




No specific abrasive cloth grade 280 No specific abrasive paper grade 400 No specific lint-free cloth No specific rounded scotch stone



Material No. 05-025 USA MIL-P-6888 POLISH METAL ALUMINUM (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 13-002 USA MIL-C-5541 MIL-C-81706 CLASS I/A CHEMICAL CONVERSION COATING YELLOW ALUMINUM (Ref. 20-31-00) Material No. 16-020 C Z-12.120 WASH PRIMER (Ref. 20-31-00)




51-75-12-300-801 Repair of Paint Damage on Aluminum and Composite Material (more than the Topcoat)

3. Job Set-up __________

Subtask 51-73-11-941-050

A. Get access to the area of the damage.


Subtask 51-73-11-320-050

A. Do the Repair

(1) For damage that has not gone through the aluminum cladding:

WARNING : OBEY THE MANUFACTURER�S INSTRUCTIONS WHEN YOU USE THE _______ SPECIAL MATERIAL. THIS MATERIAL IS DANGEROUS.

(a) Clean the repair area with the CLEANING AGENTS (Material No. 11- 004) and a lint-free cloth.

(b) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) or STRUCTURE PAINTS (Material No. 16-020) to the scratch.

(2) For minor damage that has gone through the aluminum cladding:

(a) Measure the depth of the scratch, refer to the ASRM for the permitted depth limits.

(b) Remove all of the paint from the area of the scratch with abrasive cloth grade 280 until you can see all of the scratch.

(c) Remove the scratch with a rounded scotch stone and water. Move the scotch stone along the scratch until the contour is smooth and rounded.

(d) Rub the roughened area with abrasive paper grade 400. Rub along the length of the scratch until the surface is smooth.


(e) Clean the area.

WARNING : USE SOLVENTS/CLEANING AGENTS, SEALANTS AND OTHER _______ SPECIAL MATERIALS ONLY WITH A GOOD FLOW OF AIR THROUGH THE WORK AREA. THESE MATERIALS ARE POISONOUS AND FLAMMABLE AND SKIN IRRITANTS. OBEY THE MANUFACTURERS INSTRUCTIONS. PUT ON PROTECTIVE CLOTHING. DO NOT GET THEM IN YOUR MOUTH. DO NOT SMOKE. DO NOT BREATHE THE GAS. GET MEDICAL HELP IF YOUR SKIN OR EYES BECOME IRRITATED.

1 Clean the area with CLEANING AGENTS (Material No. 11-004) and _ a lint-free cloth.

(f) 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.

(g) Clean the area with CLEANING AGENTS (Material No. 11-004) and a clean cloth.

(h) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) or STRUCTURE PAINTS (Material No. 16-020) to the metal surface.

(3) Apply the applicable surface protection (Ref. TASK 51-75-12-300-801).

5. Close-up ________

Subtask 51-73-11-942-050

A. Remove the ground support and maintenance equipment, the special and standard tools and all other items.


TASK 51-73-11-300-802

Repair of Minor Damage on Unclad Components


Self Explanatory




No specific abrasive cloth grade 280 No specific abrasive paper grade 400 No specific lint-free cloth No specific rounded scotch stone



Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 13-002 USA MIL-C-5541 MIL-C-81706 CLASS I/A CHEMICAL CONVERSION COATING YELLOW ALUMINUM (Ref. 20-31-00) Material No. 16-020 C Z-12.120 WASH PRIMER (Ref. 20-31-00)



51-75-12-300-803 Repair of Paint Damage (Topcoat Only) 51-74-11-300-801 Repair of Corroded Areas (for corrective action)


3. Job Set-up __________

Subtask 51-73-11-941-051



Subtask 51-73-11-320-052

A. Do the Repair

(1) If necessary, remove the corrosion (Ref. TASK 51-74-11-300-801).

(2) Clean the repair area.

WARNING : USE SOLVENTS/CLEANING AGENTS, SEALANTS AND OTHER SPECIAL _______ MATERIALS ONLY WITH A GOOD FLOW OF AIR THROUGH THE WORK AREA. THESE MATERIALS ARE POISONOUS AND FLAMMABLE AND SKIN IRRITANTS. OBEY THE MANUFACTURERS INSTRUCTIONS. PUT ON PROTECTIVE CLOTHING. DO NOT GET THEM IN YOUR MOUTH. DO NOT SMOKE. DO NOT BREATHE THE GAS. GET MEDICAL HELP IF YOUR SKIN OR EYES BECOME IRRITATED.

(a) Clean the repair area with CLEANING AGENTS (Material No. 11-004) and a lint-free cloth.

(3) Measure the depth of the scratch, refer to the ASRM for the permitted depth limits.

(4) Remove the scratch:

(a) Remove all of the paint from the area of the scratch with abrasive cloth grade 280 until you can see all of the scratch.

(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 paper grade 400. Rub along the length of the scratch until the surface is smooth.


(d) Clean the area.



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.

(e) Clean the area.


1 Clean the area with CLEANING AGENTS (Material No. 11-004) and _ a clean cloth.

(f) If necessary, apply PRETREATMENT FOR PAINTING (Material No. 13- 002) or STRUCTURE PAINTS (Material No. 16-020) to the metal surface.



5. Close-up ________

Subtask 51-73-11-942-051



TASK 51-73-11-300-803

Repair of Minor Damage on Titanium, Forged Aluminum, or Steel Components


Self Explanatory




No specific abrasive cloth grade 400 No specific lint-free cloth No specific rounded scotch stone



Material No. 05-042 USA MIL-C-10578 TYPE II PHOSPHATIC LIQUID (Ref. 20-31-00) Material No. 11-002 USA MIL-PRF-680 DRY CLEANING SOLVENT (VARSOL/WHITE SPIRIT) (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 13-002 USA MIL-C-5541 MIL-C-81706 CLASS I/A CHEMICAL CONVERSION COATING YELLOW ALUMINUM (Ref. 20-31-00) Material No. 16-020 C Z-12.120 WASH PRIMER (Ref. 20-31-00)




51-75-12-300-802 Repair of Paint Damage on a Steel Component (more than the Topcoat) 51-74-11-300-801 Repair of Corroded Areas (for corrective action)

3. Job Set-up __________

Subtask 51-73-11-941-052



Subtask 51-73-11-320-053

A. Do the Repair

(1) If necessary, remove the corrosion (Ref. TASK 51-74-11-300-801).




(3) Measure the depth of the scratch, refer to the ASRM for the permitted depth limits.


(4) For damage to titanium:

CAUTION : USE WATER WHEN YOU GRIND TITANIUM. TITANIUM DUST IS _______ FLAMMABLE.

(a) Remove the scratch with a rounded scotch stone and water. Move the scotch stone along the scratch until the contour is smooth and rounded.

(b) 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.

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.

(c) Clean the area.



(5) For damage to forged aluminum:

(a) Remove all of the paint from the area of the damage with abrasive cloth grade 280.

(b) Remove the scratch with abrasive cloth grade 400. Rub along the length of the scratch until the surface is smooth.

NOTE : Rub the area in the direction of the scratch. Do not use a ____ circular motion. Make sure you remove all the rough surfaces.


(c) Clean the area.



(d) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) or STRUCTURE PAINTS (Material No. 16-020) to the metal surface.

(6) For damage to steel components:

(a) Remove all of the paint from the area of the damage with abrasive cloth 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.

(d) Clean the area.




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.

(e) Apply SPECIAL MATERIALS (Material No. 05-042) to the metal surface.


5. Close-up ________

Subtask 51-73-11-942-052



TASK 51-73-11-300-804

Repair of Dents in Skin Panels


Self Explanatory




No specific abrasive cloth grade 280 No specific abrasive cloth grade 400 No specific lint-free cloth No specific masking paper No specific masking tape No specific nonmetallic scraper



Material No. 05-051 F ASNB85680 ALUMINIUM FILLER (SPECIAL MIXTURE) (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)



51-75-12-300-801 Repair of Paint Damage on Aluminum and Composite Material (more than the Topcoat) 51-75-12-300-802 Repair of Paint Damage on a Steel Component (more than the Topcoat)


3. Job Set-up __________

Subtask 51-73-11-941-053



Subtask 51-73-11-320-055

A. Do the Repair

(1) Measure the depth of the dent, refer to the ASRM for the permitted limits of dents.

(2) Remove all of the paint from the area of the dent and the adjacent 10 mm (0.3937 in.) of the dent with abrasive cloth grade 280.




WARNING : USE ONLY THE SPECIFIED TOOLS FOR THE PROTECTION OF THE _______ AIRCRAFT. DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS (STATIC, PITOT, TAT, AOA). THE SPECIFIED TOOLS : - GIVE THE CORRECT PROTECTION TO THE AIRCRAFT EQUIPMENT, - ARE EASY TO SEE FROM THE GROUND. MAKE AN ENTRY IN THE AIRCRAFT LOG BOOK OR ATTACH A TAG ON THE CAPTAIN SIDE STICK TO TELL THE CREW THAT PROTECTION COVERS/DEVICES ARE INSTALLED.


(4) Cover the area adjacent to the dent with masking paper and masking tape.

(5) Fill the dent:

(a) Mix the necessary amount of SPECIAL MATERIALS (Material No. 05- 051) to the manufacturer�s instructions.

(b) Apply the polyester filler to the repair area with a nonmetallic scraper.

(c) Refer to the manufacturer�s specifications for curing times and let the polyester filler cure.

(6) Smooth the polyester filler to the contours of the component with abrasive cloth grade 280.

(7) Smooth the polyester filler to the contours of the component with abrasive cloth grade 400.

(8) Apply the applicable surface protection (Ref. TASK 51-75-12-300-801), (Ref. TASK 51-75-12-300-802).

5. Close-up ________

Subtask 51-73-11-942-053



REPAIR OF CORRODED AREAS - DESCRIPTION AND OPERATION ____________________________________________________

1. General _______ Corrosion can effect the safe operation of the aircraft, its components and structure. When corrosion is found it must be removed and repaired 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 areas of corrosion 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 to the material center thus making the material weak. Refer to AMM 51-74-11 08 for the removal of: - corrosion, general, - corrosion on unpainted alloy, - corrosion on window frames.


REPAIR OF CORRODED AREAS - REPAIRS __________________________________

TASK 51-74-11-300-801

Repair of Corroded Areas


Self Explanatory




No specific abrasive cloth 400 grade No specific lint-free cloth No specific magnifying glass No specific masking paper No specific masking tape



Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00)



51-75-12-300-801 Repair of Paint Damage on Aluminum and Composite Material (more than the Topcoat) 51-75-12-300-802 Repair of Paint Damage on a Steel Component (more than the Topcoat) 51-76-11-300-801 Repair of the Sealant (for corrective action)


3. Job Set-up __________

Subtask 51-74-11-941-050

A. Get access to the area of the corrosion.


Subtask 51-74-11-140-050

A. Do the Repair

(1) Clean the repair area with CLEANING AGENTS (Material No. 11-001) and a lint-free cloth.


(2) Apply masking paper and masking tape to the area adjacent to the repair area.

(3) Remove the corrosion with abrasive cloth 400 grade.

NOTE : For limits refer to the related ASRM-chapter. ____

(4) Examine the area with a magnifying glass to make sure that all the corrosion is removed.

(5) If necessary, repair the damaged sealant (Ref. TASK 51-76-11-300- 801).

(6) Repair the damaged paint (Ref. TASK 51-75-12-300-801), (Ref. TASK 51- 75-12-300-802).


5. Close-up ________

Subtask 51-74-11-942-050



TASK 51-74-11-300-802

Removal of the Corrosion on Window Frames


Self Explanatory




No specific abrasive cloth (grade 280) No specific abrasive cloth (grade 400) No specific lint-free cloth No specific magnifying glass No specific masking paper No specific masking tape No specific PE-Foil No specific access platform 5.6 m (18 ft. 4 in.)



Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 13-002 USA MIL-C-5541 MIL-C-81706 CLASS I/A CHEMICAL CONVERSION COATING YELLOW ALUMINUM (Ref. 20-31-00) Material No. 16-001 ANTI-CORROSION PRIMER (POLYURETHANE ) (Ref. 20-31-00) Material No. 16-002 GB BAEP 3536 POLYURETHANE TOPCOAT GREY (FOR INTERNAL APPLIC.) (Ref. 20-31-00) Material No. 16-020 C Z-12.120 WASH PRIMER (Ref. 20-31-00)




51-76-11-300-801 Repair of the Sealant (for corrective action) 51-74-11-991-001 Fig. 801

3. Job Set-up __________

Subtask 51-74-11-941-051

A. Put the access platform in position adjacent to the area of the corrosion.


(Ref. Fig. 801/TASK 51-74-11-991-001)

Subtask 51-74-11-140-051

A. Do the Repair


(2) Apply tape 3M595 , PE-Foil and tesodur tape to the window pane.


(3) Apply masking paper and masking tape to the area adjacent to the damage.

(4) Remove the corrosion with abrasive cloth (grade 280) and abrasive cloth (grade 400).

NOTE : For limits refer to the related ASRM chapter. ____


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





(6) Examine the area with a magnifying glass to make sure all the corrosion is removed.

(7) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) or STRUCTURE PAINTS (Material No. 16-020) to the damaged area only.

(8) Apply STRUCTURE PAINTS (Material No. 16-001) and STRUCTURE PAINTS (Material No. 16-002) to the repair.

(9) If necessary, repair the damaged sealant (Ref. TASK 51-76-11-300- 801).

5. Close-up ________

Subtask 51-74-11-942-051



(2) Remove the access platform(s).

(3) Remove the ground support and maintenance equipment, the special and standard tools and all other items.


PAINT REPAIR - 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.


STRIPPING - CLEANING/PAINTING _____________________________

TASK 51-75-11-100-801

Removal of Paint by the Application of Chemical Paint Strippers


Self Explanatory




No specific abrasive paper, grade 220 or 320 No specific lint-free cloth No specific nonmetallic scraper No specific polyethylene film No specific soft brush



Material No. 08-019 FOIL, PRESSURE SENSITIVE (USE 08-108) (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 19-011 SCOTCH BRITE PADS (Ref. 20-31-00)



12-21-11-615-801 External Cleaning 51-76-11-300-801 Repair of the Sealant


3. Job Set-up __________

Subtask 51-75-11-950-050

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 the joints of external skin panels (except in fuel ____ tank areas) if: - there are no bonded doublers in the joints - the total time you apply the stripper is less than four hours.

(2) If necessary, install the correct protection covers/devices to protect the adjacent aircraft components from damage and contamination (Ref. TASK 12-21-11-615-801).


Subtask 51-75-11-150-050

A. Removal of Paint by the Application of Chemical Paint Strippers - Metallic Materials Only



CAUTION : DO NOT USE CHEMICAL PAINT STRIPPERS TO REMOVE PAINT FROM _______ COMPOSITE MATERIALS. THE STRIPPERS CAN CAUSE DAMAGE TO THE SURFACE AND DELAMINATION OF THE COMPOSITE STRUCTURE.

NOTE : This procedure gives the data necessary to remove the top coat of ____ the paint system, but not to remove the basic primer.

(1) Clean the work area with a lint-free cloth and the CLEANING AGENTS (Material No. 11-004), and let the surface dry.

(2) Use a soft brush to apply a thick layer of the chemical strippers to the work area.

NOTE : Use a paint stripper that is applicable for the metal ____ material, and for the type of paint coating.

NOTE : Do not apply the paint stripper to too large an area at one ____ time. It is recommended that one person only should apply the stripper to an area of 4 m2 (43.05 ft.2) maximum.

NOTE : Only use a paint stripper that is approved by your National ____ and/or Environmental Regulations.

NOTE : It is recommended to use the paint strippers at temperatures ____ above 20 deg.C (68.00 deg.F) , but not in hot sunlight or in rain. At temperatures below 18 deg.C (64.40 deg.F), the performance of the stripper can decrease by as much as 50%.

(3) Use a nonmetallic scraper to remove the remaining paint and paint stripper. Do this in less than 30 minutes from the time when you applied the stripper.

(4) Do a visual inspection of the work area.

(5) If the top coat of the paint system is not fully removed: - clean the surface of the work area with a soft brush and a large quantity of water - examine the condition of the masking materials - if necessary, do the masking procedure again - do the steps (1) thru (5) again, until the top coat of the paint system is fully removed.

(6) Remove and discard the masking materials.



(8) Inspect the areas that were masked for remaining paint stripper and damaged paint. If necessary: - remove the remaining paint stripper with a lint-free cloth and the CLEANING AGENTS (Material No. 11-004) - abrade the surface that was masked with the abrasive paper, grade 220 or 320 to remove the damaged paint - polish the abraded areas with a MISCELLANEOUS (Material No. 19- 011). - clean the abraded areas with a clean lint-free cloth and the CLEANING AGENTS (Material No. 11-004), and let the surface dry.

(9) Make sure that the sealing beads at the skin joints are in the correct condition.

(10) If the sealing beads are damaged or have gone soft, you must do a repair of the sealing beads at the skin joints (Ref. TASK 51-76-11- 300-801).

5. Close-up ________

Subtask 51-75-11-942-050

A. Put the aircraft back to its operational configuration.

(1) If necessary, remove the protection covers/devices you installed on the aircraft components adjacent to the work area (Ref. TASK 12-21- 11-615-801).



TASK 51-75-11-100-802

Removal of Paint by Abrasion


Self Explanatory




No specific abrasive paper, grade 220 or 320 No specific lint-free cloth No specific masking paper No specific masking tape



Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 19-011 SCOTCH BRITE PADS (Ref. 20-31-00)



12-21-11-615-801 External Cleaning 51-76-11-300-801 Repair of the Sealant


3. Job Set-up __________

Subtask 51-75-11-950-051

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 12-21-11-615-801).


Subtask 51-75-11-150-051

A. Removal of Paint by Abrasion - Metallic and Composite Materials


CAUTION : DO NOT CAUSE DAMAGE TO THE SURFACE OF THE COMPOSITE MATERIAL _______ WHEN YOU REMOVE THE PAINT COATING WITH ABRASIVE PAPER.

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.

(2) Polish the abraded areas with the MISCELLANEOUS (Material No. 19- 011).


(3) Remove and discard the masking materials.


(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 51-76-11-300-801).

5. Close-up ________

Subtask 51-75-11-942-051


(1) If necessary, remove the protection covers/devices you installed on the aircraft components adjacent to the work area (Ref. TASK 12-21- 11-615-801).



REPAIR OF PAINT COATINGS - REPAIRS __________________________________

TASK 51-75-12-300-801

Repair of Paint Damage on Aluminum and Composite Material (more than the Topcoat)

NOTE : If the standard certified color BAC 707 or the original certified color ____ is not to be used to restore the paint or for repainting of the upper surfaces of; the horizontal tail plane, the elevator, the ailerons, the spoilers or the flaps please contact Airbus Industrie for approval of the nonstandard paint color.


Self Explanatory




No specific abrasive cloth, grade 280 No specific lint-free cloth No specific masking paper No specific masking tape 98D53103000000 1 COVER - ALPHA PROBE PROTECTIVE



Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)




R ASRM 51-23-11 (for corrective action) 51-74-11-300-801 Repair of Corroded Areas (for corrective action)

3. Job Set-up __________

Subtask 51-75-12-941-050

A. Get access to the repair area.


Subtask 51-75-12-370-050

A. Repair the Paint Damage




NOTE : If you must repair paint damage adjacent the AOA sensor, you ____ must install protective cover COVER - ALPHA PROBE PROTECTIVE (98D53103000000).

(3) Remove the damaged paint and primer coatings with abrasive cloth, grade 280.

(4) Make the edges of the repair area smooth.

�� EFF : ALL � Page 802�� 51-75-12 � � Jan 01/04 � � � � SI5

(5) If necessary, repair the corrosion damage (Ref. TASK 51-74-11-300- 801).




R (7) Apply the primer coatings and paint coatings to the repair area (Ref.R ASRM 51-23-11).R

(8) Remove the masking paper, masking tape and protective covers as necessary.

5. Close-up ________

Subtask 51-75-12-942-050




�� EFF : ALL � Page 803�� 51-75-12 � � Jan 01/04 � � � � SI5

TASK 51-75-12-300-802

Repair of Paint Damage on a Steel Component (more than the Topcoat)


Self Explanatory




No specific abrasive cloth grade 280 No specific lint-free cloth No specific masking paper No specific masking tape



Material No. 05-042 USA MIL-C-10578 TYPE II PHOSPHATIC LIQUID (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00)



51-75-13-916-803 Repair to a layer of Cold Phosphate (for corrective action)

3. Job Set-Up __________

Subtask 51-75-12-941-051




Subtask 51-75-12-370-051

A. Repair the Paint Coating




(3) Remove the damaged paint and primer coatings with abrasive cloth grade 280.


(5) Apply a protective treatment of SPECIAL MATERIALS (Material No. 05- 042) to the repair area (Ref. TASK 51-75-13-916-803).

(6) Apply the primer coatings and paint coatings to the repair area (Ref. SRM 512311).

(7) Remove the masking paper and the masking tape.

5. Close-Up ________

Subtask 51-75-12-942-051





TASK 51-75-12-300-803

Repair of Paint Damage (Topcoat Only)

NOTE : If the standard certified color BAC 707 or the original certified color ____ is not to be used to restore the paint or for repainting of the upper surfaces of; the horizontal tailplane, the elevator, the ailerons, the spoilers or the flaps please contact Airbus Industrie for approval of the nonstandard paint color.


Self Explanatory




No specific abrasive cloth, grade 280 No specific lint-free cloth No specific masking paper No specific masking tape 98D53103000000 1 COVER - ALPHA PROBE PROTECTIVE



Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)

3. Job Set-Up __________

Subtask 51-75-12-941-052




Subtask 51-75-12-370-052

A. Repair the Paint Coating




NOTE : If you must repair paint damage adjacent the AOA sensor, you ____ must install protective cover COVER - ALPHA PROBE PROTECTIVE (98D53103000000).

(3) Remove the damaged topcoat of paint with abrasive cloth, grade 280.






(6) Apply the paint coatings to the repair area (Ref. ASRM 512311).


5. Close-Up ________

Subtask 51-75-12-942-052

A. Remove the Ground Support equipment




REPAIR OF SPECIAL COATINGS - REPAIRS ____________________________________

TASK 51-75-13-916-801

Repair to a layer of Moisture-Removing Oil


Self Explanatory




No specific lint-free cloth No specific masking paper No specific masking tape



Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)



51-75-13-991-002 Fig. 801


3. Job Set-up __________

(Ref. Fig. 801/TASK 51-75-13-991-002)

Subtask 51-75-13-941-050



Subtask 51-75-13-916-050



(1) Apply masking paper and masking tape to the equipment and fittings adjacent to the repair.

(2) Clean the area.


(a) Clean the area with CLEANING AGENTS (Material No. 11-004) and a lint-free cloth.

(3) Apply a layer of SPECIAL MATERIALS (Material No. 05-027) to the area.


Areas of Moisture-Removing Oil Figure 801/TASK 51-75-13-991-002


(4) Let the moisture-removing oil cure for 1 hour before you apply a second protective layer.


5. Close-up ________

Subtask 51-75-13-942-050



TASK 51-75-13-916-802

Repair to a layer of Corrosion Preventive Compound


Self Explanatory




No specific masking paper No specific masking tape No specific nonmetallic scraper



Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00)



51-75-13-916-801 Repair to a layer of Moisture-Removing Oil

3. Job Set-up __________

Subtask 51-75-13-941-051




Subtask 51-75-13-916-051




(2) Remove the damaged layer of corrosion-preventive compound with a nonmetallic scraper.

(3) Apply SPECIAL MATERIALS (Material No. 05-027) to the area (Ref. TASK 51-75-13-916-801).

(4) Apply SPECIAL MATERIALS (Material No. 05-005) to the area.


5. Close-up ________

Subtask 51-75-13-942-051



TASK 51-75-13-916-803

Repair to a layer of Cold Phosphate


Self Explanatory




No specific abrasive cloth grade 400 No specific brush No specific hot air dryer No specific lint-free cloth No specific masking paper No specific masking tape



Material No. 05-042 USA MIL-C-10578 TYPE II PHOSPHATIC LIQUID (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)

3. Job Set-up __________

Subtask 51-75-13-941-052

A. Get access to the area of thr damage.



Subtask 51-75-13-916-052




(2) Remove the damaged phosphate layer from an area of 20 mm (0.7874 in.) around the damage with abrasive cloth grade 400.

(3) Clean the area.


(a) Clean the area with CLEANING AGENTS (Material No. 11-004) and a lint-free cloth.

(4) Apply a layer of SPECIAL MATERIALS (Material No. 05-042) with a brush or a clean lint-free cloth.

(5) Let the phosphatic liquid soak into the surface of the metal until it changes to a grey-white color (between 5 and 15 minutes).

(6) Flush the area with clean water.


(7) Dry the area with a the hot air dryer.


5. Close-up ________

Subtask 51-75-13-942-052



TASK 51-75-13-916-804

Application of the Corrosion Preventing Filling Compound in the Seat Track Crowns in the Wet Areas of the Passenger Compartment


Self Explanatory




No specific goggles No specific insulated gloves No specific masking paper No specific masking tape No specific non-metallic scraper with a width of approximately 30 mm (1.1 in.) No specific non-metallic scraper with a width of approximately 9 mm (0.35 in.) No specific plugs No specific protective clothes No specific section profile, Part Number 10-6X7-6. No specific COSMOLINE APPLICATOR No specific COSPOTT



Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 15-010 USA MIL-C-11796-C CLASS 1A CORROSION PREVENTIVE FILLER COMPOUND (Ref. 20-31-00) Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)




25-28-41-000-801 Removal of the Textile Floor-Covering (TF) 25-28-41-400-801 Installation of the Textile Floor-Covering (TF) 25-28-42-000-803 Removal of Enhanced Non-Textile Floor Covering (NTF) 25-28-42-400-803 Installation of Enhanced Non-Textile Floor Covering (NTF) 25-28-43-000-801 Removal of Moisture Barrier Foil (MYLAR) 25-28-43-400-801 Installation of Moisture Barrier Foil (MYLAR) 51-75-13-991-003 Fig. 802

3. Job Set-up __________

Subtask 51-75-13-010-050

A. Get Access

(1) Get access to the subsequent wet areas of the passenger compartment: - the passenger/crew door entrance-areas, and for two frames forward and aft of these areas, - the galley areas, and for one frame forward and aft of these areas, - the lavatory areas, and for one frame forward and aft of these areas.

NOTE : The cabin utility and passenger/crew door entrance areas are ____ usually covered with non-textile floor-covering. These areas and their surroundings are specified as wet areas as they are frequently in contact with liquids.

(2) If necessary, remove the textile floor-covering (Ref. TASK 25-28-41- 000-801).

(3) If necessary, remove the non-textile floor-covering (Ref. TASK 25-28- 42-000-803).

(4) If necessary, remove the moisture barrier foil (Ref. TASK 25-28-43- 000-801).


Subtask 51-75-13-860-050

B. Preparation before Application (Ref. Fig. 802/TASK 51-75-13-991-003)

(1) Apply the masking paper and the masking tape to the equipment installed adjacent to the wet areas.


(2) If necessary, remove the old corrosion preventive filling compound STORAGE PRESERVATION (Material No. 15-010) with a non-metallic scraper with a width of approximately 9 mm (0.35 in.).

(3) Clean the applicable seat track crowns (2) with the CLEANING AGENTS (Material No. 11-004) and a clean lint-free cotton cloth MISCELLANEOUS (Material No. 19-003).

(4) Make sure that the corrosion preventing filling compound does not go into the seat tracks in areas outside of wet areas. Install plugs into the seat track crowns at the end of the wet areas to prevent this.

NOTE : You can make the plugs locally from section profile, Part ____ Number 10-6X7-6..

(5) Make sure that you obey the manufacturers instructions when you use the corrosion application tools.

(6) Make sure that you wear the correct protective equipment. Wear goggles, insulated gloves and protective clothes when you use the hot corrosion preventive filling compound.

WARNING : YOU MUST NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT _______ PARTS CAN CAUSE AN INJURY. IF YOU GET AN INJURY, PUT IT IN COLD WATER FOR 10 MINUTES AND GET MEDICAL AID.


Examples of the Application of the Corrosion Preventing Filling Compound in the Seat Track Crowns Figure 802/TASK 51-75-13-991-003 �� EFF : ALL � Page 813�� 51-75-13 � � Apr 01/03 � � � � SI5

(7) Increase the temperature of the corrosion preventive filling compound STORAGE PRESERVATION (Material No. 15-010) to between 75 deg.C (167 deg.F) and 93 deg.C (200 deg.F) with the COSMOLINE APPLICATOR (1) or the COSPOTT (3), or an alternative tool.

NOTE : The alternative tool you use must be capable to safely ____ increase the temperature of the material to the necessary temperature range.

NOTE : It is not permitted to increase the temperature of the ____ corrosion preventive filling compound STORAGE PRESERVATION (Material No. 15-010) with the COSPOTT or the alternative tool inside the passenger compartment.


Subtask 51-75-13-916-053

A. Application of the Corrosion Protection

WARNING : YOU MUST NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT _______ PARTS CAN CAUSE AN INJURY. IF YOU GET AN INJURY, PUT IT IN COLD WATER FOR 10 MINUTES AND GET MEDICAL AID.

(1) Carefully fill the seat track crowns (2) with the corrosion preventive filling compound STORAGE PRESERVATION (Material No. 15- 010). Use the COSMOLINE APPLICATOR (1), or the COSPOTT (3), or an alternative tool.

NOTE : The tool you use must be capable to safely apply the liquid ____ corrosion preventive filling compound into the cavity of the seat track crown.

(2) Make sure that the upper surface of the seat track has a layer of the corrosion preventive filling compound STORAGE PRESERVATION (Material No. 15-010).

(3) After approximately 2 to 3 minutes, remove the unwanted corrosion preventive filling compound STORAGE PRESERVATION (Material No. 15- 010) with a non-metallic scraper with a width of approximately 30 mm (1.1 in.). Do this at the top of the seat track crowns (2) to get a flush surface.

(4) Make sure that the complete seat track crown (2) is filled with the corrosion preventive filling compound STORAGE PRESERVATION (Material No. 15-010).


(5) Install the moisture barrier foil and the spacer strip to protect the seat track crown (2) (Ref. TASK 25-28-43-400-801).

NOTE : If you install the moisture barrier foil and the spacer strip ____ later,protect the top of the seat track crown (2) with the masking paper.

5. Close-up ________

Subtask 51-75-13-860-051


(1) Remove the masking paper and the masking tape. Do not remove the masking paper, if installed, from the top of the seat track crown (2) at this time.


Subtask 51-75-13-410-050

B. Close Access


(2) If necessary, remove the masking paper from the top of the seat track crown (2).

(3) If necessary, install the moisture barrier foil (Ref. TASK 25-28-43- 400-801).

(4) If necessary, install the textile floor-covering (Ref. TASK 25-28-41- 400-801).

(5) If necessary, install the non-textile floor-covering (Ref. TASK 25- 28-42-400-803).


SEALING REPAIRS - DESCRIPTION AND OPERATION ___________________________________________

1. General _______ Sealants are used on the aircraft structure to stop pressurization leaks and fuel leaks. You must repair damaged sealant. 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. 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. | -----------------------------------------------------------------------------


----------------------------------------------------------------------------- | 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. Mixing the Sealant __________________ You must refer to the manufacturers instructions for the: - mixing ratios, - application life, - tack free time, - cure time, - work life. You must mix the base compound and accelerator of the sealant slowly to an even consistency and color. Fast mixing will cause heat and air bubbles and shorten the application life of the sealant. You must mix the sealant as close to the time of application as possible.


REPAIR OF SEALING - REPAIRS ___________________________

TASK 51-76-11-300-801

Repair of the Sealant


Self explanatory




No specific lint-free cloth No specific masking paper No specific masking tape No specific nonmetallic scraper No specific soft brush



Material No. 09-013 USA MIL-PRF-81733 TYPE I CLASS A CORROSION INHIBITING BRUSH CONSISTENCY (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 16-003 F ASNB70720 COATING (OBSOLETE USE 16-021) (Ref. 20-31-00)



51-75-13-916-802 Repair to a layer of Corrosion Preventive Compound (for corrective action)


3. Job Set-up __________

Subtask 51-76-11-941-050

A. Get access to the damaged sealant.


Subtask 51-76-11-914-050

A. Repair the Sealant

(1) Remove the damaged sealant with a nonmetallic scraper.

(2) Make a chamfer on the edges of the repair area to a minimum width of 12.5 mm (0.4921 in.).






(4) Apply masking paper and masking tape to the area adjacent to the repair.

(5) Apply SEALANTS (Material No. 09-013) to the repair area and the adjacent sealant with a soft brush.

(6) Apply STRUCTURE PAINTS (Material No. 16-003) to the repair area and a width of 25.0 mm (0.9842 in.) around the repair area.

(7) If necessary, apply the surface protection (Ref. TASK 51-75-13-916- 802).

5. Close-up ________

Subtask 51-76-11-942-050



TASK 51-76-11-300-802

Repair of Sealant to Service Doors


Self Explanatory




No specific nonmetallic scraper



Material No. 05-013 D TV-53-3507/73 RELEASE AGENT (OBSOLETE USE 05-013A) (Ref. 20-31-00) Material No. 09-013 USA MIL-PRF-81733 TYPE I CLASS A CORROSION INHIBITING BRUSH CONSISTENCY (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)

3. Job Set-up __________

Subtask 51-76-11-941-051

A. Get Access

(1) Open the applicable service door.

(2) Do a check of the sealant. If the sealant is damaged, you must repair the sealant.



Subtask 51-76-11-914-051

A. Repair the Sealant:

(1) Remove the damaged sealant with a nonmetallic scraper.

(2) Clean the repair area with CLEANING AGENTS (Material No. 11-004).

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.


(3) Apply SEALANTS (Material No. 09-013) to the inner door assembly and fuselage attach area.

(4) Apply SPECIAL MATERIALS (Material No. 05-013) to the inner surface of the service door and close the door.

(5) Let the sealant cure.

(6) Open the service door and remove the unwanted sealant.

5. Close-up ________

Subtask 51-76-11-942-051

A. Close Access


(2) Close the service door.


REPAIR OF FUEL TANK SEALING - REPAIRS _____________________________________

TASK 51-76-12-300-801

Local Repair of the Fuel Tank Sealant


General repair for fuel leaks.




No specific brush No specific lint-free cloth No specific nonmetallic scraper



Material No. 09-007 USA MIL-S-4383 BRUSHABLE FUEL RESISTANT COATING (Ref. 20-31-00) Material No. 09-008 USA MIL-S-8802 CLASS A EARLY QUICK REPAIR FUEL TANK SEALANT (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)



12-11-28-650-801 General Refuel/Defuel Safety Procedures 12-11-28-650-804 Pressure Refuel With Manual Control 28-00-00-610-801 Fuel Safety Procedures 28-25-00-650-801 Pressure Defuel Procedure


3. Job Set-up __________

Subtask 51-76-12-941-050

A. Obey the fuel safety procedures (Ref. TASK 28-00-00-610-801) and (Ref. TASK 12-11-28-650-801).

Subtask 51-76-12-650-050

B. Defuel the aircraft (Ref. TASK 28-25-00-650-801).

Subtask 51-76-12-010-050

C. Get access to the area of the fuel leak.


Subtask 51-76-12-160-050

A. Prepare the Repair Area

(1) Remove the sealant from the leak point and up to a distance of 20 mm (0.7874 in.) around the leak point with a nonmetallic scraper.

(2) Make a chamfer on the edges of the repair area.





Subtask 51-76-12-914-050

B. Do the Repair

(1) Mix the necessary quantity of SEALANTS (Material No. 09-008).

(2) Apply a 1 mm (0.0393 in.) thick coat of sealant over the repair area with a brush. Refer to the manufacturer�s instructions for the cure time.

NOTE : The new coat of sealant must have an overlap of at least 25 mm ____ (0.9842 in.) on the sealant adjacent to the repair.

(3) Apply a second coat of sealant and let it cure. Refer to the manufacturer�s instructions for the cure time.

(4) Apply a topcoat of SEALANTS (Material No. 09-007) to the repair area.

NOTE : The sealant topcoat must have an overlap of at least 6 mm ____ (0.2362 in.) on the sealant adjacent to the repair.

Subtask 51-76-12-650-051

C. Refuel the Aircraft


(2) Refuel the aircraft (Ref. TASK 12-11-28-650-804).

Subtask 51-76-12-790-050

D. Examine the repair 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 51-76-12-942-051



TASK 51-76-12-300-802

Repair of the Fuel Tank Fillet


Self Explanatory




No specific flat nonmetallic tool No specific lint-free cloth No specific nonmetallic scraper



Material No. 09-001 USA MIL-S-8802 TYPE I CLASS A FUEL TANK SEALANTPOLYSULFIDE (Ref. 20-31-00) Material No. 09-002 USA MIL-S-8802 TYPE I CLASS B FUEL TANK SEALANTPOLYSULFID(NO LONGER AVAILABLE (Ref. 20-31-00)R Material No. 09-008 USA MIL-S-8802 CLASS AR EARLY QUICK REPAIR FUEL TANK SEALANT (Ref. 20-31-00) Material No. 09-016 USA MIL-PRF-81733D TYPE II CLASS B CORROSION INHIBITING FILLET CONSISTENCY (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)




12-11-28-650-801 General Refuel/Defuel Safety Procedures 12-11-28-650-804 Pressure Refuel With Manual Control 28-00-00-610-801 Fuel Safety Procedures 28-25-00-650-801 Pressure Defuel Procedure

3. Job Set-up __________

Subtask 51-76-12-941-051


Subtask 51-76-12-650-052

B. Defuel the aircraft (Ref. TASK 28-25-00-650-801).

Subtask 51-76-12-010-051

C. Get access to the area of the fuel leak.


Subtask 51-76-12-160-051

A. Prepare the Repair Area

(1) Remove the sealant around the leak point and up to a distance of 75 mm (2.9527 in.) from the leak point with a nonmetallic scraper.

NOTE : The maximum width of the fillet must not be more than 6.5 mm ____ (0.2559 in.).


�� EFF : ALL � Page 805�� 51-76-12 � � Oct 01/03 � �R � � SI5




Subtask 51-76-12-914-051

B. Do the Repair

R (1) Mix the necessary quantity of the SEALANTS (Material No. 09-002), orR the SEALANTS (Material No. 09-016), or the SEALANTS (Material No. 09-R 008).

(2) Apply a continuous fillet of sealant along the repair area. The maximum width of the fillet must not be more than 6.5 mm (0.2559 in.).

NOTE : The repair must have an overlap of at least 12.5 mm (0.4921 ____ in.) on the sealant adjacent to the repair.

(3) Move the sealant into the correct position with a flat nonmetallic tool.

(4) Let the sealant cure for half of the tack free time. Refer to the manufacturers instructions for the cure time.

(5) Apply a topcoat of SEALANTS (Material No. 09-001) to the repair area.

(6) Let the repair cure.


Subtask 51-76-12-650-053

C. Refuel the Aircraft


(2) Refuel the aircraft (Ref. TASK 12-11-28-650-804).

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.

5. Close-up ________

Subtask 51-76-12-942-052


�� EFF : ALL � Page 807�� 51-76-12 � � Oct 01/03 � �R � � SI5

TASK 51-76-12-300-803

Temporary External Repair of the Fuel Tank


Self Explanatory




No specific flat nonmetalic tool No specific lint-free cloth



Material No. 09-009 X (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)



12-11-28-650-801 General Refuel/Defuel Safety Procedures 12-11-28-650-804 Pressure Refuel With Manual Control 28-00-00-610-801 Fuel Safety Procedures 28-11-00-280-802 Fuel Tank Leaks - General Information 28-25-00-650-801 Pressure Defuel Procedure


3. Job Set-up __________

Subtask 51-76-12-941-052


Subtask 51-76-12-010-052

B. Get access to the area of the fuel leak.

Subtask 51-76-12-280-050

C. Find the rate of the leak to see if it is permitted to do a temporary repair (Ref. TASK 28-11-00-280-802).


Subtask 51-76-12-110-052

A. Clean the repair area.



Subtask 51-76-12-914-052

B. Do the Repair

(1) Apply SEALANTS (Material No. 09-009) to the leak area. Push the sealant into the leak source with a flat nonmetalic tool until the leak stops.

NOTE : If you cannot get a good seal defuel the aircraft to below the ____ level of the leak (Ref. TASK 28-25-00-650-801).

(2) Apply a second coat of SEALANTS (Material No. 09-009).


(3) Let the repair cure.

(4) If necessary, refuel the aircraft to above the level of the repair (Ref. TASK 12-11-28-650-804) and examine the repair for leaks.


5. Close-up ________

Subtask 51-76-12-942-053



TASK 51-76-12-300-804

Repair to Formed-in-Place Seal in the Fuel Tank


Procedure to repair or replace a damaged formed-in-place seal.




No specific abrasive paper No specific lint free cloth No specific masking tape No specific non metalic scraper No specific rubber ring spacer, 6 mm (0.23 in.) thickness No specific sharp non metalic knife



Material No. 05-013A C Z-24.223 RELEASE AGENT (Ref. 20-31-00) Material No. 09-002 USA MIL-S-8802 TYPE I CLASS BR FUEL TANK SEALANTPOLYSULFID(NO LONGER AVAILABLER (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)



51-76-12-991-001 Fig. 801

�� EFF : ALL � Page 811�� 51-76-12 � � Jul 01/03 � � � � SI5

3. Job Set-up __________

(Ref. Fig. 801/TASK 51-76-12-991-001)

Subtask 51-76-12-941-053

A. Preparation of the Repair Area

(1) Use a non metalic scraper to remove the damaged sealant from the sufaces of the aperture and the access panel. Where applicable, make a feathered edge with abrasive paper to the limit of the serviceable sealant.

(2) Use a lint free cloth moistened with CLEANING AGENTS (Material No. 11-004) to clean the area of the repair.


(3) Apply masking tape to surfaces where unwanted sealant will come out.

(4) Attach a rubber ring spacer, 6 mm (0.23 in.) thickness at each screw hole on the surface to be repaired. This will keep the holes free from sealant.

(5) Application of release agent:


(a) Apply a layer of SPECIAL MATERIALS (Material No. 05-013A) to the contact parts of the access panel. This will assist the next removal procedure.

(6) Let the release agent dry.


Formed-in-Place Seal Repair - Example Figure 801/TASK 51-76-12-991-001



Subtask 51-76-12-390-050

A. Repair to the Formed-in-Place Seal

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) Prepare the SEALANTS (Material No. 09-002).

(2) Apply a layer of sealant similar in thickness to the ring spacers.

(3) Put the access panel in position.

(4) Tighten the fasteners in sequence until the panel comes into contact with the spacer rings.

(5) Let the sealant cure.

(6) Remove any unwanted sealant with a sharp non metalic knife.

(7) Remove the masking tape.

5. Close-up ________

Subtask 51-76-12-942-054

A. Close Access




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 the specific repair data, material specifications and manufacturer�s instructions.

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 structures. - glassfiber materials to repair glassfiber and aramidfiber structures.

2. Types of Structure __________________

A. 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).

B. 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).

C. Mixed Structures To follow the aircraft design, some structures are mixed, for example part sandwich and part monolithic structure. For more data Ref. ASRM 51-77-00 or the ASRM chapter related to the component you will repair.


MATERIAL HANDLING AND PREPARATION - MAINTENANCE PRACTICES _________________________________________________________

TASK 51-77-11-910-801

Preparation of Composite Material Surfaces for Repair (Damage of not more than 1 Layer)

WARNING : USE SOLVENTS/CLEANING AGENTS, SEALANTS AND OTHER SPECIAL MATERIALS _______ ONLY WITH A GOOD FLOW OF AIR THROUGH THE WORK AREA. THESE MATERIALS ARE POISONOUS AND FLAMMABLE AND SKIN IRRITANTS. OBEY THE MANUFACTURERS INSTRUCTIONS. PUT ON PROTECTIVE CLOTHING. DO NOT GET THEM IN YOUR MOUTH. DO NOT SMOKE. DO NOT BREATHE THE GAS. GET MEDICAL HELP IF YOUR SKIN OR EYES BECOME IRRITATED.


Self explanatory




No specific abrasive cloth, grade 100 No specific abrasive cloth, grade 280 No specific abrasive cloth, grade 400 No specific demineralized water No specific light grit blast (400-700) micron walnut grit No specific lint-free cloth No specific masking paper No specific masking tape No specific vacuum cleaner




Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)

3. Job Set-up __________

Subtask 51-77-11-941-050

A. Get access to the area to be repaired.


Subtask 51-77-11-918-050

A. Prepare the Surface

WARNING : OBEY THE MANUFACTURER�S INSTRUCTIONS WHEN YOU USE THE SPECIAL _______ MATERIAL. THIS MATERIAL IS DANGEROUS.



NOTE : Put the CLEANING AGENTS (Material No. 11-004) on to the cloth, ____ not directly on to the repair area.



(3) Remove the surface protection from the damage and up to 50 mm (1.9685 in.) around the damage with abrasive cloth, grade 100 or light grit blast (400-700) micron walnut grit.

(4) Remove all of the damaged material but not more than one layer.


(6) Make the repair area smooth with abrasive cloth, grade 280 and abrasive cloth, grade 400.

(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 : Put the demineralized water on to the cloth, not directly on ____ to the repair.

5. Close-up ________

Subtask 51-77-11-942-050



TASK 51-77-11-700-801

Water-Break Test


Self explanatory




No specific abrasive cloth, grade 400 No specific demineralized water No specific lint-free cloth No specific spray gun

3. Job Set-up __________

Subtask 51-77-11-941-051

A. Get access to the area to be repaired.


Subtask 51-77-11-750-050

A. Do the Test

(1) Dry the repair area with a clean lint-free cloth.

(2) Apply a thin coating of demineralized water to the repair area with a spray gun.

NOTE : A thick coating of demineralized water will not show all of ____ the contamination on the repair area.

(3) Examine the wetted surface to make sure the demineralized water makes a thin continuous coating.

NOTE : Contamination is shown when the demineralized water forms into ____ beads of water.


(4) If necessary, rub down the repair area with abrasive cloth, grade 400 to remove the contamination.

(5) Repeat the procedure until no contamination is found.

(6) 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.

5. Close-up ________

Subtask 51-77-11-942-051



COMPOSITE REPAIRS - SKIN DAMAGE ALL - REPAIRS _____________________________________________

TASK 51-77-12-300-801

Temporary Skin Repair with High-Speed Tape

NOTE : You use high-speed tape to cover slight skin damage when you do not find ____ internal damage.


Self explanatory




No specific lint-free cloth



No specific abrasive cloth, grade 100 No specific abrasive cloth, grade 280 No specific abrasive cloth, grade 400 No specific high-speed tape Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)



51-77-12-991-001 Fig. 801


3. Job Set-up __________

Subtask 51-77-12-941-050



(Ref. Fig. 801/TASK 51-77-12-991-001)

Subtask 51-77-12-560-050

A. Do the Repair

(1) Remove frayed fibers.

(2) Make the sharp edges smooth with abrasive cloth, grade 100.

(3) Make the repair area smooth with abrasive cloth, grade 280 and abrasive cloth, grade 400.




(5) Prepare the tape.


(a) Cut the high-speed tape to the necessary dimensions and round off the corners.


Temporary Skin Repair with High-Speed Tape Figure 801/TASK 51-77-12-991-001


(6) Apply the high-speed tape to the repair area.

5. Close-up ________

Subtask 51-77-12-942-050





TASK 51-77-12-330-801

Permanent Skin Repair - One Ply Depth


Self explanatory




No specific abrasive cloth, grade 280 No specific abrasive cloth, grade 400 No specific polythene sheet



Material No. 05-057 C Z-18.903 MICROBALLOONS (Ref. 20-31-00) Material No. 08-010A D DAN 1199-01 EPOXY RESIN AND HARDENER ADHESIVE (Ref. 20-31-00)



51-77-11-700-801 Water-Break Test 51-77-11-910-801 Preparation of Composite Material Surfaces for Repair (Damage of not more than 1 Layer) 51-75-12-300-801 Repair of Paint Damage on Aluminum and Composite Material (more than the Topcoat) (for corrective action) 51-77-12-991-002 Fig. 802


3. Job Set-up __________

Subtask 51-77-12-941-051



(Ref. Fig. 802/TASK 51-77-12-991-002)

Subtask 51-77-12-915-052

A. Do the Repair

(1) If necessary remove the temporary skin repair.

(2) Prepare the repair area (Ref. TASK 51-77-11-910-801).

(3) Do a water-break test on the repair area (Ref. TASK 51-77-11-700- 801).

(4) Prepare the filler.

WARNING : OBEY THE MANUFACTURER�S INSTRUCTIONS WHEN YOU USE THE _______ SPECIAL MATERIAL. THIS MATERIAL IS DANGEROUS.

(a) Mix 90 parts BONDING AND ADHESIVE COMPOUNDS (Material No. 08- 010A) with 10 parts SPECIAL MATERIALS (Material No. 05-057) by weight.

(5) Apply the mixture 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.

(9) Make the repair smooth with abrasive cloth, grade 280 and abrasive cloth, grade 400 to the contours of the structure.

(10) Apply paint to the repair (Ref. TASK 51-75-12-300-801).


Temporary Skin Repair-Maximum 1 Ply Depth Figure 802/TASK 51-77-12-991-002


5. Close-up ________

Subtask 51-77-12-942-051





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 and/or contamination must be removed as soon as possible to prevent damage to the aircraft structure.


A. General

(1) Leaks from the Toilet Waste System Leaks from the toilet waste system can damage the aircraft metal components and cause corrosion.

(2) Hydraulic Fluid Contamination of the aircraft structure with hydraulic fluid can 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 the aircraft structure and components.

(5) Aggressive Media Spillage Contamination of the cargo compartments with aggressive media can cause corrosion and damage to the components of the cargo loading system.


CLEANING PROCESSES - CLEANING/PAINTING ______________________________________

TASK 51-78-00-615-801

Aircraft Cleaning after a Sewage Leakage


Self explanatory




No specific a vacuum cleaner No specific circuit breaker(s) safety clip(s) No specific hot air dryer No specific lint-free cloth No specific nonmetallic brush No specific nonmetallic scraper No specific access platform 4.60 m (15 ft. 1 in.) No specific access platform 5.20 m (17 ft. 1 in.)



No specific bicarbonate of soda Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00)




25-51-22-000-801 Removal of the Ball Mats/Ball Strips in the FWD Cargo Compartment 25-51-22-000-802 Removal of the Ball Mats/Ball Strips in the AFT Cargo Compartment 25-51-22-400-801 Installation of the Ball Mats/Ball Strips in the FWD Cargo Compartment 25-51-22-400-802 Installation of the Ball Mats/Ball Strips in the AFT Cargo Compartment 52-30-00-010-801 Opening of the FWD and AFT Cargo-Compartment Doors with the Yellow Electric Pump 53-00-00-000-802 Removal of the Floor Panels in the FWD Cargo-Compartment 53-00-00-000-803 Removal of the Floor Panels in the AFT Cargo-Compartment 53-00-00-400-802 Installation of the Floor Panels in the FWD Cargo-Compartment 53-00-00-400-803 Installation of the Floor Panels in the AFT Cargo-Compartment 51-74-11-300-801 Repair of Corroded Areas (for corrective action) 51-75-12-300-803 Repair of Paint Damage (Topcoat Only) (for corrective action) 51-75-13-916-801 Repair to a layer of Moisture-Removing Oil (for corrective action) 51-75-13-916-802 Repair to a layer of Corrosion Preventive Compound (for corrective action)

3. Job Set-up __________

Subtask 51-78-00-941-050

A. Get access to the area of the leakage

(1) Open, safety and tag the circuit breakers of all electrical components and systems in the work area.

(a) For the FWD Cargo Compartment:

1 Open the cargo compartment door (Ref. TASK 52-30-00-010-801). _

2 Put the access platform in position below the circuit breaker _ panel 5002VE.


3 Open the access panel 132UC of the circuit breaker panel _ 5002VE.

(b) For the AFT Cargo Compartment




NOTE : Open, safety and tag the subsequent circuit breakers ____ only if the leakage is in the FWD and/or AFT cargo compartment.

Subtask 51-78-00-865-050

B. Open, safety and tag this(these) circuit breaker(s):

------------------------------------------------------------------------------- PANEL DESIGNATION FIN LOCATION ------------------------------------------------------------------------------- 5002VE FWD CARGO LOADING POWER RH1 5MY A13 5002VE FWD CARGO LOADING POWER LH1 3MY A10 5002VE FWD CARGO LOADING POWER RH2 4MY B13 5002VE FWD CARGO LOADING POWER LH2 2MY B10 5002VE FWD CARGO LOADING CTL 1MY C13 5006VE AFT CARGO LOADING POWER RH1 105MY A13 5006VE AFT CARGO LOADING POWER LH1 103MY A10 5006VE AFT CARGO LOADING POWER RH2 104MY B13 5006VE AFT CARGO LOADING POWER LH2 102MY B10 5006VE AFT CARGO LOADING CTL 101MY C13

Subtask 51-78-00-010-050

C. Removal and Cleaning of Components

(1) Remove components from the area you will clean to prevent contamination from water and/or cleaning agents.

(2) If the sewage leakage is in the cargo compartment: - clean the contaminated cargo loading system components in the workshop - if necessary, apply lubricants and corrosion preventive materials.



Subtask 51-78-00-160-051

A. Clean the Area


(1) Remove loose materials with a nonmetallic scraper, a vacuum cleaner, or a nonmetallic brush.

(2) Do a check of the drain filters in the contaminated area and clean them if necessary.

(3) Install protective covers at all electrical outlets to protect them from water.


(5) Make a cleaning solution of 10 % of bicarbonate of soda or CLEANING AGENTS (Material No. 11-001) and water. Mix 100 g (3.52 oz) of bicarbonate of soda or CLEANING AGENTS (Material No. 11-001) with every 1 l (0.2641 USgal) of water.

(6) Clean the area with the cleaning solution and a lint-free cloth.


(8) Make a cleaning solution of 0.5 % CLEANING AGENTS (Material No. 11- 001) and water.



(11) Dry the area with a hot air dryer.


(12) If the floor structure of the FWD or the AFT cargo compartment is contaminated:

(a) Remove the applicable floor panels and/or ball mats (Ref. TASK 53-00-00-000-802), (Ref. TASK 53-00-00-000-803) and/or (Ref. TASK 25-51-22-000-801), (Ref. TASK 25-51-22-000-802).

(b) Do the steps (1) thru (11) again.

(13) If necessary, repair corrosion damage (Ref. TASK 51-74-11-300-801).

(14) If necessary, repair the paint layers (Ref. TASK 51-75-12-300-803).

(15) If necessary, apply a layer of SPECIAL MATERIALS (Material No. 05- 027) to the area (Ref. TASK 51-75-13-916-801).


(17) Remove all the protective covers from the electrical outlets.

5. Close-up ________

Subtask 51-78-00-410-050

A. Installation

(1) Install all the components that were removed for the cleaning task.

(2) If the floor panels and/or ball mats are removed install them again (Ref. TASK 53-00-00-400-802), (Ref. TASK 53-00-00-400-803) and/or (Ref. TASK 25-51-22-400-801), (Ref. TASK 25-51-22-400-802).

Subtask 51-78-00-865-051

B. 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.

Subtask 51-78-00-942-050

C. Remove the ground support and maintenance equipment, the special and standard tools and all other items.


TASK 51-78-00-615-802

Aircraft Cleaning after a Hydraulic Fluid Leakage



Self explanatory




No specific a vacuum cleaner No specific circuit breaker(s) safety clip(s) No specific hot air dryer No specific lint-free cloth No specific nonmetallic brush No specific nonmetallic scraper No specific access platform 4.60 m (15 ft. 1 in.) No specific access platform 5.20 m (17 ft. 1 in.)




Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 05-038 POWDER (REMOVAL OF HYDRAULIC FLUID SPILLAGE) (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00) Material No. 11-003 USA TT-M-261 METHYL-ETHYL-KETONE (Ref. 20-31-00)



25-51-22-000-801 Removal of the Ball Mats/Ball Strips in the FWD Cargo Compartment 25-51-22-000-802 Removal of the Ball Mats/Ball Strips in the AFT Cargo Compartment 25-51-22-400-801 Installation of the Ball Mats/Ball Strips in the FWD Cargo Compartment 25-51-22-400-802 Installation of the Ball Mats/Ball Strips in the AFT Cargo Compartment 52-30-00-010-801 Opening of the FWD and AFT Cargo-Compartment Doors with the Yellow Electric Pump 53-00-00-000-802 Removal of the Floor Panels in the FWD Cargo-Compartment 53-00-00-000-803 Removal of the Floor Panels in the AFT Cargo-Compartment 53-00-00-400-802 Installation of the Floor Panels in the FWD Cargo-Compartment 53-00-00-400-803 Installation of the Floor Panels in the AFT Cargo-Compartment 51-74-11-300-801 Repair of Corroded Areas (for corrective action) 51-75-12-300-803 Repair of Paint Damage (Topcoat Only) (for corrective action)



51-75-13-916-801 Repair to a layer of Moisture-Removing Oil (for corrective action) 51-75-13-916-802 Repair to a layer of Corrosion Preventive Compound (for corrective action) 51-76-11-300-801 Repair of the Sealant (for corrective action)

3. Job Set-up __________

Subtask 51-78-00-941-051













Subtask 51-78-00-865-052



Subtask 51-78-00-010-051



(2) If the hydraulic leakage is in the cargo compartment: - Clean the contaminated cargo loading system components in the workshop - if necessary, apply lubricants and corrosion preventive materials.


Subtask 51-78-00-160-052

A. Clean the Area


(1) Remove the hydraulic fluid with a lint-free cloth.


(2) Remove loose materials with a nonmetallic scraper, a vacuum cleaner or a nonmetallic brush.



(5) Clean the area with CLEANING AGENTS (Material No. 11-003) and a lint-free cloth.

(6) 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.

(7) If necessary, repeat the procedure until the unwanted hydraulic fluid is removed.

(8) Clean the area with the CLEANING AGENTS (Material No. 11-001) and a lint-free cloth.








(14) If necessary, repair the filler seals (Ref. TASK 51-76-11-300-801).





5. Close-up ________

Subtask 51-78-00-410-051

A. Installation



Subtask 51-78-00-865-053

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 51-78-00-942-051



TASK 51-78-00-615-803

Aircraft Cleaning after a Fish Shipment


Self explanatory




No specific a vacuum cleaner No specific circuit breaker(s) safety clip(s) No specific hot air dryer No specific nonmetallic brush No specific nonmetallic scraper No specific access platform 4.60 m (15 ft. 1 in.) No specific access platform 5.20 m (17 ft. 1 in.)



Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00)





3. Job Set-up __________

Subtask 51-78-00-941-052













Subtask 51-78-00-865-054



Subtask 51-78-00-010-052



(2) Clean the contaminated cargo loading system components in the workshop. If necessary, apply lubricants and corrosion preventive materials.



Subtask 51-78-00-160-053

A. Clean the Area


(1) Remove loose materials with a nonmetallic scraper, a vacuum cleaner, or a nonmetallic brush.




(5) Clean the area with CLEANING AGENTS (Material No. 11-001).


(7) Make a cleaning solution of 0.5 % CLEANING AGENTS (Material No. 11- 001) and water.













5. Close-up ________

Subtask 51-78-00-410-052

A. Installation



Subtask 51-78-00-865-055


Subtask 51-78-00-942-052



TASK 51-78-00-615-804

Aircraft Cleaning after an Acid or Alkali Leakage


Self explanatory




No specific a vacuum cleaner No specific boric acid No specific circuit breaker(s) safety clip(s) No specific hot air dryer No specific lint-free cloth No specific nonmetallic brush No specific nonmetallic scraper No specific plastic container No specific plastic sheets No specific sodium bicarbonate No specific soft brush No specific sponge No specific universal indicator paper No specific access platform 4.60 m (15 ft. 1 in.) No specific access platform 5.20 m (17 ft. 1 in.)



Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 05-038 POWDER (REMOVAL OF HYDRAULIC FLUID SPILLAGE) (Ref. 20-31-00)





3. Job Set-up __________

Subtask 51-78-00-941-053













Subtask 51-78-00-865-056



Subtask 51-78-00-010-053



(2) If the Acid or Alkali Leakage is in the cargo compartment: - clean the contaminated cargo loading system components in the workshop - if necessary, apply lubricants and corrosion preventive materials.




WARNING : ALWAYS PUT ON RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHES TO _______ PREVENT INFECTION WHEN YOU DO THIS WORK.

Subtask 51-78-00-160-054

A. Clean the Area


(1) Put plastic sheets over components and areas adjacent to the leakage.

NOTE : Use a plastic container for used cloths and/or sponges. ____

(2) Soak up the contamination with a lint-free cloth or a sponge.

(3) In areas that you can not dry with a cloth use SPECIAL MATERIALS (Material No. 05-038).

(4) Remove loose materials with a nonmetallic scraper, a vacuum cleaner or a nonmetallic brush.

(5) Prepare the necessary solution.

(a) 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.


(b) 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 a nonmetallic brush and/or lint- free cloth.

(7) Apply the solution until the chemical reaction stops. Leave the solution on the surface for a further 5 minutes.

(8) Remove the neutralized mixture with a cloth and/or a sponge.




(12) Remove the water with a soft brush.

Subtask 51-78-00-280-050

B. Do a test to measure the pH-value of the leakage area.

(1) Use universal indicator paper to do the test.

(2) Make sure that the pH-value is not more than 7 and not less than 5.5.

(3) You must do a test on areas where it is not easy to get access.

(4) If the pH-valve is not correct clean the area again.

Subtask 51-78-00-916-053

C. Apply the Special Materials





(b) Do the steps A.(1) thru C.(1) again.






5. Close-up ________

Subtask 51-78-00-410-053

A. Installation



Subtask 51-78-00-865-057

B. Remove the safety clip(s) and tag(s) and close the circuit breakers of the electrical components and systems in the work area.

Subtask 51-78-00-942-053



TASK 51-78-00-615-805

Aircraft Cleaning after a Fuel Leakage


Self Explanatory




No specific fuel-proof container No specific lint-free cloth



Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00) Material No. 11-003 USA TT-M-261 METHYL-ETHYL-KETONE (Ref. 20-31-00)




28-00-00-610-801 Fuel Safety Procedures 51-74-11-300-801 Repair of Corroded Areas (for corrective action) 51-75-12-300-803 Repair of Paint Damage (Topcoat Only) (for corrective action) 51-75-13-916-801 Repair to a layer of Moisture-Removing Oil (for corrective action) 51-75-13-916-802 Repair to a layer of Corrosion Preventive Compound (for corrective action) 51-76-11-300-801 Repair of the Sealant (for corrective action)

3. Job Set-up __________

Subtask 51-78-00-941-054

A. Get Access

(1) Obey the fuel safety procedures (Ref. TASK 28-00-00-610-801)

(2) Get access to the area of the damage.

Subtask 51-78-00-865-058

B. Open, safety and tag the circuit breakers of all the electrical components and systems in the work area.

Subtask 51-78-00-010-054

C. Remove components from the area you will clean to prevent contamination from cleaning agents.



Subtask 51-78-00-160-055

A. Clean the Area

WARNING : OBEY THE FUEL SAFETY PROCEDURES. THIS CAN PREVENT INJURY AND _______ DAMAGE.

WARNING : DO NOT GET AIRCRAFT FUEL: _______ - IN YOUR MOUTH - IN YOUR EYES - ON YOUR SKIN FOR A LONG TIME.

WARNING : DO NOT GET YOUR CLOTHES SOAKED WITH FUEL. _______ AIRCRAFT FUEL IS POISONOUS AND CAN GO THROUGH YOUR SKIN INTO YOUR BODY. IF YOU ARE CONTAMINATED WASH WITH CLEAN WATER AND IF NECESSARY GET MEDICAL HELP.


(1) Remove the fuel with a lint-free cloth.

NOTE : Big quantities of fuel should be drained into a fuel-proof ____ container

(2) Clean the area with CLEANING AGENTS (Material No. 11-003) and a lint-free cloth.

(3) Clean the area with the CLEANING AGENTS (Material No. 11-001) and a lint-free cloth.



(6) If necessary, repair the filler seals (Ref. TASK 51-76-11-300-801).




5. Close-up ________

Subtask 51-78-00-410-054

A. Install all the components that were removed for the cleaning task.

Subtask 51-78-00-865-059


Subtask 51-78-00-942-054



TASK 51-78-00-615-806

Aircraft Cleaning after a Leakage of Aggressive Media in the Cargo Compartments


Self Explanatory




No specific hot air dryer No specific vacuum cleaner No specific access platform 4.60 m (15 ft. 1 in.) No specific access platform 5.20 m (17 ft. 1 in.) No specific 1 BRUSH - NON METALLIC No specific 1 BRUSH - WASHING No specific 1 CONTAINER 100 L(25 USGAL) No specific 1 SCRAPER - NON METALLIC



Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 USA MIL-L-81309 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 09-018 USA AMS 3267/3 CORROSION INHIBITING LOW ADHESION SEALANT (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I DETERGENT (Ref. 20-31-00)




25-51-22-000-801 Removal of the Ball Mats/Ball Strips in the FWD Cargo Compartment 25-51-22-000-802 Removal of the Ball Mats/Ball Strips in the AFT Cargo Compartment 25-51-22-400-801 Installation of the Ball Mats/Ball Strips in the FWD Cargo Compartment 25-51-22-400-802 Installation of the Ball Mats/Ball Strips in the AFT Cargo Compartment 25-51-26-000-801 Removal of the Power Drive Units 25-51-26-400-801 Installation of the Power Drive Units 25-51-58-000-801 Removal of the Drain System in the FWD Cargo Compartment 25-51-58-000-802 Removal of the Drain System in the AFT Cargo Compartment 52-30-00-010-801 Opening of the FWD and AFT Cargo-Compartment Doors with the Yellow Electric Pump 52-30-00-410-801 Closing of the FWD and AFT Cargo-Compartment Doors with the Yellow Electric Pump 52-30-00-480-801 Installation of the Safety Support Equipment 53-00-00-000-802 Removal of the Floor Panels in the FWD Cargo-Compartment 53-00-00-000-803 Removal of the Floor Panels in the AFT Cargo-Compartment 53-00-00-400-802 Installation of the Floor Panels in the FWD Cargo-Compartment 53-00-00-400-803 Installation of the Floor Panels in the AFT Cargo-Compartment 51-74-11-300-801 Repair of Corroded Areas (for corrective action) 51-75-12-300-803 Repair of Paint Damage (Topcoat Only) (for corrective action) 51-75-13-916-801 Repair to a layer of Moisture-Removing Oil (for corrective action) 51-75-13-916-802 Repair to a layer of Corrosion Preventive Compound (for corrective action)


3. Job Set-up __________

Subtask 51-78-00-941-055


(1) For the FWD Cargo Compartment:

(a) Open the cargo compartment door (Ref. TASK 52-30-00-010-801).

(b) Install the safety lock on the actuator of the FWD cargo-compartment door (Ref. TASK 52-30-00-480-801).

(c) Set the light switch 6LU on the service panel 5022VE to ON.

(d) Put the access platform in position below the circuit breaker panel 5002VE.

(e) Open the access panel 132UC of the circuit breaker panel 5002VE.

(2) For the AFT Cargo Compartment

(a) Open the cargo compartment door (Ref. TASK 52-30-00-010-801).

(b) Install the safety lock on the actuator of the AFT cargo-compartment door (Ref. TASK 52-30-00-480-801).

(c) Set the light switch 30LU on the service panel 5024VE to ON.

(d) Put the access platform in position below the circuit breaker panel 5006VE.

(e) Open the access panel 152UC of the circuit breaker panel 5006VE.


Subtask 51-78-00-865-060

B. Make sure that this(these) circuit breaker(s) is(are) closed:

------------------------------------------------------------------------------- PANEL DESIGNATION FIN LOCATION ------------------------------------------------------------------------------- FOR 5050VE, 5054VE 5002VE FWD CARGO LOADING POWER RH1 5MY A13 5002VE FWD CARGO LOADING 307MY1 A13 5002VE FWD CARGO LOADING POWER LH1 3MY A10 5002VE FWD CARGO LOADING POWER RH2 4MY B13 5002VE FWD CARGO LOADING 306MY1 B13 5002VE FWD CARGO LOADING POWER LH2 2MY B10 5002VE FWD CARGO LOADING 304MY1 B10 5002VE DC POWER CTL 301MY1 C14 5002VE FWD CARGO LOADING CTL 1MY C13 5002VE DC POWER LH1 RH 1 302MY1 C13 5002VE DC POWER LH2 RH 2 303MY1 C12 5006VE AFT CARGO LOADING 305MY2 A10 FOR 5052VE 5006VE AFT CARGO LOADING POWER RH1 105MY A13 5006VE AFT CARGO LOADING 307MY2 A13 5006VE AFT CARGO LOADING POWER LH1 103MY A10 5006VE AFT CARGO LOADING 305MY2 A10 5006VE AFT CARGO LOADING POWER RH2 104MY B13 5006VE AFT CARGO LOADING 306MY2 B13 5006VE AFT CARGO LOADING POWER LH2 102MY B10 5006VE AFT CARGO LOADING 304MY2 B10 5006VE DC POWER CTL 301MY2 C14 5006VE AFT CARGO LOADING CTL 101MY C13 5006VE DC POWER LH1 RH 1 302MY2 C13 5006VE DC POWER LH2 RH 2 303MY2 C12

Subtask 51-78-00-010-055



(2) Clean the contaminated cargo loading system components in the workshop. If necessary, apply lubricants and corrosion preventive materials.



Subtask 51-78-00-160-056

A. Clean the Area


(1) Identify the type of the aggressive media and make it neutral.

(2) Remove loose materials with a SCRAPER - NON METALLIC, a BRUSH - NON METALLIC or a vacuum cleaner.

(3) Do a check of the drain filters in the contaminated area and clean or replace them if necessary.

(4) Remove the power drive units before you start the wet cleaning (Ref. TASK 25-51-26-000-801).


(6) Use SEALANTS (Material No. 09-018) to prevent corrosion at the bonding point fixation holes of the power drive units.

(7) Put a CONTAINER 100 L(25 USGAL) in position below the drain mast outlets.


(9) Make a cleaning solution of 0.5 % of CLEANING AGENTS (Material No. 11-001) and hot water (max. 60 DEG.C (140.00 DEG.F)).

(10) Clean the area with the cleaning solution. Obey the recommendations that follow:

(a) The rate of flow of the cleaning solution must not be more than 5 l.min (1.3208 USgal.mn).


(b) Make sure that you clean these areas: - the floor panel area of the aft end of the FWD cargo compartment - the ballmat area of the AFT cargo compartment - the outboard located rigid corner sheets and sloping side walls.

(c) You can clean the ballmats and roller tracks with the cleaning solution and water.

NOTE : Do not let the cleaning solution or the water flow ____ directly on the other cargo loading system parts.

(d) Use a BRUSH - WASHING to clean the roller track outer flanges.

(e) Make sure that all the dirty solutions flows freely from the fuselage drain masts.

(11) Do a check of the drainage system filters for clogging or contamination and if necessary clean or replace them (Ref. TASK 25- 51-58-000-801) and/or (Ref. TASK 25-51-58-000-802).






(15) If necessary, repair the surface finish (Ref. TASK 51-75-12-300-803).




(19) Remove the sealant from the bonding point fixation holes with a SCRAPER - NON METALLIC.


5. Close-up ________

Subtask 51-78-00-410-055

A. Installation


(a) Install the power drive units (Ref. TASK 25-51-26-400-801).


Subtask 51-78-00-865-061

B. 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.

Subtask 51-78-00-942-055

C. Close Access


(2) For the FWD cargo compartment:

(a) Close the access panel 132UC.

(b) Set the light switch 6LU on the service panel 5022VE to OFF.

(c) Remove the actuator safety lock and close the FWD cargo-compartment door (Ref. TASK 52-30-00-410-801).

(3) For the AFT cargo compartment:

(a) Close the access panel 152UC.

(b) Set the light switch 30LU on the service panel 5024VE to OFF.

(c) Remove the actuator safety lock and close the AFT cargo-compartment door (Ref. TASK 52-30-00-410-801).


fammsi5a_000032

Documents