STRUCTURAL REPAIR MANUAL TABLE OF CONTENTS SUBJECT TITLE PAGE

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Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALCHAPTER 51 Structures GeneralTABLE OF tural DefinitionGeneralGeneral11Major Structural Breakdown DiagramsGeneralAircraft Description and Dimensions11Restricted Areas DiagramGeneralDefinition of Restricted Repair Areas11Glossary of Structural TermsGeneralGlossary of Terms11Aircraft CoatingsRepairEpoxy Primer Coating — Preparation and Application (Including Finish2012)Surface Preparation and Painting ProcedureEpoxy Primer Coating — Hydraulic Fluid Resistant (Finish 2012)Waterborne Epoxy Primer — Preparation and Application (Finish 3012)Gloss Epoxy Finish — Application (Includes Finish 2013 and 3013)Epoxy Topcoat — Hydraulic Fluid Resistant Series 2000Application of Epoxy Polyamide Primer CoatingUrethane Enamel — Preparation and ApplicationWhite Primer Coating / Sanding SealerAntistatic Epoxy PrimerAntistatic Epoxy Primer — General Application201207217220235239242244250254260Damage ClassificationAllowable DamageDamage101101Corrosion Removal and Preventive ProceduresGeneralCorrosion Removal and Preventive ProceduresTypes of CorrosionCorrosion InhibitorsCorrosion Removal Techniques — Safety PrecautionsCorrosion Levels and Rework LimitsCorrosion Rework PreparationsStandard Surface Treatment Methods20111291013182051 TABLE OF CONTENTSPage 1December 31/07

Title PagePrev PageNext PageSTRUCTURAL REPAIR 51-20-0051-21-00TITLEPAGECorrosion RemovalRepairCorrosion Removal201201Aluminum and Aluminum Alloy Corrosion RemovalRepairAluminum and Aluminum Alloy — Corrosion Removal201201Magnesium Alloy Corrosion RemovalRepairMagnesium Alloy — Corrosion Removal201201Alloy Steel Corrosion RemovalRepairAlloy Steel — Corrosion Removal201201Stainless Steel and Nickel Chromium Alloy Corrosion RemovalRepairStainless Steel and Nickel Chromium Alloy — Corrosion Removal201201Titanium Alloy Corrosion RemovalRepairTitanium Alloy — Corrosion Removal201201Plated or Phosphated Surfaces Corrosion RemovalRepairPlated or Phosphated Surfaces — Corrosion Removal201201Tungsten Ballast Weights Corrosion RemovalRepairTungsten Ballast Weights — Corrosion Removal201201Aerodynamic Smoothness RequirementsRepairAerodynamic Contour SmoothnessSealing of Surfaces for Aerodynamic SmoothnessGIV Finish SpecificationGIV Sealing dual Process and Finish CodesFinishes, Processes and Nondestructive Test (NDT) Inspection —Methodology and EquipmentOriginal FinishesChemical Treatment of MaterialsRepair51 TABLE OF CONTENTSPage 2December 31/0711430201

Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALCHAPTER/SECTIONSUBJECTTITLEPAGEChromate Conversion Coating of Aluminum AlloysCleaning and Chemical Surface Treatment of Aircraft SurfacesAlkaline Cleaning of Ferrous and Nonferrous AlloysCleaning and Descaling of Titanium and Titanium AlloysAerodynamic Sealant CompoundFuel Resistant Sealing Compound — Fillet and Faying ( 65 F to 360 luminum and Aluminium Alloy Surface Treatment MethodRepairAluminum and Aluminum Alloys — Surface Treatment201201Magnesium Alloy Surface Treatment MethodRepairMagnesium Alloys — Surface Treatment201201Low Alloy Steel Surface Treatment MethodRepairLow Alloy Steels — Surface Treatment201201Stainless Steel and Nickel Chromium Alloy Surface Treatment MethodRepairStainless Steel and Nickel Chromium Alloy — Surface Treatment201201Titanium Alloy Surface Treatment MethodRepairTitanium Alloy — Surface Treatment201201Cadmium Plated or Phosphated Metals Surface Treatment MethodRepairCadmium Plated or Phosphated Metals — Surface Treatment201201Sealing / Filling Materials CuringRepairSealing Pressurized Areas, Skin Joints, Faying Surfaces, Access Closuresand Coating Exterior SurfacesFaying Surface Sealing Compound — Corrosion InhibitiveIntegral Fuel Tank Coating — MIL-C-27725 Application201208210Integral Fuel Tank SealingGeneralFuel Access Door Assembly Anti-chafing GasketRepairSealing the GIV Wing11201201Permaswage FittingsRepairSwaging of Tubing to Deutsch PermaswageT Fittings20120120151 TABLE OF CONTENTSPage 3December 31/07

Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALCHAPTER/SECTIONSUBJECTTITLEInstallation of Externally Swaged Tube Fittings (PermaswageT 1-36-0051-41-0051-42-0051-43-00PAGE219Preparation of Surfaces by Abrasive MethodsRepairPreparation of Surfaces by Abrasive Methods201201Ultrasonic TestingAllowable DamageUltrasonic Testing of In Service Composite PartsRepairUltrasonic Quality Requirements for Aluminum Alloy Products101101201201MaterialsGeneralApproved Materials and Solutions11Approved AdhesivesGeneralMixing and Handling Repair Adhesives - General RequirementsApproved Repair Adhesive Charts112Formed Repair MaterialsGeneralTolerances — Sheet Metal Forming11Materials Cross ReferenceGeneralMaterial Substitution11Fastener Types, Materials and SizesStructural IdentificationClampsFasteners Bolts / ScrewsFasteners — Hi-Lok / Hi-TigueFasteners — RivetsShimsFastener Preparation and InstallationRepairComposite Fasteners and Fastener Hole — TreatmentHole Preparation Specification — Metallic and Composite StructureFastenersFastener Strength Values and Substitution Cross ReferenceGeneralSubstitutionGulfstream to Vendor Fastener Conversion Table51 TABLE OF CONTENTSPage 4December 31/07114141718201201202112

Title PagePrev PageNext PageSTRUCTURAL REPAIR 0051-70-56TITLEPAGESupport of Aircraft for Repair and Alignment Check ProceduresGeneralGear CollapseSupport LocationsGeneralShoring of AircraftRepairGeneral Aligning ProceduresAircraft Shoring Potting Material11201201212Repairs (General Aircraft)GeneralStructural Repairs — GeneralMinimum Fastener Edge and Center-to-Center DistancesRepairShy Edge Distance On Spliced Member — Splice PlateShy Edge Distance On Spliced Member — Spliced MemberShy Edge Distance — Intersection of Two FlangesShy Edge Distance — Clip or GussetShy Material at Edge — End or Cutout of Sheet Metal PartShy Edge Distance on Flange EndFastener Hole Breaking Out — Flange EndFastener Head, Tail, Collar or Nut Riding Radius of FlangeExcessive Depth of Countersink — Shallow Head / Flush High StrengthFastenersShallow Countersink or Dimple — High Rivet HeadDeep Countersink or Dimple — Oversize, Oblique or Elongated HoleIncorrect Holes or Countersinks — Shallow Head RivetsOversize, Elongated or Damaged HolesExtraneous Holes in Aluminum Alloy Parts and AssembliesMinor Scratches, Wrinkles, Dents or Depressions in Pressurized andNonpressurized Sheet MetalRivet Set CutsCrack in Radius of FlangeCracked Lightening Hole FlangeLateral Crack in Flange or Angle LegDrill MarksCrack or Puncture in Interior or Exterior SkinsCrack or Puncture in Continuous or Spliced Interior or Exterior Skin —Flanged SideCrack or Puncture in Continuous or Spliced Interior or Exterior Skin —Opposite Flanged SideCracks on Edges of Flat or Contoured SkinsWindow 721822122422623023323423723824024124524825120151 TABLE OF CONTENTSPage 5December 31/07

Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALCHAPTER/SECTIONSUBJECTTITLEPits, Nicks, Surface Scratches on Cockpit and Cabin Windows —Removal PAGE201Main Landing Gear Structural ComponentsGeneralMain Landing Gear — Blend Out Limits11Nose Landing Gear Structural ComponentsGeneralNose Landing Gear — Blend Out Limits11Repairs to Thin Wall Tubes and DuctingGeneralThin Wall Tubes and DuctingSupplier ListingsMaterial Listings11823Duct InspectionGeneralApplicable GIV Ducts / TubesTube Repair — Chapter 21 Air Conditioning Ducts (within PressureVessel)Tube Repair — Chapter 21 Equipment Cooling DuctsTube Repair — Chapter 21 Air Conditioning Ducts (External to PressureVessel)Tube Repair — Chapter 28 Fuel LinesTube Repair — Chapter 30 Ice and RainTube Repair — Chapter 36 Pneumatic DuctsTube Repair — ATA Chapter 71: Powerplant DuctsTube Repair — ATA Chapter 75: Air DuctsTube Repair — ATA Chapter 80: Starting DuctsDucts / Tubes — Press Fit BushingDucts / Tubes — Slip Fit BushingDucts / Tubes — V-Band Splice SleeveDucts / Tubes — Splice Sleeve Butt WeldDucts / Tubes — Splice Sleeve Fillet WeldDuct RepairAllowable DamageDuct Cleaning and PassivationDuct InspectionAlkaline CleaningNitric Acid CleaningNitric Acid PassivationAluminum Alloy Acid 13114Fusion WeldingRepairFusion Welding Procedure20120151 TABLE OF CONTENTSPage 6December 31/07111417

Title PagePrev PageNext PageSTRUCTURAL REPAIR atic Pressure TestingRepairHydrostatic Pressure Test201201Finish RequirementsRepairFinish Special Tools and FixturesRepairSpecial Tools and FixturesPlug And Ball Mandrel FabricationFemale V-Band Test FlangeMating Test Flange For 20075-300FR FlangeMale V-Band Test FlangeMating Test Flange For 20074 - 500FI FlangeMating Test Flange For C-2330-400F FlangeMating Test Flange For 20070-0250M FlangeMating Test Flange For GF530A-M300A FlangeMating Test Flange For 20060-300N FlangeMating Test Flange For 20045-300F FlangeMating Test Flange For MFB65202-250 FlangeGammah P/N T2009 Nut — Test PlugGammah P/N F1042-250 Nut — Test CapBeaded End Test 43Corrosion ReworkRepairCorrosion ReworkPatch Doubler Repair — CorrosionReinforcement Strap Repair — CorrosionReinforcement Strap Repair — Under Support ClampReinforcement Strap Repair — Corrosion (Filler Installation)201201223223224224Scratch and Abrasion ReworkRepairScratch and Abrasion Rework201201Dent and Puncture ReworkRepairDent and Puncture ReworkPatch Doubler Repair — Dents and PuncturesReinforcement Strap Repair — Dents and PuncturesReinforcement Strap Repair — Dents and Punctures (Filler Installation)20120120220320651 TABLE OF CONTENTSPage 7December 31/07

Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALCHAPTER/SECTIONSUBJECTTITLEReinforcement Strap Repair — Under Support -18PAGE208Duct Reinforcement RepairRepairDuct Reinforcement RepairDuct Reinforcement Welding RequirementsDuct Straight Section Reinforcement Patch Repair — GeneralDuct Curved Section Reinforcement Patch Repair — GeneralDuct Straight Section Reinforcement Repair — GeneralDuct Conic Section Reinforcement Repair — General201201215215216217218Duct Crack RepairRepairDuct Crack RepairCrack Repair Welding InstructionsSingle Crack Patch Doubler RepairReinforcement Patch Repair — Boss ReinforcementDuct Attachment Doubler InstallationReinforcement Strap Repair — Multiple CracksReinforcement Patch / Strap Repair — Multiple CracksReinforcement Patch / Strap Repair — Boss ReinforcementReinforcement Strap Repair — Cracks Under Support Clamp201201212212212213214214215215Welded Attachment Crack RepairRepairWelded Attachment Crack Repair — GeneralWelded Attachment Crack — RepairWelded Attachment Crack Repair — Doubler Installation201201208208Gamah CouplingsRepairGammah Coupling End Flange ReplacementGammah Couplings — Swaged ReplacementGammah Couplings (Swaged) — Duct Section ReplacementGammah Couplings — Butt Welded Replacement201201202205207Duct Section ReplacementRepairDuct Section ReplacementDamaged Duct Section Replacement — Splice SleeveDamaged Duct Section ReplacementDamaged Beaded End ReplacementDamaged Beaded End Replacement — Splice Sleeve201201207207207208V-Band Flange ReplacementRepairV-Band Flange Replacement20120151 TABLE OF CONTENTSPage 8December 31/07

Title PagePrev PageNext PageSTRUCTURAL REPAIR 2151-77-2251-77-2351-78-00TITLEPAGEDuct Component ReplacementRepairDuct Component ReplacementDamaged Component Section Replacement — Splice SleeveDamaged Component Section Replacement201201204205Oversize Bushing RepairRepairOversize Bushing Repair201201Electrical Bonding Strap RepairRepairElectrical Bonding Strap Repair201201Miscellaneous RepairsRepairMiscellaneous RepairsDamage To Butt Weld201201206Threaded Boss / Port RepairRepairThreaded Boss / Port RepairAS3077 Series Lockring InstallationAS3077 Series Lockring RemovalAS3078 Series Insert Removal Procedure201201215216216Repairs to CompositesRepairCuts, Scratches, Pits, Erosion of Outer Fiberglass PlyMissing or Torn Outer Fiberglass Ply — Less Than 1.00 Inch in Length orDiameterMissing or Torn Outer Fiberglass Ply — Larger Than 1.00 Inch in Lengthor DiameterInternal Delamination Around Fastener HoleExternal Delaminations With No Missing PliesImpact Damage Resulting in External Delaminations on the Edge of PartWith Missing PliesInternal Delamination Not Open to an EdgeInternal Delamination Open to an Edge — Injected from Part EdgeInternal Delamination Open to Part Edge — Pressure InjectionSmall Indent / Gouge Less Than 0.25 Inch in Diameter That Does NotPenetrate SkinSmall Puncture Less Than 0.25 Inch Diameter That Penetrates Skin(Using Fastener Plug)Small Puncture Less Than 0.25 Inch in Diameter That Penetrates Skin(Using Adhesive Plug)Deep CountersinkElongated / Oversize Drilled Holes With Edge 751 TABLE OF CONTENTSPage 9December 31/07

Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALCHAPTER/SECTIONSUBJECTTITLETorn or Missing Conductive Wire Mesh51-78-1051-79-0051-79-10Composite Repair TechniquesGeneralComposite ComponentsRepairVacuum Injection of Liquid Repair AdhesiveUsing Vacuum to Assist Pressure InjectionWater Removal From Composite SurfacesUsing a Router to Remove Damaged SkinUsing a Hole Saw to Remove Damaged SkinAir Flow Test For Verifying an Adhesive Flow PathSaturating Dry Repair Cloth With Repair AdhesivePressure Application Methods Using Clamps, Weights, and Vacuum BagVacuum Bag Installation Working Upside Down or on a SideCold Weather Curing OperationsRepairs to Aluminum HoneycombRepairScratches, Nicks and Dings on Face Sheets of Aluminum SandwichAssemblyMinor Skin Dents and Depressions in Aluminum Sandwich AssemblySmall Puncture on External or Internal Sandwich AssembliesVoids / Unbond Around Fastener Holes on Bonded Metal PanelsSkin Puncture Through Both Skins of a Sandwich AssemblySkin Puncture on Both Skins of a Sandwich AssemblySkin Puncture or Crack Through One Skin Only With Core Damage DepthBeing 20% of Depth or LessUnbond Between Skin and Core on One Side Only — Pressure InjectionMethodUnbond Between Skin and Core on One Side Only — Vacuum InjectionMethodVoids / Unbond Along a Foam Fill JointDepression in Aluminum Sandwich Assembly with a Diameter Less Than1.5 Inch — Minor Core DamageSpinning Insert with Access for RemovalSkin Crack / Puncture Around Inserts — Honeycomb BoardImpact Damage on Extreme Trailing Edge (Dents or Fracture) — ExternalSurface PatchAluminum Repair TechniquesGeneralMetal Honeycomb and Metal to Metal Bonded AssembliesRepairVacuum Injection of Liquid Repair AdhesivesUsing Vacuum to Assist Pressure InjectionWater Removal From Sandwich Assemblies with Known Water Entrapmentor with a Skin Puncture51 TABLE OF CONTENTSPage 10December 204205

Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALCHAPTER/SECTIONSUBJECTTITLEPAGERemoval of a Single SkinRemoving and Installing Replacement CoreRemoval of Two Discrepant Skins and CoreAir Flow Test for Verifying an Adhesive Flow PathPressure Application Examples Using Clamps, Dead Weights and VacuumBagVacuum Bag Installation Working Upside Down or on a SideCold Weather Curing OperationsMethods for Removing Paint and Primer From Aluminum SurfaceCleaning Aluminum for Bonding Using Pasa Jell 105 Acid PasteRecommended Methods for Removing InsertsConstruction of Peel Process Control PanelFly Cutting Honeycomb Core51-80-00Electrical BondingGeneralBonding Safety and PrecautionsRepairElectrical Bonding 20120151 TABLE OF CONTENTSPage 11December 31/07

Title PagePrev PageNext PageSTRUCTURAL REPAIR MANUALTHIS PAGE IS INTENTIONALLY LEFT BLANK51 TABLE OF CONTENTSPage 12December 31/07

Crack in Radius of Flange 234 Cracked Lightening Hole Flange 237 Lateral Crack in Flange or Angle Leg 238 Drill Marks 240 Crack or Puncture in Interior or Exterior Skins 241 Crack or Puncture in Continuous or Spliced Interior or Exterior Skin — Flanged Side 245 Crack or Puncture in Continuous or Spliced Interior or Exterior Skin —

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