nammwzza_000031

HIGHLIGHTS __________

REVISION NO. 11 Aug 01/09

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 PAGES

51-HIGHLIGHTS of 1 REVISION NO. 11 Aug 01/09

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CHAPTER 51 __________

STANDARD PRACTICES AND STRUCTURES - GENE

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 51-73-11 806 Nov01/06 51-75-13 804 Feb01/08OF TEMP. 51-73-11 807 Nov01/06 51-75-13 805 Feb01/08REVISION 51-73-11 808 Feb01/08 51-75-13 806 Feb01/08 51-73-11 809 Nov01/06 51-75-13 807 Aug01/08L.E.P. R 1- 2 Aug01/09 51-73-11 810 Nov01/06 51-75-13 808 Feb01/08T. of C. 1 Nov01/08 51-73-11 811 Nov01/06 51-75-13 809 Feb01/08T. of C. 2 Nov01/08 51-73-11 812 Nov01/07T. of C. 3 Nov01/08 51-73-11 813 Nov01/07 51-76-00 1 Nov01/06T. of C. 4 Nov01/08 51-73-11 814 Nov01/07 51-76-00 2 Nov01/06 51-76-00 3 Nov01/0651-00-00 1 Nov01/06 51-74-00 1 Nov01/06 51-76-11 801 Nov01/0851-00-00 2 Nov01/06 51-74-11 801 May01/07 51-76-11 802 Nov01/0651-00-00 3 Nov01/06 51-74-11 802 Feb01/08 51-76-11 803 Feb01/08 51-74-11 803 Feb01/08 51-76-12 801 Nov01/0751-21-00 1 Nov01/06 51-74-11 804 May01/07 51-76-12 802 Nov01/0751-21-00 2 Nov01/06 51-74-11 805 Feb01/08 51-76-12 803 Nov01/0751-21-00 3 Nov01/06 51-74-11 806 Feb01/08 51-76-12 804 Nov01/0751-21-00 4 Nov01/06 51-74-11 807 May01/07 51-76-12 805 Nov01/0751-21-00 701 Nov01/06 51-74-11 808 Feb01/08 51-76-12 806 Nov01/0751-21-00 702 Feb01/08 51-74-11 809 Nov01/06 51-76-12 807 May01/0951-21-00 703 Nov01/06 51-74-11 810 Feb01/08 51-76-12 808 Nov01/08 51-76-12 809 Nov01/0851-22-00 1 Nov01/06 51-75-00 1 Nov01/0651-22-00 2 Nov01/06 51-75-11 701 May01/09 51-77-00 1 Nov01/06 51-75-11 702 May01/09 51-77-11 201 Nov01/0651-23-00 1 Nov01/08 51-75-11 703 Nov01/06 51-77-11 202 Feb01/08 51-75-11 704 May01/09 51-77-11 203 Feb01/0851-24-00 1 Nov01/06 51-75-11 705 May01/09 51-77-11 204 Nov01/0651-24-00 2 Nov01/06 51-75-11 706 May01/09 51-77-11 205 Nov01/0651-24-00 3 Nov01/06 51-75-12 801 Feb01/08 51-77-11 206 Nov01/06 51-75-12 802 May01/07 51-77-11 207 Nov01/0651-70-00 1 Nov01/06 51-75-12 803 Feb01/08 51-77-12 801 Nov01/06 51-75-12 804 Feb01/08 51-77-12 802 Aug01/0851-73-00 1 Nov01/06 51-75-12 805 Aug01/08 51-77-12 803 Nov01/0651-73-00 601 Nov01/06 51-75-12 806 Feb01/08 51-77-12 804 Feb01/0851-73-00 602 Feb01/08 51-75-12 807 Feb01/08 51-77-12 805 Nov01/0651-73-00 603 Feb01/08 51-75-12 808 Feb01/08 51-77-12 806 Nov01/0651-73-11 801 Nov01/06 51-75-12 809 Feb01/08 51-77-12 807 Nov01/0651-73-11 802 Feb01/08 51-75-12 810 Feb01/0851-73-11 803 Nov01/06 51-75-13 801 Nov01/06 51-78-00 1 Nov01/0651-73-11 804 Nov01/06 51-75-13 802 Feb01/08 51-78-00 701 Nov01/0651-73-11 805 Feb01/08 51-75-13 803 Feb01/08 51-78-00 702 May01/07

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

51-78-00 703 Nov01/0651-78-00 704 Nov01/0651-78-00 705 May01/0751-78-00 706 Nov01/0651-78-00 707 Nov01/0651-78-00 708 May01/0751-78-00 709 Nov01/0651-78-00 710 Nov01/0651-78-00 711 Nov01/0651-78-00 712 Nov01/0651-78-00 713 Nov01/0651-78-00 714 Nov01/0651-78-00 715 Nov01/0651-78-00 716 Nov01/0651-78-00 717 Nov01/0651-78-00 718 May01/0951-78-00 719 May01/0951-78-00 720 Nov01/0651-78-00 721 Nov01/0651-78-00 722 Nov01/0651-78-00 723 Nov01/0651-78-00 724 Nov01/0651-78-00 725 Nov01/0651-78-00 726 Nov01/0651-78-00 727 Nov01/0651-78-00 728 Nov01/0651-78-00 729 May01/0951-78-00 730 Nov01/0651-78-00 731 May01/0951-78-00 732 May01/0951-78-00 733 Nov01/06

51-L.E.P. Page 2 Aug 01/09

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CHAPTER 51 __________

STANDARD PRACTICES AND STRUCTURES - GENERAL

TABLE OF CONTENTS _________________

SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ STANDARDS 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 Abbreviations 2 ALL

PROTECTIVE TREATMENT 51-21-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Unpainted Areas 1 ALL Aircraft Internal Areas 4 ALL Types of Protective Treatments 4 ALL Pretreatments 4 ALL Paint Coatings 4 ALL Special Coatings 4 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 Description 1 ALL Corrosion Protection 1 ALL Surface Treatments (Galvanic or 1 ALL Chemical) 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

51-CONTENTS Page 1 Nov 01/08R WZZ

CHAPTER 51 __________



SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________

SEALING - GENERAL 51-24-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Use of Sealants 1 ALL Sealed Areas 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

REPAIRS OF MINOR DAMAGE 51-73-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL

REPAIRS OF MINOR DAMAGE 51-73-00 INSPECTION/CHECK 601 ALL Inspection of Minor Damage to 601 ALL Aluminum Cladding REPAIR 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 805 ALL Components Repair of Minor Damage on 808 ALL Titanium, Forged Aluminum, or Steel Components Repair of Dents in Skin Panels 812 ALL

REPAIRS OF CORRODED AREAS 51-74-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL REPAIR OF CORRODED AREAS 51-74-11 REPAIRS 801 ALL Repair of Corroded Areas 801 ALL Removal of the Corrosion on 804 ALL


CHAPTER 51 __________



SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ Unpainted Light Alloy Removal of the Corrosion on Window 807 ALL Frames

PAINT REPAIRS 51-75-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL STRIPPING/PAINT REMOVAL 51-75-11 CLEANING/PAINTING 701 ALL Removal of Paint by the 701 ALL Application of Chemical Paint Strippers Removal of Paint by Abrasion 704 ALL REPAIR OF PAINT COATINGS 51-75-12 REPAIRS 801 ALL Repair of Major Paint Damage on 801 ALL Light Alloy and Composite Material Repair of Major Paint Damage on 805 ALL Steel Component Repair of Minor Paint Damage 808 ALL (Topcoat 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 804 ALL Preventive Compound Repair to a layer of Cold 807 ALL Phosphate

SEALING REPAIRS 51-76-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Terms and Definitions 1 ALL Sealant Preparation 2 ALL Mixing the Sealant 2 ALL REPAIR OF SEALING EXCLUDING FUEL TANK 51-76-11 REPAIRS 801 ALL Repair of the Sealing 801 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 807 ALL


CHAPTER 51 __________



SUBJECT CH/SE/SU C PAGE EFFECTIVITY _______ ________ _ ____ ___________ Fuel Tank

STANDARD COMPOSITE REPAIRS 51-77-00 DESCRIPTION AND OPERATION 1 ALL General 1 ALL Description 1 ALL Types of Structure 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 Preparation of a 206 ALL Corrosion-Resistant Steel Doubler COMPOSITE REPAIRS - SKIN DAMAGE ALL 51-77-12 STRUCTURES REPAIRS 801 ALL Temporary Skin Repair with 801 ALL High-Speed Tape Permanent Skin Repair - One Ply 804 ALL Depth

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

CLEANING PROCESSES 51-78-00 CLEANING/PAINTING 701 ALL Aircraft Cleaning after a Sewage 701 ALL Leakage Aircraft Cleaning after a 705 ALL Hydraulic Fluid Leakage Aircraft Cleaning after Leakage 708 ALL from a Fish Shipment Aircraft Cleaning after an Acid or 711 ALL Alkali Leakage Inspection after Mercury Spillage 715 ALL Removal of Corrosion Preventive 721 ALL Compound Application of Temporary 725 ALL Protection System (TPS) Cleaning of the Door Entry Drains 731 ALL


STANDARDS PRACTICES AND STRUCTURES - GENERAL - DESCRIPTION AND OPERATION ________________________________________________________________________

1. General _______

This chapter provides the instructions related to the standard practices applicable to the airframe, doors, wings, engine pylons and stabilizers. These practices include: - Protective Treatment (Ref. AMM 51-21-00) - Corrosion Prevention (Ref. AMM 51-22-00) - Coatings Application (Ref. AMM 51-23-00) - Sealing - General (Ref. AMM 51-24-00) - Repairs (Ref. AMM 51-70-00) - Repair of Minor Damage (Ref. AMM 51-73-00) - Repair of Corroded Areas (Ref. AMM 51-74-00) - Paint Repair (Ref. AMM 51-75-00) - Sealing Repairs (Ref. AMM 51-76-00) - Standard Composite Repairs (Ref. AMM 51-77-00) - Cleaning Processes (Ref. AMM 51-78-00)

2. Description ___________

A. Aircraft Zoning and Dimensions (Ref. AMM 06-00-00)

B. Restricted Areas (Ref. AMM 12-11-28) (Ref. AMM 09-20-00)

C. Access - Door and Panel Identification (Ref. AMM 06-40-00)

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


Aircraft Structure 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 metal structure, the protective treatment protects against corrosion and damage by corrosive fluids and prevents erosion. Composite structures have a protective treatment to protect against the effects of lightning, ultra violet rays and erosion.

The material, the function and the location of a component have an effect upon the type of protective treatment applied to a component.

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

2. Description ___________ (Ref. Fig. 001, 002)

A. Unpainted Areas The protective treatment build-up is not the same for all aircraft structures. The areas that are made of corrosion resistant material, or areas where the performance of the component would change, are not painted. These areas include: - the leading edges of the slats and the engine inlet cowl, - the external surfaces of the engine pylon that are made of corrosion resistant materials, - passenger and cargo-compartment door scuff-plates, - APU exhaust, - angle of attack sensors and static ports.


Protective Treatment Zones - Fuselage and Stabilizers Figure 001


Protective Treatment Zones - Wing Figure 002


B. Aircraft Internal Areas The internal areas of the aircraft are divided into four categories. These categories, which have different protection requirements, are as follows:

(1) Category A: - Areas which have contact with air and water.

(2) Category B: - Fuel tanks.

(3) Catagory C1: - Areas where water/condensation is possible.

(4) Catagory C2: - The area below STGR32 and the floor structure around the doors, galleys and toilets. Areas where contact with hydraulic fluid, lubricants and/or waste water is possible and inaccessible areas.

3. Types of Protective Treatments ______________________________

A. Pretreatments The pretreatment of a material increases the corrosion resistant properties of the material and provides a good surface for the adhesion of the paint coatings. The chemical or galvanic applied film passivates the surface and prevents corrosion.

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

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


PROTECTIVE TREATMENT - CLEANING/PAINTING ________________________________________

TASK 51-21-00-916-001

Wax and Polish Protection on Unpainted Light Alloy Areas

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

WARNING : DO NOT GET THE FLUID ON YOUR SKIN OR IN YOUR EYES. IF YOU DO: _______ - FLUSH IT AWAY WITH CLEAN WATER - GET MEDICAL AID.

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

1. Reason for the Job __________________

Self Explanatory

2. Job Set-up Information ______________________

A. Fixtures, Tools, Test and Support Equipment

------------------------------------------------------------------------------- REFERENCE QTY DESIGNATION -------------------------------------------------------------------------------

No specific access platform No specific lint-free cloth


B. Consumable Materials

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

R Material No. 05-025 USA A-A-59318 POLISH METAL ALUMINUM (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I NO LONGER AVAILABLE (Ref. 20-31-00)

3. Job Set-up __________

Subtask 51-21-00-941-050

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

4. Procedure _________

Subtask 51-21-00-110-050

A. Wax and polish.

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

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

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

(2) If necessary, repair the corrosion damage (Ref SRM 51-74-00).

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

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5. Close-up ________

Subtask 51-21-00-942-050

A. Close-up

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

(2) Remove the access platform(s).


CORROSION PREVENTION - DESCRIPTION AND OPERATION ________________________________________________

1. General _______ Corrosion, the removal of corrosion and subsequent maintenance have a direct effect on the operational safety and the in-service capability of the aircraft.

2. Description ___________ Corrosion-resistant materials and protective coatings are applied at the construction stage to obtain the maximum possible resistance to corrosion.

3. Corrosion Protection ____________________

A. Surface Treatments (Galvanic or Chemical)

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

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

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

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

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

B. Protection of Mating Surfaces

(1) In addition to the surface treatments already applied, a sealant or anticorrosion material is applied between components assembled together.

(2) A chemical conversion coating is applied to rivets installed in light alloy, anodized titanium and cadmium-plated steel components.

(3) Shafts are assembled installed and coated with grease or anticorrosion materials.


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

(5) Sealant is applied to protect bonded edges, in areas exposed to corrosion attack.

(6) Soft varnish is applied to protect fillet seals, in areas exposed to chemical attack.

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


COATINGS APPLICATION - GENERAL - DESCRIPTION AND OPERATION __________________________________________________________

R 1. General _______R This topic gives data about the paint and protective coatings on theR aircraft.R For more information about the coatings Ref. ASRM 51-23-00.

R 2. Description ___________

R A. Aluminum Alloy Structure

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

R Aluminum alloy structure is CAA prepared and then painted. ExternalR surfaces and some internal surfaces have a primer coating and a coat ofR paint.

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

R C. Composite ComponentsR Composite components have a pore filler applied, to make the surfaceR smooth, and a coat of paint.R Some external composite components have an antistatic paint coating.

R D. Corrosion-Resistant Steel ComponentsR Corrosion-resistant steel components and components where the applicationR 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 reasons for the use of sealants on the aircraft and the primary sealing areas. For sealing repairs (Ref. AMM 51-76-00).

2. Description ___________ (Ref. Fig. 001)

A. Use of Sealants

(1) The primary uses for sealants on the aircraft are: - sealing the fuselage structure to make sure that the necessary internal pressure is kept during the flight, - sealing the fuel tanks (Ref. AMM 51-76-12 for the repair of fuel tank sealing), - sealing the external joints of the aircraft structure to make sure that water does not go into the structure and to make the structure smoother, - sealing riveted and bolted joints to make sure that liquids do not get into the joints, - sealing sandwich structures to make sure that moisture does not go into the structure, - to prevent corrosion (galvanic action) between different metals, - to prevent corrosion between different materials, especially between CFRP and aluminum alloys, - to prevent fretting corrosion (fatigue stress or vibration between parts of the structure can cause this), - to fill cavities, - to protect the surface on housings, channels, tubes, electrical cables and electrical components, - where it is necessary to make sure that any leakage of the aircraft fluids is kept in the areas from which you can drain them, for example, under the galleys and lavatories. (Ref. Fig. 001)

B. Sealed Areas

(1) The aircraft is divided into three primary areas for sealing:

(a) The pressurized area of the fuselage which is from STA350(FR1) to STA3365(FR70). It includes the cockpit, the cabin and the cargo compartments.


Areas of Sealing Figure 001


(b) The nonpressurized areas of the aircraft which include: - the MLG and NLG bay, - the wing center box, - the airconditioning and hydraulic compartments, - the tail section of the rear fuselage aft of FR70, - the vertical and horizontal stabilizers, - the wings.

(c) The fuel system


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).


REPAIRS OF MINOR DAMAGE - DESCRIPTION AND OPERATION ___________________________________________________

1. General _______

Minor damage such as scratches, dents and marks can cause cracks and corrosion. Minor damage must be repaired.

Refer to AMM 51-73-11 08 for the repair of: - minor damage on aluminum clad components - minor damage on unclad components - minor damage on titanium, aluminum forged or steel components - dents in skin panels

Refer to the ASRM 51-73-00 for further data.


REPAIRS OF MINOR DAMAGE - INSPECTION/CHECK __________________________________________

TASK 51-73-00-200-001

Inspection of Minor Damage to Aluminum Cladding



To find out if the minor damage has gone through the aluminum cladding.




No specific hot air dryer No specific lint-free cloth No specific masking paper No specific masking tape No specific pipette



No specific chromic oxide No specific distilled water No specific potassium nitrate No specific sodium hydroxide Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)


3. Job Set-up __________

Subtask 51-73-00-941-050

A. Get access to the area of the damage.


Subtask 51-73-00-230-050

A. Inspection Procedure of Minor Damage

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


R WARNING : DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS _______R (STATIC, PITOT, TAT, AOA). USE ONLY THE SPECIFIED TOOLS FORR THE PROTECTION OF THE AIRCRAFT. THE SPECIFIED TOOLS:R - GIVE THE CORRECT PROTECTION TO THE AIRCRAFT EQUIPMENT,R - ARE EASY TO SEE FROM THE GROUND,R - ARE EASY TO REMOVE.R IF YOU USE TAPE, THERE IS A RISK THAT SOME TAPE, ORR ADHESIVE FROM THE TAPE, WILL STAY ON THE PROBES, DUCTS ORR SENSORS. THIS CAN CAUSE INCORRECT INDICATIONS ON THER RELATED COCKPIT INSTRUMENTS.

(2) Cover the area adjacent to the minor damage with masking tape and masking paper.

CAUTION : DO NOT LET THE TEST SOLUTION ENTER JOINTS OR GO BELOW RIVET _______ HEADS. THE TEST SOLUTION CAN CAUSE CORROSION.

(3) Make a test solution with 20 g (0.70 oz), potassium nitrate, 10 g (0.35 oz) sodium hydroxide 0.01 l (0.0026 USgal) distilled water.

(4) With a pipette, apply 3 or 4 drops of the test solution to the minor damage.

(5) Let the solution take effect for 1 to 3 minutes. If the minor damage has gone through the aluminum cladding, the exposed alloy will go black/ brown, the cladding will not change color.

(6) Flush the test area with clean water before the solution dries.


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

(8) Flush the test area with clean water.

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

5. Close-up ________

Subtask 51-73-00-942-050

R A. Removal of Equipment

R (1) Make sure that the work area is clean and clear of tool(s) and otherR items.R

R (2) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

R (3) Make an entry in the aircraft logbook and attach a tag on the captainR side stick to tell the crew that:R - Protection covers/devices have been installed.


REPAIR OF MINOR DAMAGE - REPAIRS ________________________________

TASK 51-73-11-300-001

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 No specific steel roller




Material No. 04-012 USA VV-P-236 PURE MINERALVASELINE OR PETRO- LATUM (Ref. 20-31-00)R Material No. 05-025 USA A-A-59318 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)

C. Referenced Information


51-73-00-200-001 Inspection of Minor Damage to Aluminum Cladding 51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite Material

3. Job Set-up __________

Subtask 51-73-11-941-051



Subtask 51-73-11-320-050

A. Repair of Minor Damage

(1) Do an inspection of the depth of the minor damage (Ref. TASK 51-73- 00-200-001).

(2) Refer to the ASRM 51-73-00 and the applicable ASRM-chapter 52 thru 57 for the permitted depth limits.


(3) Repair the minor damage that has not gone through the aluminum cladding as follows:

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

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

(5) Apply COMMON GREASE (Material No. 04-012) to the scratch.

(6) Force the aluminum cladding into the scratch with a steel roller.

NOTE : Use the roller along the length of the scratch until the ____ aluminum cladding has sealed the surface.

(7) Repair the minor damage that has gone through the aluminum cladding as follows:

(8) Measure the depth of the scratch.


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

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

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



(14) Polish the bare metal with SPECIAL MATERIALS (Material No. 05-025) and a lint-free cloth:

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


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

(16) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) to the metal surface.

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

5. Close-up ________

Subtask 51-73-11-942-051

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


TASK 51-73-11-300-004

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 lint-free cloth No specific rounded scotch stone



R Material No. 05-025 USA A-A-59318 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)




51-74-11-300-001 Repair of Corroded Areas 51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite Material

3. Job Set-up __________

Subtask 51-73-11-941-052



Subtask 51-73-11-320-054


(1) If necessary, remove any corrosion (Ref. TASK 51-74-11-300-001).



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

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

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

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




(9) Polish the bare metal with SPECIAL MATERIALS (Material No. 05-025) and a lint-free cloth:

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

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

(11) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) to the metal surface.


5. Close-up ________

Subtask 51-73-11-942-052



TASK 51-73-11-300-002

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



Self Explanatory




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



R Material No. 05-025 USA A-A-59318 POLISH METAL ALUMINUM (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)



51-74-11-300-001 Repair of Corroded Areas 51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite Material

3. Job Set-up __________

Subtask 51-73-11-941-053



Subtask 51-73-11-320-055


(1) If necessary, remove any corrosion (Ref. TASK 51-74-11-300-001).



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

(5) For damage to titanium:

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

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


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

(c) Rub the roughened area with abrasive cloth grade 400 and CLEANING AGENTS (Material No. 11-002). Rub along the length of the scratch until the surface is smooth.


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

(e) Polish the bare metal with SPECIAL MATERIALS (Material No. 05- 025) and a lint-free cloth.

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

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

(6) For damage to forged aluminum:


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


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

(d) Polish the bare metal with SPECIAL MATERIALS (Material No. 05- 025) and a lint-free cloth.

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


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

(f) Apply PRETREATMENT FOR PAINTING (Material No. 13-002) to the metal surface.

(7) For damage to steel components:


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

(e) 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 ____ in a circular motion. Make sure you remove all the rough surface.

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


5. Close-up ________

Subtask 51-73-11-942-053



TASK 51-73-11-300-003

Repair of Dents in Skin Panels



Self Explanatory




R No specific 1 CLOTH-EMERY (GRADE 400)R No specific 1 CLOTH-EMERY (GRADE 240)R No specific 1 SPATULA - NON METALLIC



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




51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite MaterialR ASRM 517300

3. Job Set-up __________

Subtask 51-73-11-941-054



Subtask 51-73-11-320-053

A. Repair of Dents

R (1) Measure the depth of the dent.

R (2) Refer to the ASRM (Ref. ASRM 517300) and the applicable ASRM-chapterR 52 thru 57 for the permitted limits of the dent.

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

R (a) Remove all of the paint from the area of the dent and 10 mmR (0.3937 in.) around the dent with CLOTH-EMERY (GRADE 240).

R (b) Clean the repair area with the CLEANING AGENTS (Material No. 11-R 026) and a clean lint-free cloth MISCELLANEOUS (Material No. 19- 003)R

R (4) Apply masking paper and masking tape to the area around the dent.

R (5) Fill the dent:

R (a) Mix the necessary quantity of the BONDING AND ADHESIVE COMPOUNDSR (Material No. 08-078).


R (b) Apply the BONDING AND ADHESIVE COMPOUNDS (Material No. 08-078) toR the repair area with a SPATULA - NON METALLIC.R

R (6) Make sure that the area is dry before you continue with the stepsR that follow.R

R (7) Smooth the BONDING AND ADHESIVE COMPOUNDS (Material No. 08-078) toR the contours of the component with CLOTH-EMERY (GRADE 240).R

R (8) Smooth the BONDING AND ADHESIVE COMPOUNDS (Material No. 08-078) toR the contours of the component with CLOTH-EMERY (GRADE 400).R

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

5. Close-up ________

Subtask 51-73-11-942-054



REPAIRS OF CORRODED AREAS - DESCRIPTION AND OPERATION _____________________________________________________

1. General _______ Corrosion can seriously effect the safe operation of the aircraft, its components and structure. When corrosion is found it must be removed as soon as possible. The area of the corrosion damage must be inspected before the repair can be started. It is very important that all corrosion deposits are removed. Any corrosion remaining can become a starting point for more corrosion. Refer to ASRM 51-74-00 for more data.

2. Description ___________ Corrosion usually starts on the material surface. It then goes towards the material center destroying its solid substance. Refer to AMM 51-74-11 08 for the removal of: - corrosion, general, - corrosion on unpainted alloy, - corrosion on window frames.


REPAIR OF CORRODED AREAS - REPAIRS __________________________________

TASK 51-74-11-300-001

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

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51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite Material 51-76-11-300-001 Repair of the Sealing

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. Repair of Corrosion




(2) Cover the area adjacent to the damage with masking paper and masking tape.

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

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



(5) Make a visual inspection with a magnifying glass to make sure that all the corrosion is removed.

(6) If necessary, repair the damaged sealant (Ref. TASK 51-76-11-300- 001).

(7) Repair the damaged paint (Ref. TASK 51-75-12-300-001).

5. Close-up ________

Subtask 51-74-11-942-050

R A. Removal of EquipmentR

R (1) Make sure that the work area is clean and clear of tool(s) and otherR items.


R (3) Make an entry in the aircraft log book and attach a tag on theR captain side stick to tell the crew that:R - Protection covers/devices have been installed.


TASK 51-74-11-300-002

Removal of the Corrosion on Unpainted Light Alloy



Self Explanatory




No specific abrasive cloth (grade 400) No specific lint-free cloth No specific magnifying glass







51-21-00-916-001 Wax and Polish Protection on Unpainted Light Alloy Areas

3. Job Set-up __________

Subtask 51-74-11-941-051

A. Get access to the area of the corrosion.


Subtask 51-74-11-140-051

A. Remove the Corrosion





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



(5) Make a visual inspection with a magnifying glass to make sure that all the corrosion is removed.

(6) Wax and polish the repair area (Ref. TASK 51-21-00-916-001).

5. Close-up ________

Subtask 51-74-11-942-051




R (3) Make an entry in the aircraft log book and attach a tag to theR captain side stick to tell the crew that:R - Protection covers/devices have been installed.


TASK 51-74-11-300-003

Removal of the Corrosion on Window Frames



Self Explanatory




No specific access platform No specific aluminum oxide (80-120 microns) No specific light grit blasting equipment No specific lint-free cloth No specific magnifying glass No specific PE-Foil







51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite Material 51-76-11-300-001 Repair of the Sealing 51-74-11-991-001 Fig. 801

3. Job Set-up __________

Subtask 51-74-11-941-052

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


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

Subtask 51-74-11-140-052

A. Removal of the Corrosion




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


Masking of the Windows Figure 801/TASK 51-74-11-991-001



(4) Remove the corrosion with light grit blasting equipment and aluminum oxide (80-120 microns) at a pressure of 4 bar (58.0150 psi).

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


(6) Make a visual inspection of the repair area with a magnifying glass to make sure all the corrosion is removed.

(7) If necessary, repair the damaged sealant (Ref. TASK 51-76-11-300- 001).

(8) Repair the damaged paint (Ref. TASK 51-75-12-300-001).

5. Close-up ________

Subtask 51-74-11-942-052

R A. Removal of EquipmentR

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


R (3) Make an entry in the aircraft log book and attach a tag on theR captain side stick to tell the crew that:R - Protection covers/devices have been installed.


PAINT REPAIRS - DESCRIPTION AND OPERATION _________________________________________

1. General _______

Paint and/or special coatings seal the aircraft structures against corrosion. The type of protective coating used depends on the location, function and corrosion resistance of the component.

You must repair any damage to the original protective treatment. Refer to AMM 51-23-00 and SRM 51-75-00 for the original build up.


STRIPPING/PAINT REMOVAL - CLEANING/PAINTING ___________________________________________

TASK 51-75-11-100-001

Removal of Paint by the Application of Chemical Paint Strippers


Self Explanatory




No specific polyethylene film



Material No. 08-019 FOIL, PRESSURE SENSITIVE (USE 08-108) (Ref. 20-31-00)



R 12-21-11-615-002 External Cleaning ASRM 51-75-11


3. Job Set-up __________

Subtask 51-75-11-950-052

A. Protection of the Aircraft

CAUTION : MAKE SURE THAT THE MATERIALS, AREAS AND PARTS WHICH FOLLOW HAVE _______ THE CORRECT PROTECTION FROM CHEMICAL PAINT STRIPPERS: - RUBBER, ALL COMPOSITE PARTS, ACRYLIC MATERIALS, AERODYNAMIC SMOOTHER, METAL BONDED EDGES, PITOT PROBES, SENSORS, STATIC PORTS, ENGINE AIR INTAKE, PRECOOLER AIR OUTLET SCREEN, ENGINE EXHAUST DUCT, APU EXHAUST, APU INTAKES AND OUTLETS, AIR-CONDITIONING RAM AIR INLETS, LANDING GEARS, DOOR SEALS, ACCESS DOORS, CABIN WINDOW AND WINDSHIELD PANELS AND SEALS, ELECTRICAL EQUIPMENT AND CABLES, PLASTIC MATERIALS, EXTERNAL SKIN PANEL JOINTS, HIGH STRENGTH STEEL PARTS, DRAIN HOLES, VENTS AND ALL ANTENNAS.

(1) Use the polyethylene film and the BONDING AND ADHESIVE COMPOUNDS (Material No. 08-019) to mask the areas adjacent to the work area.

NOTE : Do not mask 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 andR contamination (Ref. TASK 12-21-11-615-002).


Subtask 51-75-11-150-050

A. Removal of Paint by the Application of Chemical Paint Strippers - Metallic Materials Only (Ref. ASRM 51-75-11).

5. Close-up ________

Subtask 51-75-11-942-051

A. Put the aircraft back to the serviceable condition.

(1) If necessary, remove the protection covers/devices you installed onR the aircraft components adjacent to the work area (Ref. TASK 12-21-R 11-615-002).


TASK 51-75-11-100-002

Removal of Paint by Abrasion


Self Explanatory




No specific abrasive paper, grade 220 or 320 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. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00) Material No. 19-011 SCOTCH BRITE PADS (Ref. 20-31-00)



R 12-21-11-615-002 External Cleaning 51-76-11-300-001 Repair of the Sealing


3. Job Set-up __________

Subtask 51-75-11-950-053

A. Protection of the Aircraft

(1) Use the masking paper and the masking tape to mask the areas adjacent to the work area.

(2) If necessary, install the correct protection covers/devices to protect the adjacent aircraft components from damage andR contamination (Ref. TASK 12-21-11-615-002).


Subtask 51-75-11-150-052

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.

CAUTION : DO NOT USE A METAL SCRAPER TO REMOVE THE UNWANTED MATERIAL. A _______ METAL SCRAPER CAN CAUSE DAMAGE TO THE SURFACE OF THE COMPONENT.

NOTE : This procedure gives the data necessary to remove the paint ____ coatings from composite materials. The procedure can also be used to remove paint coatings from metallic materials, as an alternative procedure to chemical paint stripping.

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

(1) Lightly abrade the surface of the work area with the abrasive paper, grade 220 or 320, until the layer of basic primer comes fully into view.


(2) Polish the abraded areas with the scotch-brite pad, MISCELLANEOUS (Material No. 19-011).

(3) Remove and discard the masking materials.

(4) Clean the work area with a lint-free cloth MISCELLANEOUS (Material No. 19-003) and the CLEANING AGENTS (Material No. 11-004), and let the surface dry.

(5) Inspect the areas that were masked for damaged paint.

(6) If necessary, do the steps (1), (2) and (4) again, to remove the damaged paint.

(7) If applicable, inspect the work area for damage to the sealing beads of the skin joints.

(8) If necessary, repair the damaged sealing beads at the skin joints (Ref. TASK 51-76-11-300-001).

5. Close-up ________

Subtask 51-75-11-942-052

A. Put the aircraft back to the serviceable condition.

(1) If necessary, remove the protection covers/devices you installed onR the aircraft components adjacent to the work area (Ref. TASK 12-21-R 11-615-002).



REPAIR OF PAINT COATINGS - REPAIRS __________________________________

TASK 51-75-12-300-001

Repair of Major Paint Damage on Light Alloy and Composite Material


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


Self Explanatory




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




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



51-74-11-300-001 Repair of Corroded Areas

3. Job Set-up __________

Subtask 51-75-12-941-050

A. Get access to the area to be repaired.


Subtask 51-75-12-350-052

A. Repair the Paint Damage





(2) If necessary, repair the corrosion damage (Ref. TASK 51-74-11-300- 001).

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

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

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

(5) Feather the edges of the undamaged paint to give a smooth surface to the repair area.


(7) Apply the primer coatings and paint coatings to the repair area.

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

5. Close-up ________

Subtask 51-75-12-942-050




TASK 51-75-12-300-002

Repair of Major Paint Damage on Steel Component


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 IIR PHOSPHATIC LIQUID NO LONGER AVAILABLE (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE I NO LONGER AVAILABLE (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00)



51-75-13-916-003 Repair to a layer of Cold Phosphate ASRM 512311000

�� EFF : ALL � Page 805�� 51-75-12 � � Aug 01/08 � � � � WZZ

3. Job Set-up __________

Subtask 51-75-12-941-051



Subtask 51-75-12-350-053






(3) If necessary, repair the corrosion damage (Ref. SRM 51-74-00).

(4) If necessary repair the minor damage (Ref. SRM 51-73-00).

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

(6) Feather the edges of the undamaged paint to give a smooth surface to the repair area.

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


(8) Apply a protective treatment of SPECIAL MATERIALS (Material No. 05- 042) to the repair area. (Ref. TASK 51-75-13-916-003)

(9) Apply the paint coating to the repair area (Ref. ASRM 512311000).

(10) Remove the masking paper/masking tape.

5. Close-up ________

Subtask 51-75-12-942-051






TASK 51-75-12-300-003

Repair of Minor 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 the repainting of the upper surfaces of the horizontal tail plane, elevator, ailerons, spoilers or the flaps, please contact Airbus Industrie for approval of the non-standard paint color.


Self Explanatory




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




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



ASRM 512311000

3. Job Set-up __________

Subtask 51-75-12-941-052



Subtask 51-75-12-350-054






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

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

(4) Feather the edges of the undamaged topcoat to give a smooth surface to the repair area.


(6) Apply the paint coatings to the repair area (Ref. ASRM 512311000).

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

5. Close-up ________

Subtask 51-75-12-942-052






REPAIR OF SPECIAL COATINGS - REPAIRS ____________________________________

TASK 51-75-13-916-001

Repair to a layer of Moisture-Removing Oil



Self Explanatory




No specific lintfree cloth No specific masking paper No specific masking tape



Material No. 05-027 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)


3. Job Set-up __________

Subtask 51-75-13-941-050



Subtask 51-75-13-110-050

A. Repair a layer of Moisture-Removing Oil

R WARNING : DO NOT APPLY ADHESIVE TAPE ON THE PROBES, DUCTS, SENSORS _______R (STATIC, PITOT, TAT, AOA). USE ONLY THE SPECIFIED TOOLS FOR THER PROTECTION OF THE AIRCRAFT. THE SPECIFIED TOOLS:R - GIVE THE CORRECT PROTECTION TO THE AIRCRAFT EQUIPMENT,R - ARE EASY TO SEE FROM THE GROUND,R - ARE EASY TO REMOVE.R IF YOU USE TAPE, THERE IS A RISK THAT SOME TAPE, OR ADHESIVER FROM THE TAPE, WILL STAY ON THE PROBES, DUCTS OR SENSORS. THISR CAN CAUSE INCORRECT INDICATIONS ON THE RELATED COCKPITR INSTRUMENTS.

(1) Cover the equipment and fittings adjacent to the area with masking paper and masking tape.


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

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

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

(5) Remove the masking paper or the masking tape.


5. Close-up ________

Subtask 51-75-13-942-050






TASK 51-75-13-916-002

Repair to a layer of Corrosion Preventive Compound



Self Explanatory




No specific masking paper No specific masking tape No specific 1 SCRAPER - NON METALLIC



Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 15-010 USA MIL-C-11796-C CLASS 1A CORROSION PREVENTIVE FILLER COMPOUND (Ref. 20-31-00)

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51-75-13-916-001 Repair to a layer of Moisture-Removing Oil

3. Job Set-up __________

Subtask 51-75-13-941-051



Subtask 51-75-13-140-050

A. Repair of a layer of Corrosion Preventive Compound



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

(2) Remove the damaged layer of corrosion-preventive compound with the SCRAPER - NON METALLIC.

(3) Repair the layer of the moisture-removing oil (Ref. TASK 51-75-13- 916-001).


(4) Apply the special materials

(a) Apply the corrosion-preventive compound STORAGE PRESERVATION (Material No. 15-010) to the area.


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

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

5. Close-up ________

Subtask 51-75-13-942-051






TASK 51-75-13-916-003

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 lintfree cloth No specific masking paper No specific masking tape



Material No. 05-042 USA MIL-C-10578 TYPE IIR PHOSPHATIC LIQUID NO LONGER AVAILABLE (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 applicable area.


Subtask 51-75-13-120-050

A. Repair a layer of Cold Phosphate


(1) Cover the equipment and fittings adjacent to the area with the masking paper or masking tape.

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


(3) Clean the area with CLEANING AGENTS (Material No. 11-004) and the lintfree cloth.

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

(5) Let the phosphatic liquid soak into the metal surface for 5 to 15 minutes.

(6) When the surface of the metal has changed to a grey-white color, rinse the area with clean water.

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


(8) Remove the masking paper or the masking tape.

5. Close-up ________

Subtask 51-75-13-942-052






SEALING REPAIRS - DESCRIPTION AND OPERATION ___________________________________________

1. General _______ Sealants are used on the aircraft structure to stop pressurization and fuel leaks. You must repair the sealant when it has been damaged during maintenance or found damaged on an inspection/check. For the repair of general sealants Ref. AMM 51-76-11 08. For the repair of fuel tank sealing Ref. AMM 51-76-12 08. For more data Ref. ASRM 51-24-00 and ASRM 51-76-00.


A. Terms and Definitions The table below shows some of the terms used in sealant procedures and their definitions.

----------------------------------------------------------------------------- | TERM | DEFINITION | |------------------------|----------------------------------------------------| | Application Life or | This is the period of time that a sealant remains | | Pot Life | suitable for application after it has been mixed. | |------------------------|----------------------------------------------------| | Barrier Coating | A layer of quick-drying sealant that is applied | | | over a layer of slow-drying sealant before it has | | | fully cured. This term also applies when a layer | | | of special material is put over the original | | | sealant to protect it. | |------------------------|----------------------------------------------------| | Breakable Joint | A joint that can be easily disassembled. | |------------------------|----------------------------------------------------| | Cure | This refers to the change of a sealant from its | | | original mixed condition to its final condition. | -----------------------------------------------------------------------------


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

3. Sealant Preparation ___________________

A. Mixing the Sealant

(1) Refer to the manufacturers instructions for : - mixing ratios, - application life, - tack free time, - cure time, - work life.


(2) Mix the base compound and sealant accelerator slowly until you get an even consistency and color. If you mix quickly you will cause heat and air bubbles and shorten the application life of the sealant.

(3) You must mix the sealant as close to the time of application as possible.


REPAIR OF SEALING EXCLUDING FUEL TANK - REPAIRS _______________________________________________

TASK 51-76-11-300-001

Repair of the Sealing



Self Explanatory




No specific 1 BRUSH - NON METALLIC No specific 1 SCRAPER - NON METALLIC



No specific masking paper No specific masking tapeR Material No. 09-013 USA MIL-PRF-81733R SEALANT-BRUSH CONSIS TENCY (OBSOLETE) (Ref. 20-31-00) Material No. 11-004 USA MIL-T-81533 1.1.1TRICHLOROETHANE (METHYL CHLOROFORM) (Ref. 20-31-00) Material No. 16-021 F ASNB70720 FLEXIBLE POLYURETHANE (Ref. 20-31-00)



Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)



51-75-13-916-002 Repair to a layer of Corrosion Preventive Compound

3. Job Set-up __________

Subtask 51-76-11-941-050

A. Get access to the damaged sealant.


Subtask 51-76-11-110-050

A. Repair the Sealing


(1) Remove the damaged sealant with a SCRAPER - NON METALLIC.

(2) Make a chamfer on the undamaged sealant to give a repair overlap to a minimum width of 12.7 mm (0.5000 in.).

(3) Make the surface of the chamfer rough.


(4) Clean the repair area.

(a) Clean the repair area with CLEANING AGENTS (Material No. 11-004) and a lint free-cloth, MISCELLANEOUS (Material No. 19-003) and let it dry.


(5) Use a BRUSH - NON METALLIC apply the SEALANTS (Material No. 09-013) to the repair area with an overlap of the undamaged sealant.

(6) Let the sealant cure for a minimum of 1 hour.


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

(8) Apply the STRUCTURE PAINTS (Material No. 16-021) to the repair area to a width of 25.0 mm (0.9842 in.) around the repair area.

(9) Let the nylon coating cure for a minimum of 1 hour.

(10) If necessary, apply the surface protection (Ref. TASK 51-75-13-916- 002).

5. Close-up ________

Subtask 51-76-11-942-050

R A. Removal or Equipment





REPAIR OF FUEL TANK SEALING - REPAIRS _____________________________________

TASK 51-76-12-300-001

Local Repair of the Fuel Tank Sealant


General repair of fuel leaks.




R No specific 1 SCRAPER - NON METALLIC



R Material No. 11-026 GB DEF-STAN 68-148/1R SOLVENT GENERAL PURPOSE (Ref. 20-31-00) Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)



12-11-28-650-001 General Refuel/Defuel Safety Procedures 28-00-00-910-001 Fuel Safety Procedures 28-10-00-910-001 Safety Procedures When You Do Work in a Fuel Tank 28-10-00-910-002 Access to the Fuel Tanks and the Work AreasR SRM 517612 P. Block 1


3. Job Set-up __________

Subtask 51-76-12-941-050

A. Obey the fuel safety procedures (Ref. TASK 28-00-00-910-001), (Ref. TASK 28-10-00-910-001) and (Ref. TASK 28-10-00-910-002).

Subtask 51-76-12-650-050

B. Defuel the aircraft. (Ref. TASK 12-11-28-650-001)

Subtask 51-76-12-010-050

C. Get access to the fuel leak area.


Subtask 51-76-12-160-050

R A. Preparation for the Repair


R (1) Remove the sealant from around the leak point area for a minimumR distance of 75 mm (2.9527 in.) with a SCRAPER - NON METALLIC.

(2) Chamfer the edges of the sealant that is not damaged.R

R (3) Clean the repair area with the CLEANING AGENTS (Material No. 11-026)R and a clean lint free-cloth MISCELLANEOUS (Material No. 19-003).

Subtask 51-76-12-914-050

R B. Repair

R (1) Do the local repair of the fuel tank sealant (Ref. SRM 517612 P.R Block 1).R

Subtask 51-76-12-650-051

C. Refuel the aircraft (Ref. TASK 12-11-28-650-001).


Subtask 51-76-12-790-050

D. Examine the repair area for leaks.

NOTE : Leaks are not permitted. ____

(1) If there are leaks, refer to SRM 51-76-12, P. Block 1, for corrective action.

5. Close-up ________

Subtask 51-76-12-942-050


�� EFF : ALL � Page 803�� 51-76-12 � � Nov 01/07 � �R � � WZZ

TASK 51-76-12-300-002

Repair of the Fuel Tank Fillet


Self Explanatory




R No specific 1 SCRAPER - NON METALLIC



R Material No. 11-026 GB DEF-STAN 68-148/1R SOLVENT GENERAL PURPOSE (Ref. 20-31-00) Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)



12-11-28-650-001 General Refuel/Defuel Safety Procedures 28-00-00-910-001 Fuel Safety Procedures 28-10-00-910-002 Access to the Fuel Tanks and the Work AreasR SRM 517612 P. Block 1

3. Job Set-up __________

Subtask 51-76-12-941-051

A. Obey the fuel safety procedures (Ref. TASK 28-00-00-910-001) and (Ref. TASK 28-10-00-910-002).


Subtask 51-76-12-650-052

B. Defuel the aircraft (Ref. TASK 12-11-28-650-001).

Subtask 51-76-12-010-051

C. Get access to the fuel leak area.


Subtask 51-76-12-160-051

R A. Preparation for the Repair


(1) Remove the sealant from the leak point and up to a distance of 75 mmR (2.9527 in.) from the leak point area with a SCRAPER - NON METALLIC.R

R (2) Chamfer the edges of the sealant that is not damaged. Clean theR repair area.R

R (3) Clean the repair area with the CLEANING AGENTS (Material No. 11-026)R and a clean lint-free cloth MISCELLANEOUS (Material No. 19-003).

Subtask 51-76-12-914-051

R B. Repair

R (1) Do the repair of the fuel tank fillet (Ref. SRM 517612 P. Block 1).R

Subtask 51-76-12-650-053

C. Refuel the aircraft. (Ref. TASK 12-11-28-650-001)

Subtask 51-76-12-790-051

D. Examine the repair for leaks.


(1) If there are leaks, refer to SRM 51-76-12, P. Block 1, for corrective action.


5. Close-up ________

Subtask 51-76-12-942-051



TASK 51-76-12-300-003

Temporary External Repair of the Fuel Tank


Self Explanatory




No specific 1 SCRAPER - NON METALLIC



Material No. 09-008CR EARLY QUICK REPAIR F UEL TANK SEALANT (Ref. 20-31-00) Material No. 11-026 GB DEF-STAN 68-148/1 SOLVENT GENERAL PURPOSE (Ref. 20-31-00) Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)



12-11-28-650-004 Pressure Refuel with Manual Control 28-00-00-910-001 Fuel Safety Procedures 28-10-00-910-002 Access to the Fuel Tanks and the Work Areas 28-11-00-280-002 Structural Fuel Tank Leaks - General Information 28-25-00-650-001 Pressure Defuel


3. Job Set-up __________

Subtask 51-76-12-941-052

A. Obey the fuel safety procedures (Ref. TASK 28-00-00-910-001) and (Ref. TASK 28-10-00-910-002).

Subtask 51-76-12-010-052

B. Get access to the fuel leak area.

Subtask 51-76-12-280-050

C. Calculate the leak rate (Ref. TASK 28-11-00-280-002) and make sure that a temporary repair is permitted.


Subtask 51-76-12-110-052

A. Prepare the Repair Area

(1) Clean the repair area with the CLEANING AGENTS (Material No. 11-026) and a clean lint-free cloth MISCELLANEOUS (Material No. 19-003).

Subtask 51-76-12-914-052

B. Repair


(1) Apply the SEALANTS (Material No. 09-008C) to the leak area. Push the sealant into the leak source with a SCRAPER - NON METALLIC until the leak stops.

(2) If you cannot get a good seal, defuel the aircraft to below the leak level (Ref. TASK 28-25-00-650-001).

��R �EFF : ALL � Page 808�� 51-76-12 � � Nov 01/08 � � � � WZZ

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

(4) Let the repair cure.

(5) Refuel the aircraft above the level of the repair (Ref. TASK 12-11- 28-650-004) and examine the fuel tank for leaks.


5. Close-up ________

Subtask 51-76-12-942-052



STANDARD COMPOSITE REPAIRS - DESCRIPTION AND OPERATION ______________________________________________________

1. General _______

This topic gives information on minor and temporary repairs to composite material components. The information is of a general type only. You must refer to specific repair data, material specifications and manufacturer�s instructions. Failure to do so could result in an unauthorised repair.

The composite materials used are Glassfiber Reinforced Plastic (GFRP), Carbonfiber Reinforced Plastic (CFRP) and Aramidfiber Reinforced Plastic (AFRP). These materials are used in the construction of composite structures.

When you do a repair to composite structures, the repair materials are: - carbonfiber materials to repair carbonfiber structure. - glassfiber materials to repair glassfiber and aromidfiber structures.


A. Types of Structure

(1) Sandwich Structures Composite material is used for the skin of structures which is then bonded to a metallic or nonmetallic core. The core is usually a honeycomb structure (Ref. AMM 51-77-12 08).

(2) Monolithic Structures These structures have a composite material skin with internal stringers, ribs and spars to give rigidity and strength (Ref. AMM 51-77-14 08).

(3) Mixed Structures To follow the aircraft design, some structures are mixed; part sandwich and part monolithic structure.

NOTE : For more data Ref. ASRM 51-77-00 or the ASRM chapter related ____ to the component you will repair.


MATERIAL HANDLING AND PREPARATION - MAINTENANCE PRACTICES _________________________________________________________

TASK 51-77-11-910-006

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



Self Explanatory




No specific demineralized water No specific emery paper grade 100 No specific emery paper grade 280 No specific emery paper grade 400 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 51-77-11-010-052

A. There is no special job set-up for this task.


Subtask 51-77-11-918-052

A. Prepare the Composite Material Surfaces for Repair


(1) Cover the area adjacent to the repair area with masking paper and masking tape.

(2) Remove the surface protection and up to 50 mm (1.9685 in.) around the repair area with emery paper grade 100 or light grit blast (400-700) micron walnut grit.

(3) Remove all damaged material but not more than one layer.

(4) Feather the edges of the undamaged area to give a smooth edge to the repair area.


(5) Make the repair area smooth with emery paper grade 280 and emery paper grade 400.



NOTE : Do not pour the vapor degreaser directly on the repair area. ____ Moisten the lint-free cloth with vapor degreaser.

(7) Remove all loose and unwanted material with a vacuum cleaner.

(8) Clean the repair area with demineralized water and a lint-free cloth.

NOTE : Do not pour demineralized water directly on the repair area. ____ Moisten the lint-free cloth with demineralized water.

R 5. Close-up ________

R Subtask 51-77-11-942-050


R (1) Make sure that the work area is clean and clear of tool(s) and otherR items.

R (2) Remove the ground support and maintenance equipment, the special andR standard tools and all other items.



TASK 51-77-11-700-001

Water Break Test


Self Explanatory




No specific demineralized water No specific emery paper grade 400 No specific lint-free cloth

3. Job Set-up __________

Subtask 51-77-11-010-051



Subtask 51-77-11-750-050

A. Do the Water Break Test

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

(2) Spray a thin coating of demineralized water on the repair area.

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

(3) Inspect the wetted surface to make sure the water forms a thin continuous coating.

(4) A defect is shown when the demineralized water is repelled and forms into beads of water.

(5) If necessary, rub down the repair area with emery paper grade 400 to remove the defect.


(6) If necessary, clean the repair area with demineralized water and a lint-free cloth.

(7) If necessary, repeat the water-break test until there are no defects on the repair area surface.

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

NOTE : On completion of the water-break test, do not touch the repair ____ area. Do the repair quickly to prevent contamination.

(9) At the repair area apply new paint as necessary (Ref. SRM 51-75-12).


TASK 51-77-11-910-008

Preparation of a Corrosion-Resistant Steel Doubler



Self Explanatory




No specific corrosion-resistant steel sheet No specific lint-free cloth



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

3. Job Set-up __________

Subtask 51-77-11-010-050




Subtask 51-77-11-918-054

A. Prepare a Corrosion-Resistent Steel Doubler

(1) If the specific repair data does not give a doubler thickness, the doubler thickness is as follows:

(a) For a skin thickness up to 3 mm (0.1181 in.), the doubler thickness is 1.5 mm (0.0590 in.).

(2) For a skin thickness over 3 mm (0.1181 in.), the doubler thickness is half of the skin thickness.

(a) Cut the doubler from corrosion-resistant steel sheet to the necessary dimensions.

(b) Make a chamfer on the edges of the doubler.

(c) If necessary, shape and form the doubler to match the contours of the composite structure.

NOTE : The gap between the doubler and the composite structure ____ must not exceed 0.3 mm (0.0118 in.).

(3) Clean the doubler


(a) Clean the doubler with CLEANING AGENTS (Material No. 11-002) and a lint-free cloth.


COMPOSITE REPAIRS - SKIN DAMAGE ALL STRUCTURES - REPAIRS ________________________________________________________

TASK 51-77-12-300-001

Temporary Skin Repair with High-Speed Tape


NOTE : You can use high-speed tape to cover light skin damage when internal ____ damage is not found.


Self Explanatory


A. Consumable Materials


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

B. Referenced Information


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 51-77-12-350-050

A. Do the Temporary Skin Repair

(1) Remove frayed fibers.

(2) Make the sharp edges smooth with emery paper, grade 100.

(3) Make the repair area smooth with emery paper, grade 280 and emery paper, grade 400.


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

Subtask 51-77-12-560-050

B. Prepare the High-Speed Tape

R CAUTION : USE ONLY THE SPECIFIED MATERIALS AND OBEY THE INSTRUCTIONS FROM _______R THE MANUFACTURERS. OTHER MATERIALS CAN CAUSE DAMAGE TO THER SURFACE PROTECTION OF THE COMPONENTS AND THE RELATED AREA.

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

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

5. Close-up ________

Subtask 51-77-12-942-050



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


TASK 51-77-12-330-005

Permanent Skin Repair - One Ply Depth


Self Explanatory


A. Consumable Materials


No specific emery paper, Grade 280 No specific emery paper, Grade 400 No specific polythene sheet Material No. 05-057 C Z-18.903 MICROBALLOONS (Ref. 20-31-00) Material No. 08-010C X (Ref. 20-31-00)



51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite Material 51-77-11-700-001 Water Break Test 51-77-11-910-006 Preparation of Composite Material Surfaces for Repair (Damage of not more than 1 Layer) 51-77-12-991-003 Fig. 802

3. Job Set-up __________

Subtask 51-77-12-941-057

R A. Get access to the area to be repaired.



(Ref. Fig. 802/TASK 51-77-12-991-003)

Subtask 51-77-12-350-051

A. Do the Skin Repair

(1) If necessary, remove the temporary skin repair.

(2) Prepare the repair area (Ref. TASK 51-77-11-910-006).

(3) Do a water-break test on the repair area (Ref. TASK 51-77-11-700- 001).


(4) Mix the necessary amount of adhesive. Use BONDING AND ADHESIVE COMPOUNDS (Material No. 08-010C), SPECIAL MATERIALS (Material No. 05- 057).

(5) Apply the adhesive to the repair area.

(6) Put a polythene sheet over the repair area.

(7) Refer to the material specification for the curing time and let the adhesive cure.

(8) Remove the polythene sheet when the adhesive has cured.

(9) Rub down the adhesive with emery paper, Grade 280 and emery paper, Grade 400 to the contours of the composite structure.

(10) Apply the protective treatment. (Ref. TASK 51-75-12-300-001)


Permanent Skin Repair - One Ply Depth Figure 802/TASK 51-77-12-991-003


5. Close-up ________

Subtask 51-77-12-942-057

A. Close up


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


CLEANING PROCESSES - DESCRIPTION AND OPERATION ______________________________________________

1. General _______ This topic gives information on the cleaning of the aircraft structure after a spillage or contamination of the structure. A spillage must be removed as soon as possible to prevent damage to the aircraft structure.


A. Type of Contamination

(1) Sewage Sewage can damage the aircraft metallic components and cause corrosion.

(2) Hydraulic Fluid Contamination of the aircraft structure with hydraulic fluid, for a long time, will damage the corrosion-protection-paint.

(3) Acid and Alkali Spillage Acids and alkalies can cause corrosion very quickly and damage the aircraft protective paint finish.

(4) Fish Container Leakage Contamination of the aircraft structure with fish slime or sea water can cause corrosion to metal structure and components.


CLEANING PROCESSES - CLEANING/PAINTING ______________________________________

TASK 51-78-00-615-001

Aircraft Cleaning after a Sewage Leakage



Self Explanatory




No specific bicarbonate of soda No specific potassium bichromate No specific 1 BRUSH - NON METALLIC No specific 1 HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F) No specific 1 SCRAPER - NON METALLIC No specific 1 VACUUM EQUIPMENT 0 TO 0.4 BAR (6 PSI)




Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE IR NO LONGER AVAILABLE (Ref. 20-31-00) Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)



51-74-11-300-001 Repair of Corroded Areas 51-75-12-300-003 Repair of Minor Paint Damage (Topcoat Only) 51-75-13-916-001 Repair to a layer of Moisture-Removing Oil 51-75-13-916-002 Repair to a layer of Corrosion Preventive Compound

3. Job Set-up __________

Subtask 51-78-00-865-050

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

Subtask 51-78-00-010-050

B. Get Access

(1) Get access to the area of the leakage.

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

NOTE : Make sure that all electrical outlets are covered to protect ____ them from water.



Subtask 51-78-00-110-050

A. Cleaning Procedure


(1) Remove the loose materials with a SCRAPER - NON METALLIC, a VACUUM EQUIPMENT 0 TO 0.4 BAR (6 PSI), or a BRUSH - NON METALLIC.

(2) Flush the area with clean water.


(3) Mix water and 10 % of the bicarbonate of soda or the CLEANING AGENTS (Material No. 11-001) to make a cleaning solution.

(4) Clean the area with the cleaning solution and a lint-free cloth MISCELLANEOUS (Material No. 19-003).


(6) Prepare one of the cleaning solutions that follow: - mix water with 5 % potassium bichromate and 0.5 % of the CLEANING AGENTS (Material No. 11-001) or - mix water with 0.5 % of the CLEANING AGENTS (Material No. 11-001).

(7) Clean the area with the cleaning solution and a lint-free cloth MISCELLANEOUS (Material No. 19-003).


(9) Dry the area with a HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F).

(10) If necessary, repair corrosion damage (Ref. TASK 51-74-11-300-001).

(11) If necessary, repair the paint layers (Ref. TASK 51-75-12-300-003).

(12) If necessary, apply a layer of the SPECIAL MATERIALS (Material No. 05-027) to the area (Ref. TASK 51-75-13-916-001).



5. Close-up ________

Subtask 51-78-00-410-050

A. Close Access

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

(2) Remove the safety clips(s) and the tag(s) and close the circuit breaker(s) of all the electrical components and systems in the work area.



TASK 51-78-00-615-002

Aircraft Cleaning after a Hydraulic Fluid Leakage



Self Explanatory




No specific hot air dryer 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 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 IR NO LONGER AVAILABLE (Ref. 20-31-00) Material No. 11-003 USA ASTM D 740 METHYL-ETHYL-KETONE (Ref. 20-31-00)




51-74-11-300-001 Repair of Corroded Areas 51-75-12-300-003 Repair of Minor Paint Damage (Topcoat Only) 51-75-13-916-001 Repair to a layer of Moisture-Removing Oil 51-75-13-916-002 Repair to a layer of Corrosion Preventive Compound 51-76-11-300-001 Repair of the Sealing

3. Job Set-up __________

Subtask 51-78-00-865-052

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

Subtask 51-78-00-010-051

B. Get Access


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



Subtask 51-78-00-110-051


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


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


(3) Apply SPECIAL MATERIALS (Material No. 05-038) to the area, let it stay on the area for 30 minutes.

NOTE : The Met-L-chek developer will stay wet if there is unwanted ____ hydraulic fluid.

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

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





(10) If necessary, repair the filler seals (Ref. TASK 51-76-11-300-001).

(11) If necessary, apply a layer of SPECIAL MATERIALS (Material No. 05- 027) to the area (Ref. TASK 51-75-13-916-001).


5. Close-up ________

Subtask 51-78-00-410-051

A. Close Access


(2) Remove the safety clip(s) and tag(s) and close the circuit breaker(s) of all the electrical components and systems in the work area.



TASK 51-78-00-615-003

Aircraft Cleaning after Leakage from a Fish Shipment



Clean the aircraft structure after a leak from a fish container.




No specific 1 BRUSH - NON METALLIC No specific 1 HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F) No specific 1 SCRAPER - NON METALLIC No specific 1 VACUUM EQUIPMENT 0 TO 0.4 BAR (6 PSI)



Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 RUST INHIBITOR(FOR CORROSION USE 15-004) (Ref. 20-31-00) Material No. 11-001 USA MIL-D-16791 TYPE IR NO LONGER AVAILABLE (Ref. 20-31-00) Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)




51-74-11-300-001 Repair of Corroded Areas 51-75-12-300-003 Repair of Minor Paint Damage (Topcoat Only) 51-75-13-916-001 Repair to a layer of Moisture-Removing Oil 51-75-13-916-002 Repair to a layer of Corrosion Preventive Compound 51-76-11-300-001 Repair of the Sealing

3. Job Set-up __________

Subtask 51-78-00-865-054

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

Subtask 51-78-00-010-052

B. Get Access


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



Subtask 51-78-00-110-052



(1) Remove the loose materials with a SCRAPER - NON METALLIC, a VACUUM EQUIPMENT 0 TO 0.4 BAR (6 PSI), or a BRUSH - NON METALLIC.

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



(4) Prepare one of the cleaning solution that follow: - mix water with 5 % potassium bichromate and 0.5 % of the CLEANING AGENTS (Material No. 11-001) or - mix water with 0.5 % of the CLEANING AGENTS (Material No. 11-001).

(5) Clean the area with the cleaning solution.

(6) Remove the solution with a clean lint-free cloth MISCELLANEOUS (Material No. 19-003).



(9) If necessary, repair the corrosion damage (Ref. TASK 51-74-11-300- 001).


(11) If necessary, repair the clear nylon coating to the sealant (Ref. TASK 51-76-11-300-001).



5. Close-up ________

Subtask 51-78-00-410-052

A. Close Access


(2) Remove the safety clip(s) and tag(s) and close the circuit breaker(s) of all the electrical components and systems in the work area.



TASK 51-78-00-615-004

Aircraft Cleaning after an Acid or Alkali Leakage


WARNING : YOU MUST ALWAYS WEAR RUBBER GLOVES WHEN YOU DO THIS PROCEDURE. _______


Self Explanatory




No specific boric acid No specific hot air dryer No specific lint-free cloth No specific nonmetallic brush No specific plastic container No specific plastic sheets No specific sodium bicarbonate No specific soft brush No specific sponge No specific universal indicator paper




Material No. 05-005 USA MIL-C-16173 GRADE II CORROSION PREVENTIVE (Ref. 20-31-00) Material No. 05-027 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)



51-74-11-300-001 Repair of Corroded Areas 51-75-12-300-003 Repair of Minor Paint Damage (Topcoat Only) 51-75-13-916-001 Repair to a layer of Moisture-Removing Oil 51-75-13-916-002 Repair to a layer of Corrosion Preventive Compound

3. Job Set-up __________

Subtask 51-78-00-865-056

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

Subtask 51-78-00-010-053

B. Get Access


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


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


(4) Use a plastic container for used cloths and/or sponges.


Subtask 51-78-00-110-053


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

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

(3) Prepare the necessary solution.

(4) For alkali leakage mix a solution of 5 % boric acid and water. Mix 50 g (1.76 oz) of boric acid with 1 l (0.2641 USgal) of water to get the necessary solution.

(5) For acid leakage mix a solution of 5 % sodium bicarbonate and water. Mix 50 g (1.76 oz) of sodium bicarbonate with 1 l (0.2641 USgal) of water to get the necessary solution.

(6) Apply the solution to the dirty area with a nonmetallic brush and/or lint-free cloth.

(7) Apply the solution until the chemical reaction stops. Keep the solution on the surface for 5 min.

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


(10) Use a soft brush to remove the clean water.

(11) Do a test to measure the pH-value of the leakage area.

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

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

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

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







5. Close-up ________

Subtask 51-78-00-410-053

A. Close Access


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



TASK 51-78-00-200-001

Inspection after Mercury Spillage

WARNING : ALWAYS SUPPLY SUFFICIENT VENTILATION WHILE YOU CLEAN AREAS WHERE _______ THERE IS MERCURY CONTAMINATION.MERCURY VAPORS ARE TOXIC.

WARNING : DO NOT TRY TO COLLECT MERCURY BY HAND. _______

WARNING : DO NOT BREATHE MERCURY VAPORS.THE AIR FROM THE VACUUM CLEANER _______ CONTAINS MERCURY VAPORS COLLECTED DURING CONTACT WITH THE MERCURY DEPOSITED IN THE GLASS CONTAINER.

WARNING : DO NOT USE THE AIR HOSE TO REMOVE MERCURY FROM THE AIRCRAFT. _______


You must do the inspection when mercury is spilled in the cargo compartment. Mercury and mercury compounds, are heavily corrosive on a wide range of metallic materials, especially on aluminum alloys. When mercury is spilled in the aircraft there is a high risk of serious damage to the structure. Corrosion caused by spilled mercury can destroy a large area, although only a small amount of mercury is spilled. Heavy destruction can occur within a few hours.




No specific air compressor No specific battery water rubber-syringe No specific cardboard No specific cellulose tape No specific glass fiber sheets No specific medicine dropper No specific mercury sniffer No specific paper trough No specific portable X-ray equipment No specific safety barriers No specific soap No specific vacuum cleaner No specific warning notice No specific woods




52-30-00-860-001 Open the FWD or AFT Cargo-Compartment Door with the Yellow Electric Pump 52-30-00-860-003 Open the FWD or AFT Cargo-Compartment Door with the Hand Pump 53-22-14-000-001 Removal of the FWD Cargo-Compartment Floor-Panels 53-22-14-400-001 Installation of the FWD Cargo-Compartment Floor-Panels 53-42-14-000-001 Removal of the AFT Cargo-Compartment Floor-Panels Zone 150 53-42-14-400-001 Installation of the AFT Cargo-Compartment Floor-Panels Zone 150 SRM 51220000 SRM 53020002

3. Job Set-up __________

Subtask 51-78-00-941-055

A. Safety Precautions

(1) Put the safety barriers in position.

(2) On the panel 2020VU put a warning notice to tell persons to keep out of the work areas.

Subtask 51-78-00-010-054

B. Get Access

(1) Open the cargo compartment doors 825 and 826 (Ref. TASK 52-30-00-860- 001).

Subtask 51-78-00-869-050

C. Ventilation of the Cargo Compartment

(1) Blow clean filtered air from an air compressor through the cargo compartment, as follows:

(a) Put the air compressor near the aircraft.


(b) Put the end of the air compressor supply hose into the compartment through the door.

(c) Start the air compressor and make sure that the air flows through the cargo compartment.


Subtask 51-78-00-615-050

A. Cleaning of the Contaminated Area

(1) Mark the area that is contaminated by mercury spillage.

(2) Isolate the contaminated area, do not let mercury spread from the contaminated areas to the clean areas. Do not walk through or move parts from the contaminated area into the clean areas of the aircraft.

(3) Do not touch the surfaces that you suspect of contamination. Use woods and glass fiber sheets to support your body while you work on the contaminated area.

NOTE : Do not use contaminated protective clothing in clean areas. ____

(4) Remove mercury spillage as follows:

(a) Collect all the visible mercury with a cardboard or a paper trough.

(b) Collect the mercury with a vacuum cleaner.

(c) To collect small particles of mercury use cellulose tape.

(d) If there is a larger quantity collect the mercury with a medicine dropper or a battery water rubber-syringe.

(e) To check under floor zones, use a mercury sniffer and a portable X-ray equipment.


Subtask 51-78-00-210-050

B. Inspection of the Cargo Compartment (Ref. TASK 53-22-14-000-001) (Ref. TASK 53-42-14-000-001) (Ref. SRM 51220000) (Ref. SRM 53020002)

NOTE : When you find mercury on the floor, do not remove ____ access/inspection plates, screws, rivets, bolts, etc., from the floor. A hole in the contaminated area of the floor may let the mercury spread to the structure below the floor.

------------------------------------------------------------------------------ | |INSP.| |PHASE|PHASE|PHASE|INSP.|DETAIL| |ITEM | | INSP. TASKS TO BE ACCOMPLISHED | 1 | 2 | 3 |SIGN |(FIG) | | |CODE | | | | | | |R |-----|-----|---------------------------------|-----|-----|-----|-----|------| | 1 | 2 | | 4 | 5 | 6 | 7 | 8 |R |-----|-----|---------------------------------|-----|-----|-----|-----|------| |1. | | Do a visual inspection of the | X | | | | | | | | cargo compartment floor, the | | | | | | | | | componemts of the cargo loading | | | | | | | | | system and the lowest point of | | | | | | | | | the structure: | | | | | | | | | - remove the mercury. | | | | | |R |-----|-----|---------------------------------|-----|-----|-----|-----|------|R |2. | | Do a visual inspection of the | X | | | | | | | | non-visible contamined areas | | | | | | | | | with a mercury sniffer: | | | | | | | | | - remove the mercury. | | | | | |R |-----|-----|---------------------------------|-----|-----|-----|-----|------|R |3. | | Remove floor panels in the | X | | | | | | | | contaminated zones: | | | | | | | | | - FWD cargo compartment floor | | | | | | | | | (Ref. TASK 53-22-14-000-001), | | | | | | | | | - aft cargo compartment floor | | | | | | | | | (Ref. TASK 53-43-14-00-001). | | | | | |R |-----|-----|---------------------------------|-----|-----|-----|-----|------|R |4. | | Do a visual inspection of the | X | | | | | | | | bottom of the fuselage. | | | | | | | | | Do an inspection of the skin and| | | | | | | | | the internal structure below the| | | | | | | | | point of spillage. | | | | | | | | | If mercury spillage has occurred| | | | | | | | | in the cargo area, do an | | | | | | | | | inspection of the lowest point | | | | | |


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


5. Close-up ________

Subtask 51-78-00-110-055

A. Cleaning of the Tools

(1) Clean all the tools used in the contaminated areas with steam or hot water and soap.

(2) Discard twist drills and other cutting tools used on the contaminated structure.

(3) Thoroughly clean all the protective clothing with water and soap after use in the contaminated areas. Thoroughly wash your hands with water and soap before you touch your face.

Subtask 51-78-00-410-054

B. Close Access

(1) Install the floor panels of the cargo compartment (Ref. TASK 53-22- 14-400-001) (Ref. TASK 53-42-14-400-001).

(2) Close the cargo compartment doors (Ref. TASK 52-30-00-860-003).

Subtask 51-78-00-942-054

C. Put the Aircraft Back to its Initial Configuration

(1) Remove the warning notice(s).




TASK 51-78-00-615-005

Removal of Corrosion Preventive Compound


CAUTION : DO NOT POINT THE SPRAY GUN OF THE WATER HIGH-PRESSURE CLEANER AT _______ ELECTRICAL COMPONENTS, HARNESSES, SENSORS, CONNECTORS, EQUIPMENT AND ACTUATOR BEARINGS. WATER CAN CAUSE DAMAGE TO THESE COMPONENTS.

CAUTION : DO NOT APPLY THE CLEANING AGENTS TO THESE PARTS: _______ - BEARINGS, ACTUATORS, FITTINGS - ACRYLICS OR POLYCARBONATE MATERIALS - ELECTRICAL HARNESSES, SENSORS, CONNECTORS. CLEANING AGENT ON OR IN THESE PARTS CAN CAUSE DAMAGE.


This is an alternative method to solvent cleaning for the removal of corrosion preventive compounds, Material Nos. (15-004, 15-005, 15-006, 15-007, 15-008 and 15-009 from large areas).




No specific 1 CLEANING EQUIPMENT - HIGH PRESSURE No specific 1 HOT AIR BLOWER OPERATING 40 DEG C (100 DEG F)




Material No. 11-032 WAX REMOVER (Ref. 20-31-00)



ASRM 51-23-12-001 (for corrective action) 51-74-11-300-001 Repair of Corroded Areas (for corrective action) 51-75-12-300-001 Repair of Major Paint Damage on Light Alloy and Composite Material (for corrective action) 51-75-12-300-003 Repair of Minor Paint Damage (Topcoat Only) (for corrective action)

3. Job Set-up __________

Subtask 51-78-00-865-061

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

Subtask 51-78-00-941-056

B. Get Access

(1) Get access to the area(s) where you will do the work.

Subtask 51-78-00-010-055

C. Removal and Cleaning of Components

(1) Remove the components from the area where the corrosion preventive compound must be removed.

(2) Install protective covers on all the electrical outlets to protect them against contamination.



Subtask 51-78-00-160-051

A. Removal of the Corrosion Preventive Compound

WARNING : OBEY THE MANUFACTURER�S INSTRUCTIONS WHEN YOU USE THIS/THESE _______ MATERIAL/S. USE PROTECTIVE CLOTHING, RUBBER GLOVES, GOGGLES AND A MASK.

(1) Apply a thin layer of the CLEANING AGENTS (Material No. 11-032) to the area.

(2) Let the CLEANING AGENTS (Material No. 11-032) soak into the corrosion preventive compound for a minimum of 20 minutes.

(3) Flush the area with water with a maximum temperature of 50 deg.C (122.00 deg.F). Use a CLEANING EQUIPMENT - HIGH PRESSURE to do this, as follows:

(a) Hold the spray gun of the CLEANING EQUIPMENT - HIGH PRESSURE with an angle of 30 to 45 degrees to the surface.

(b) Make sure that the distance between the nozzle of the CLEANING EQUIPMENT - HIGH PRESSURE and the surface is more than 250 mm (9.8425 in.).

(c) Do not apply more than 80 bar (1160.3016 psi) water pressure to the structure.

(d) Do not apply more than 2 bar (29.0075 psi) water pressure to the composite materials.


(5) If necessary repair the corroded areas (Ref. TASK 51-74-11-300-001).

(6) If necessary repair the damaged paint on aluminum and/or composite materials (Ref. TASK 51-75-12-300-001) and (Ref. TASK 51-75-12-300- 003).

(7) Apply the new corrosion preventive compound as necessary (Ref. ASRM 51-23-12-001).


5. Close-up ________

Subtask 51-78-00-410-055

A. Close Access


(2) Install all the components that were removed for the removal of the corrosion preventive compound.

Subtask 51-78-00-865-062

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

Subtask 51-78-00-942-055

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


TASK 51-78-00-916-001

Application of Temporary Protection System (TPS)

CAUTION : DO NOT APPLY THE CLEANING AGENTS TO THESE PARTS: _______ - BEARINGS, ACTUATORS, FITTINGS - ACRYLICS OR POLYCARBONATE MATERIALS - ELECTRICAL HARNESSES, SENSORS, CONNECTORS. CLEANING AGENT ON OR IN THESE PARTS CAN CAUSE DAMAGE.


Self Explanatory




No specific 1 SCRAPER - NON METALLIC



Material No. 11-026 GB DEF-STAN 68-148/1 SOLVENT GENERAL PURPOSE (Ref. 20-31-00) Material No. 15-005 AIB TN 10138 TYPE I GRADE 2 CORROSION PREVENTIVE TEMPORARY PROTECTIVE COMPOUND (Ref. 20-31-00) Material No. 15-006 AIB TN 10138 TYPE I GRADE 3 CORROSION PREVENTIVE TEMPORARY PROTECTIVE COMPOUND (Ref. 20-31-00) Material No. 15-007 AIB TN 10138 TYPE II GRADE 1 CORROSION PREVENTIVE TEMPORARY PROTECTIVE COMPOUND (Ref. 20-31-00) Material No. 15-008 AIB TN 10138 TYPE II GRADE 2 CORROSION PREVENTIVE TEMPORARY PROTECTIVE COMPOUND (Ref. 20-31-00) Material No. 15-009 F AIMS 09-08-003 TYPE III CORROSION PREVENTIVE TEMPORY PROTECTIVE COMPOUND (Ref. 20-31-00)



Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)



51-78-00-991-002 Fig. 701

3. Job Set-up __________

Subtask 51-78-00-865-063

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

Subtask 51-78-00-941-057

B. Get Access

(1) Get access to the area(s) where you will do the inspection/check.

Subtask 51-78-00-010-056

C. Removal of components

(1) Remove all components necessary from the TPS inspection/check area.

(2) Remove all insulation blankets/material from the inspection/check area.



(Ref. Fig. 701/TASK 51-78-00-991-002)

Subtask 51-78-00-160-052

A. Cleaning and/or removal of the Temporary Protective System (TPS)

(1) Does the MPD task make the removal of the TPS necessary.

(a) If the TPS does not need to be removed, clean the inspection area with the CLEANING AGENTS (Material No. 11-026) and a clean lint-free cloth MISCELLANEOUS (Material No. 19-003).

(b) If the TPS has to be removed, use a SCRAPER - NON METALLIC to remove the TPS application. Only remove sufficient TPS to allow for the inspection procedure. Clean the area with the CLEANING AGENTS (Material No. 11-026) and a clean lint-free cloth MISCELLANEOUS (Material No. 19-003).

Subtask 51-78-00-210-051

B. Inspection of the Temporary Protection System (TPS)

(1) Inspect the area where the TPS is applied.

(2) If the TPS is in the correct condition, a secondary layer of the same TPS can be applied over the first layer.

(3) If the TPS is not in the correct condition, remove the TPS, clean the area and apply a new layer of the correct TPS type.

(4) If the TPS has been removed for an inspection, apply a new layer of the TPS to the inspection area.


Temporary Protection System (TPS) Figure 701/TASK 51-78-00-991-002


Subtask 51-78-00-916-054

C. Application of the Temporary Protection System (TPS)


(1) The three types of TPS are:R - STORAGE PRESERVATION (Material No. 15-005), STORAGE PRESERVATIONR (Material No. 15-006), TPS type 1R - STORAGE PRESERVATION (Material No. 15-007), STORAGE PRESERVATIONR (Material No. 15-008), TPS type 2R - STORAGE PRESERVATION (Material No. 15-009), TPS type 3.

(2) Make sure the correct TPS type is applied to the surface.

(3) If TPS type 1 has been removed, apply the same TPS type 1 to the surface.

(4) If TPS type 1 and TPS type 2 have been applied in an inspection area and are removed: - Apply the same TPS type 1 and type 2 or, as an alternative, apply the TPS type 3 to the inspection area.

(5) Make sure that the TPS is not applied to the insulating blankets/material.

5. Close-up ________

Subtask 51-78-00-410-056

A. Close Access



Subtask 51-78-00-865-064

B. Remove the safety clip(s) and tag(s) and close the circuit breaker(s) of all the electrical components and systems in the inspection area.

(1) Install the insulation blankets/material if necessary.

Subtask 51-78-00-942-056

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


TASK 51-78-00-615-006

Cleaning of the Door Entry Drains



Self Explanatory




No specific 1 ACCESS PLATFORM 3M (10 FT)- ADJUSTABLER No specific 1 AIR SOURCE 0,3 TO 0,7 BAR (5 TO 10 PSI)- FILTERED,R DRY No specific 1 SCRAPER - NON METALLIC



Material No. 11-026 GB DEF-STAN 68-148/1 SOLVENT GENERAL PURPOSE (Ref. 20-31-00) Material No. 19-003 USA AMS 3819 LINT-FREE COTTON CLOTH (Ref. 20-31-00)


3. Job Set-up __________

Subtask 51-78-00-010-057

A. Get Access

(1) Put the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE in position at the applicable passenger door.

(2) Open the applicable passenger door.

(3) Get access to the applicable water drain(s).

(4) Remove the correct forward or aft floor panel(s) at the door entry position.


Subtask 51-78-00-110-056


(1) Clean the floor panel with the CLEANING AGENTS (Material No. 11-026) and a clean lint-free cloth MISCELLANEOUS (Material No. 19-003).

(2) Make sure that the water drain collector(s) are clean and in the correct condition.

(3) Remove the sealant/contamination with a SCRAPER - NON METALLIC and a clean lint-free cloth MISCELLANEOUS (Material No. 19-003)

(4) Examine the condition of the drains:

(a) Put water down the drain collector(s) and let it drain.

(b) Make sure that the water drains away from below the fuselage.

(5) If the water does not drain away from the drain collector(s):

R (a) Use a low pressure AIR SOURCE 0,3 TO 0,7 BAR (5 TO 10 PSI)-R FILTERED, DRY attached to the drain collector(s) to remove the contamination.

(b) Put water down the drain collector(s) and make sure that it drains away from below the fuselage.


5. Close-up ________

Subtask 51-78-00-410-057

A. Close Access

(1) Install the entry-door floor panel(s) in the correct position(s).



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