Airbus A340-200 Structural Repair Manual

Brand
Airbus
Model
A340-200
Type
Structural Repair Manual

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STRUCTURALREPAIRMANUAL
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STRINGERSANDSKINSTIFFENERS
1. General
Thistopiccontainsrepairproceduresfordamagetostringers.ForSection
andFRdesignationrefertoChapter53−00−00 PageBlock001.Therepairs
arelistedinTable201anddescribedinmoredetailinthefollowing
text.
NOTE: ForDamage/RepairDataRecordingrefertoChapter51−11−15.
NOTE: FordetaileddefinitionofRepairCategoriesrefertoChapter
51−11−14.
2. SafetyPrecautions
WARNING: OBEYTHEMANUFACTURERSINSTRUCTIONSWHENYOUUSECLEANINGAGENTS,
BONDINGANDADHESIVECOMPOUNDS,SEALANTS,SPECIALMATERIALSAND
STRUCTUREPAINTS.THESEMATERIALSAREDANGEROUS.
CAUTION: REFERTOEACHREPAIRTODETERMINETHEREPAIRAPPLICABILITY.
CAUTION: USEONLYSPECIFIEDCLEANINGMATERIALSANDSOLUTIONSORTHEIR
EQUIVALENTS.THESURFACEPROTECTIONCOULDBEDAMAGED,IFUNSPECI
FIEDMATERIALSAREUSED.ITISIMPORTANTTHATTHEMANUFACTURER’S
MIXING,APPLICATIONANDTREATMENTINSTRUCTIONSAREFOLLOWED.
CAUTION: TOPREVENTDAMAGETOTHESURFACEPROTECTION,MECHANICALANDELEC
TRICALSYSTEMS,THEAREASURROUNDINGTHEREPAIRMUSTBECOVERED
WITHPLASTICFOILMASKINGTAPE.
CAUTION: OBEYTHEGIVENINSPECTIONINSTRUCTIONREFERENCEWHICHLEADSTOTHE
APPLICABLEINSPECTIONPROGRAMDEFINEDINCHAPTERSTRUCTURALREPAIR
INSPECTIONS(SRI)OFTHESRM.
3. RepairScheme
REPAIRPROCEDURE PARAGRAPH FIGURE REPAIR
CATEGORY
INSPECTION
INSTRUCTION
REFERENCE
StringerRepair−Stringer
madefromDAN2,DAN50and
comparable
4.A. 201<1> B 53−00−13−2−001−00
BondingDefectsatStringer 4.B. 202<1> − −
StringerOuterFlangeRepair 4.C. B 53−00−13−2−002−00
−Cutout 203<1> −
−ReworkofCorrosion 204<1> −
Table201
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REPAIRPROCEDURE
INSPECTION
INSTRUCTION
REFERENCE
REPAIR
CATEGORY
FIGUREPARAGRAPH
StringerRepair−Stringer
madefromDAN51B,DAN58Band
comparable
4.D. 205−208
<1> B 53−00−13−2−003−00
FloorAttachmentStringer
Repair 4.E. 209<2> B 53−00−13−2−004−00
Definitionofminimumdis
tancebetweenrepaircou
plingsorrepaircouplings
toexistingstructureparts
4.F. 210<1> A −
Table201
<1> validfor:
Section13and14
Section15:FR53.3−FR54,STGR31(LH)−STGR31(RH)(uppershell)
Section16−19
<2> validfor:
Section16−18
4. StringerandSkinStiffener−Repairs
CAUTION: THISREPAIRMUSTBEINSPECTEDATDEFINEDINTERVALS.THEACCORDING
INSPECTIONINSTRUCTIONREFERENCEISIIR53−00−13−2−001−00ANDIS
DESCRIBEDINCHAPTERSTRUCTURALREPAIRINSPECTIONS(SRI)OFTHE
SRM.INFORMYOURPLANNINGDEPARTMENTANDPROVIDETHEMWITHTHE
NECESSARYINFORMATION.
CAUTION: OBEYTHEREPAIREFFECTIVITYPERWEIGHTVARIANTANDAIRCRAFTTYPE
GIVENINTABLE202.
A. StringerRepair−StringermadefromDAN2,DAN50andcomparable
Therepairisapplicabletoformedandextrudedstringers−madefrom
DAN2,DAN50andcomparable−whenastringerisdamagedoraskinre
pairrequiresastringersplice.
NOTE: Therepairisapplicableonlyintheareasindicatedontherele
vantFigure.Therepaireffectivityofthisrepairisshownin
Table202.
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AIRCRAFT WEIGHTVARIANT
A340−2XX 000,001,002
A340−2XX 021
A340−3XX 000,001,002,003,004
A340−3XX 020,021,024,026,027,028,050,051,052
RepairEffectivityperWeightVariantandAircraftType
Table202
NOTE: RefertotheWeightVariantIdentificationListgiveninthe
IntroductionoftheSRM.ThisTableshowsallnecessaryinformation
relatedtotheweightvariantandtheirmaximumvaluesandthe
modificationassociatedtotheaircrafttype.
(1) RepairMaterials
ITEM NOMENCLATURE QTY MATERIAL/REMARKS
1−4 asshowninIllustration − RefertoFigure201
− Sealant AR MaterialNo.09−013(Referto
Chapter51−35−00)
− CleaningAgent AR MaterialNo.11−003or11−004
(RefertoChapter51−35−00)
− Pretreatmentforpainting
(Chemicalconversioncoat
ing)
AR MaterialNo.13−002(Referto
Chapter51−35−00)
− Storagepreservation(Cor
rosionpreventivetemporary
protectivecompound)
AR MaterialNo.15−005A(Referto
Chapter51−35−00)
− Storagepreservation(Cor
rosionpreventivetemporary
protectivecompound)
AR MaterialNo.15−007(Referto
Chapter51−35−00)
− StructurePaint(Polyure
thaneprimer)
AR MaterialNo.16−001(Referto
Chapter51−35−00)
− StructurePaint(Polyure
thanetopcoat,grey)
AR MaterialNo.16−002(Referto
Chapter51−35−00)
− StructurePaint(Washprim
er)
AR MaterialNo.16−020(Referto
Chapter51−35−00)
− StructurePaint(flexible
polyurethane)
AR MaterialNo.16−021(Referto
Chapter51−35−00)
(2) RepairInstructions,refertoFigure201
(a) Removeallfastenersasnecessaryfortherepair.
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CAUTION: IFTHECOMPLETEDAMAGEDSTRINGERSECTIONMUSTBECUTOUT,
USEAPLASTICWEDGETOCAREFULLYREMOVETHESECTIONAWAY
FROMTHESKIN.PLACEAMETALSHEETBETWEENSTRINGERAND
SKINTOAVOIDDAMAGETOTHESTRUCTUREDURINGTHECUTOUT
ACTION.
CAUTION: IFYOUMUSTHEATTHEREPAIRAREATOHELPSEPARATETHE
STRINGERCUTOUTFROMTHESKIN,DONOTUSEATEMPERATURE
MORETHAN130C°(266.0F°)
(b) Cutoutthedamagedsectionofthestringeranddeburrthe
edges.
NOTE: Ifpossible,leavethestringerflangeinpositionanduse
itasafillerpiece.
(c) Preparetherepairpartstosuitthedamagedareaanddeburr
edges,refertoFigure201.
(d) Attachtherepairpartsintheircorrectposition.Transferdrill
existingfastenerholesfromtheouterflangetotherepair
parts.Markanddrilladditionalholes.
NOTE: UsetransitionfitforHi−Lokfastenerinstallation(Refer
toChapter51−44−11).
(e) Removetherepairpartsanddeburrallfastenerholes.
WARNING: CLEANINGAGENT(MATERIALNO.11−003)ISDANGEROUS.
WARNING: CLEANINGAGENT(MATERIALNO.11−004)ISDANGEROUS.
(f) Cleantherepairpartsandtherepairareawithcleaningagent
(MaterialNo.11−003or11−004).
WARNING: STRUCTUREPAINT(MATERIALNO.16−020)ISDANGEROUS.
(g) Applywashprimer(MaterialNo.16−020)totherepairarea(Refer
toChapterChapter51−23−00).
WARNING: CHROMICACIDANODIZING(CAA)ISDANGEROUS.
WARNING: PRETREATMENTFORPAINTING(MATERIALNO.13−002)ISPOISON
OUS.
(h) PretreattherepairpartsbyChromicAcidAnodizing(CAA)oruse
chemicalconversioncoating(MaterialNo.13−002).
NOTE: ForprotectionbyCAAandtheapplicationofchemicalcon
versioncoatingrefertoChapter51−21−11.
WARNING: STRUCTUREPAINT(MATERIALNO.16−001)ISDANGEROUS.
(i) Applypolyurethaneprimer(MaterialNo.16−001)totherepair
parts.
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WARNING: STRUCTUREPAINT(MATERIALNO.16−002)ISDANGEROUS.
(j) Applypolyurethanetopcoat(MaterialNo.16−002)totherepair
parts.
WARNING: SEALANT(MATERIALNO.09−013)ISDANGEROUS.
(k) Applysealant(MaterialNo.09−013)tothematingsurfacesofthe
repairparts(RefertoChapter51−76−11.
(l) Attachtherepairpartsintheircorrectpositionandinstallall
fastenerswetwithsealant(MaterialNo.09−013).
NOTE: Installthefastenerswithintheapplicationlifeofthe
sealant.Ifthisisnotpossible,installatleastevery
thirdfastenerwithintheapplicationlifeofthesealant
(RefertoChapter51−76−00).
(m) Applyabeadofsealant(MaterialNo.09−013)totheedgesofthe
repairparts.
(n) Ifnecessary,applyflexiblepolyurethane(MaterialNo.16−021)
tothesealantbeads.
NOTE: RefertoChapter51−23−12forinformationaboutareasof
application.
WARNING: STRUCTUREPAINT(MATERIALNO.16−001)ISDANGEROUS.
(o) Restorethepaintfinisharoundtherepairarea.Usepolyurethane
primer(MaterialNo.16−001)andafterthatpolyurethanetopcoat
(MaterialNo.16−002).
WARNING: DONOTAPPLYSTORAGEPRESERVATION(MATERIALNO.15−005A)IN
AREAOFOXYGENEQUIPMENTANDOXYGENPIPES.
WARNING: STORAGEPRESERVATION(MATERIALNO.15−005A)ISDANGEROUS.
(p) Ifnecessary,applyacorrosionpreventivetemporaryprotective
compoundtotherepairarea.FirstapplyMaterialNo.15−005Aand
afterthatMaterialNo.15−007.
NOTE: BeforeapplicationofMaterialNo.15−007let
MaterialNo.15−005Adryforapproximately1hour.
NOTE: Thisisasupplementandmeanstopreventcorrosionin
areaswherespecialprotectionisrequired.RefertoChapter
51−23−12forinformationabouttheseareas.
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StringerRepair−StringermadefromDAN2,DAN50andcomparable
Figure201(sheet1)
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StringerRepair−StringermadefromDAN2,DAN50andcomparable
Figure201(sheet2)
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StringerRepair−StringermadefromDAN2,DAN50andcomparable
Figure201(sheet3)
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Useof5/32in.Fastenerinsteadof3/16in.Fastener
Figure201(sheet4)
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CAUTION: THISREPAIRINFORMATIONISAPPLICABLEASFOLLOWS:
−BEFOREMODIFICATION48827D42881
FORTHEEFFECTIVITYOFTHEGIVENMODIFICATIONREFERTOTHEMODIFI
CATION/SERVICEBULLETINLISTGIVENINChapter53−40−00 PageBlock
001.
B. BondingDefectsatStringer
NOTE: Thisrepairisapplicabletobondingdefectsatstringer.
(1) RepairMaterials
ITEM NOMENCLATURE QTY MATERIAL/REMARKS
− SpecialMaterial AR MaterialNo.05−027,(Referto
Chapter51−35−00)
− Sealant AR MaterialNo.09−013,(Referto
Chapter51−35−00)
− CleaningAgent AR MaterialNo.11−003,(Referto
Chapter51−35−00)
− CleaningAgent AR MaterialNo.11−004,(Referto
Chapter51−35−00)
− StructurePaint AR MaterialNo.16−001,(Referto
Chapter51−35−00)
− StructurePaint AR MaterialNo.16−002,(Referto
Chapter51−35−00)
− StructurePaint AR MaterialNo.16−003,(Referto
Chapter51−35−00)
− StructurePaint AR MaterialNo.16−020,(Referto
Chapter51−35−00)
(2) RepairInstructions,refertoFigure202.
(a) Determineareaofthedefectivebondingatthestringerusinga
bondtester.
WARNING: CLEANINGAGENT(MATERIALNO.11−003)ISDANGEROUS.
WARNING: CLEANINGAGENT(MATERIALNO.11−004)ISDANGEROUS.
(b) Removetheremainingsealantandcleantherepairareawith
cleaningagent(MaterialNo.11−003)orcleaningagent(Materi
alNo.11−004).
(c) Checktherepairareaforcorrosion.
NOTE: Ifcorrosionisfoundbetweenthestringerandtheskin,
thestringermustberepaired,refertoFigure201.
NOTE: ForremovalofcorrosionrefertoChapter51−74−00.
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(d) Markoutthefastenerspacing,refertoFigure202.
NOTE: Selectthefastenerdiameterandthefastenerspacing,de
pendingontheareaintheaircraftandtheskinthickness,
refertoFigure202.Thehighervaluesoffastenerspacing
withinthegivenlimitsarepreferred.Rivetthedebonded
stringertotheskinwithinentireframebayandfourfas
tenersbeyondeachframe.
(e) Deburrthefastenerholes.
WARNING: CLEANINGAGENT(MATERIALNO.11−003)ISDANGEROUS.
WARNING: CLEANINGAGENT(MATERIALNO.11−004)ISDANGEROUS.
WARNING: STRUCTUREPAINT(MATERIALNO.16−020)ISDANGEROUS.
(f) Degreasethefastenerholeswithcleaningagent(Materi
alNo.11−003)orcleaningagent(MaterialNo.11−004)andapply
structurepaint(MaterialNo.16−020).
WARNING: SEALANT(MATERIALNO.09−013)ISDANGEROUS.
(g) Ifthebondedjointbetweenthestringerandtheskinhassepa
ratedcompletely,applysealant(MaterialNo.09−013),referto
Chapter51−76−00.
(h) Installthefastenerswetwithsealant(MaterialNo.09−013),re
fertoChapter51−76−00.
NOTE: Ensurethattheprocessofrivetingisfinishedduringthe
curingtimeofthesealant.
(i) Rivetthebondedstringer.
WARNING: STRUCTUREPAINT(MATERIALNO.16−003)ISDANGEROUS.
(j) Sealtheedgesofthestringerandthefastenerheadswithseal
ant(MaterialNo.09−013),refertoChapter51−76−00.
NOTE: Applystructurepaint(MaterialNo.16−003)tothesealant
beadinthelowershell,refertoChapter51−23−00.
WARNING: STRUCTUREPAINT(MATERIALNO.16−001)ISDANGEROUS.
(k) Applystructurepaint(MaterialNo.16−001)tothesurfaceofthe
internalrepairarea.
WARNING: STRUCTUREPAINT(MATERIALNO.16−002)ISDANGEROUS.
(l) Applystructurepaint(MaterialNo.16−002)totheinternalsur
faceoftherepairarea.
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WARNING: DONOTAPPLYSPECIALMATERIAL(MATERIALNO.05−027)INAREA
ADJACENTTOOXYGENEQUIPMENTOROXYGENPIPES.
WARNING: SPECIALMATERIAL(MATERIALNO.05−027)ISDANGEROUS.
(m) Applyspecialmaterial(MaterialNo.05−027)orequivalenttothe
repairareainsidethelowershell,refertoChapter51−23−00.
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BondingDefectsatStringers
Figure202
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CAUTION: THISREPAIRMUSTBEINSPECTEDATDEFINEDINTERVALS.THEACCORDING
INSPECTIONINSTRUCTIONREFERENCEISIIR53−00−13−2−002−00ANDIS
DESCRIBEDINCHAPTERSTRUCTURALREPAIRINSPECTIONS(SRI)OFTHE
SRM.INFORMYOURPLANNINGDEPARTMENTANDPROVIDETHEMWITHTHE
NECESSARYINFORMATION.
CAUTION: OBEYTHEREPAIREFFECTIVITYPERWEIGHTVARIANTANDAIRCRAFTTYPE
GIVENINTABLE203.
C. StringerOuterFlangeRepair
Therepairisapplicabletoformedandextrudedstringersasfollows:
− ifastringerouterflangeisdamagedoraskinrepairrequiresa
stringerouterflangecutout(Figure203)
− iftheouterflangeofthestringeriscorroded(Figure204).
NOTE: Therepairisapplicableonlyintheareasindicatedontherele
vantFigure.Therepaireffectivityofthisrepairisshownin
Table
AIRCRAFT WEIGHTVARIANT
A340−2XX 000,001,002,
A340−2XX 021
A340−3XX 000,001,002,003,004
A340−3XX 020,021,024,026,027
RepairEffectivityperWeightVariantandAircraftType
Table203
NOTE: RefertotheWeightVariantIdentificationListgiveninthe
IntroductionoftheSRM.ThisTableshowsallnecessaryinformation
relatedtotheweightvariantandtheirmaximumvaluesandthe
modificationassociatedtotheaircrafttype.
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(1) RepairMaterials
ITEM NOMENCLATURE QTY MATERIAL/REMARKS
1 Coupling − RefertoFigure203or204
2 FillerorShim − RefertoFigure203or204
− Sealant AR MaterialNo.09−013(Referto
Chapter51−35−00)
− CleaningAgent AR MaterialNo.11−003or11−004
(RefertoChapter51−35−00)
− Pretreatmentforpainting
(Chemicalconversioncoat
ing)
AR MaterialNo.13−002(Referto
Chapter51−35−00)
− Storagepreservation(Cor
rosionpreventivetemporary
protectivecompound)
AR MaterialNo.15−005A(Referto
Chapter51−35−00)
− Storagepreservation(Cor
rosionpreventivetemporary
protectivecompound)
AR MaterialNo.15−007(Referto
Chapter51−35−00)
− StructurePaint(Polyure
thaneprimer)
AR MaterialNo.16−001(Referto
Chapter51−35−00)
− StructurePaint(Polyure
thanetopcoat,grey)
AR MaterialNo.16−002(Referto
Chapter51−35−00)
− StructurePaint(Washprim
er)
AR MaterialNo.16−020(Referto
Chapter51−35−00)
− StructurePaint(flexible
polyurethane)
AR MaterialNo.16−021(Referto
Chapter51−35−00)
(2) RepairInstruction(RefertoFigure203and/or204)
(a) Removeallfastenersasnecessaryfortherepair.
(b) Reworkthedamagedpartofstringerouterflangeanddeburrthe
edges.
NOTE: Makesurenottodamagetheadjacentstructure.
(c) Ifthereiscorrosion(RefertoFigure204):
1 Examinetherepairareaandremoveallsignsofcorrosion(Re
fertoChapter51−74−00.
2 Checkremainingthicknessoftheareafromwhichthecorrosion
hasbeenremoved.Ifthethicknessislessthan0.8mm(0.03
in.)cutouttheouterflange.
(d) Preparetherepairpartsanddeburrtheedges(Refertothe
relevantFigure).
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(e) Attachtherepairpartsintheircorrectposition.Transferdrill
existingfastenerholesfromtheouterflangetotherepair
parts.Markanddrilladditionalholes.
NOTE: UsetransitionfitforHi−Lokfastenerinstallation(Refer
toChapter51−44−11).
(f) Removetherepairpartsanddeburrallfastenerholes.
WARNING: CLEANINGAGENT(MATERIALNO.11−003)ISDANGEROUS.
WARNING: CLEANINGAGENT(MATERIALNO.11−004)ISDANGEROUS.
(g) Cleantherepairpartsandtherepairareawithcleaningagent
(MaterialNo.11−003or11−004).
WARNING: STRUCTUREPAINT(MATERIALNO.16−020)ISDANGEROUS.
(h) Applywashprimer(MaterialNo.16−020)totherepairarea(Refer
toChapter51−23−00).
WARNING: CHROMICACIDANODIZING(CAA)ISDANGEROUS.
WARNING: PRETREATMENTFORPAINTING(MATERIALNO.13−002)ISPOISON
OUS.
(i) PretreattherepairpartsbyChromicAcidAnodizing(CAA)oruse
chemicalconversioncoating(MaterialNo.13−002).
NOTE: ForprotectionbyCAAandtheapplicationofchemicalcon
versioncoatingrefertoChapter51−21−11.
WARNING: STRUCTUREPAINT(MATERIALNO.16−001)ISDANGEROUS.
(j) Applypolyurethaneprimer(MaterialNo.16−001)totherepair
parts.
WARNING: STRUCTUREPAINT(MATERIALNO.16−002)ISDANGEROUS.
(k) Applypolyurethanetopcoat(MaterialNo.16−002)totherepair
parts.
WARNING: SEALANT(MATERIALNO.09−013)ISDANGEROUS.
(l) Applysealant(MaterialNo.09−013)tothematingsurfacesofthe
repairparts(RefertoChapter51−76−11).
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WARNING: SEALANT(MATERIALNO.09−013)ISDANGEROUS.
(m) Attachtherepairpartsintheircorrectpositionandinstallall
fastenerswetwithsealant(MaterialNo.09−013).
NOTE: Installthefastenerswithintheapplicationlifeofthe
sealant.Ifthisisnotpossible,installatleastevery
thirdfastenerwithintheapplicationlifeofthesealant
(RefertoChapter51−76−00).
(n) Applyabeadofsealant(MaterialNo.09−013)totheedgesofthe
repairparts.
(o) Ifnecessary,applyflexiblepolyurethane(MaterialNo.16−021)to
thesealantbeads.
NOTE: RefertoChapter51−23−12forinformationaboutareasof
application.
WARNING: STRUCTUREPAINT(MATERIALNO.16−001)ISDANGEROUS.
WARNING: STRUCTUREPAINT(MATERIALNO.16−002)ISDANGEROUS.
(p) Restorethepaintfinisharoundtherepairarea.Usepolyurethane
primer(MaterialNo.16−001)andafterthatpolyurethanetopcoat
(MaterialNo.16−002).
WARNING: DONOTAPPLYSTORAGEPRESERVATION(MATERIALNO.15−005A)IN
AREAOFOXYGENEQUIPMENTANDOXYGENPIPES.
WARNING: STORAGEPRESERVATION(MATERIALNO.15−005A)ISDANGEROUS.
(q) Ifnecessary,applyacorrosionpreventivetemporaryprotective
compoundtotherepairarea.FirstapplyMaterialNo.15−005Aand
afterthatMaterialNo.15−007.
NOTE: BeforeapplicationofMaterialNo.15−007let
MaterialNo.15−005Adryforapproximately1hour.
NOTE: Thisisasupplementandmeanstopreventcorrosionin
areaswherespecialprotectionisrequired.RefertoChapter
51−23−12forinformationabouttheseareas.
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StringerOuterFlangeRepair−Cutout
Figure203(sheet1)
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StringerOuterFlangeRepair−Cutout
Figure203(sheet2)
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StringerOuterFlangeRepair−Cutout
Figure203(sheet3)
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Airbus A340-200 Structural Repair Manual

Brand
Airbus
Model
A340-200
Type
Structural Repair Manual
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