Training Manual

Fundamentals

Structural Repair
Manual (SRM)

Lufthansa
Technical Training GmbH For Training Purposes Only
Book No: SRM HANDBOOK TRAINING E Lufthansa Base Lufthansa
For training purpose and internal use only.
Copyright by Lufthansa Technical Training GmbH.
All rights reserved. No parts of this training
manual may be sold or reproduced in any form
without permission of:

Lufthansa Technical Training GmbH

Lufthansa Base Frankfurt

D-60546 Frankfurt/Main
Tel. +49 69 / 696 41 78
Fax +49 69 / 696 63 84

Lufthansa Base Hamburg

Weg beim Jäger 193
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Tel. +49 40 / 5070 24 13
Fax +49 40 / 5070 47 46
Lufthansa Technical Training
STRUCTURAL REPAIR MANUALS INTRODUCTION
MANUALS

AIRCRAFT MANUALS INTRODUCTION

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GENERAL
The Aircraft Manuals have been prepared by the Airplane manufacturers, for Specification Number 100 :
example Boeing Commercial Airplane Company or Airbus Industries, in accor- -- Specifications for Manufacturers Technical Data.
dance with the Air Transport Association of America
This specification is the industry’s recommended format and contains standards
for technical manuals written by aviation manufacturers and used by airlines and
others in the aviation industry.

TYPES OF MANUALS
Customize Manuals Non-customize Manuals but not Type-effective
The following Manuals are supplied to the customer, they are type effective These Manuals are non--customized and not type effective. They are contai-
and reflect the customers configuration: ning cross references, typical procedures and standard information.
AMM Aircraft Maintenance Manual CMM Component Maintenance Manual
MM Maintenance Manual NDT Non-- Destructive Testing Manual
IPC Illustrated Parts Catalog SM Standards Manual
AIPC Aircraft Illustrated Parts Catalog SPM Standard Practice Manual
WDM Wiring Diagram Manual TEM Illustrated Tool and Equipment Manual
WBM Weight and Balance Manual
Non-customize Manuals but Type-effective
SOPM Standard Overhaul Practice
Other manuals are non-- customized, but type effective, that means, that the
content belongs to the hole fleet of that type.
SRM Structural Repair Manual
TSM Trouble Shooting Manual
EIPC Engine Illustrated Parts Catalog
PBM Power Plant Built-- up Manual
EM Engine Manual
ARM Aircraft Recovery Manual
SSM System Schematics Manual
Nur zur Schulung

FIM Fault Isolation Manual

FRM Fault Reporting Manual

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MANUAL ARRANGEMENT
The subject matter in the manual is divided into chapters and groups of chap-
ters to facilitate the location of information by the using personnel. This chapte-
rization provides a functional breakdown of the entire airplane. Information on
all units comprising a system will be found in the chapter identified by the
name of that system or by a general name indicative of the several systems
which may be covered in this chapter.
Thus, all units relating to the generation and distribution of electrical power are
covered in the chapter 24, ELECTRICAL POWER, while electrically driven
pumps and valves serving the fuel system are covered in chapter 28, FUEL.
Also all units of the elevator control system, hydraulic, mechanical, and electri-
cal units, are included in chapter 27, FLIGHT CONTROLS.
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ATA 100 (CHAPTER AND TITLE)

AIRCRAFT 49 Airborne Aux. Power
5 Time Limits
STRUCTURES
6 Dimensions and Areas
51 Structure General
7 Lifting and Shoring
52 Doors
8 Leveling and Weighing
53 Fuselage
9 Towing and Taxing
54 Nacelles and Pylons
10 Parking and Mooring
55 Stabilizers
11 Required Placards
56 Windows
12 Servicing
57 Wings
13 Processes And Procedures
PROPELLERS / ROTOR
AIRFRAME SYSTEMS
60 Propellers and Rotors Standard Practice
20 General
61 Propellers
21 Air Conditioning
65 Rotors
22 Autopilot
23 Communications POWER PLANT
24 Electrical Power 70 Engine Standard Practices
25 Equipment and Furnishings 71 Power Plant General
26 Fire Protection 72 Engines
27 Flight Controls 73 Engine and Fuel Control
28 Fuel 74 Ignition
29 Hydraulic Power 75 Air
30 Ice And Rain Protection 76 Engine Controls
31 Instruments 77 Engine Indicating
32 Landing Gear 78 Exhaust
33 Lights 79 Oil
34 Navigation 80 Starting
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35 Oxygen 81 Turbines
36 Pneumatic 82 Water Injection
37 Vacuum 83 Accessory Gear Boxes
38 Water and Waste The detailed usage of each manual, refer to the INTRODUCTION section in
the appropriate manual.
39 Electronic Panels And Multipurpose

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REVISION SERVICE
List OF EFFECTIVE PAGES
A list of effective pages is provided in each printed manual.
The list is in numerical order and is located at the beginning of the chapter. The
pages are identified in the lower outside corner by the words:
-- List of Effective Pages and are numbered separately,
starting with page 1.
Revisions
Revision service to these manuals will be issued frequently. Pages that are
revised will be so indicated on the list of effective pages by an asterisk (*) and
identified by both, a date and a page code. On each individual page, the revi-
sed area is indicated by a revision bar on the left margin.
Temporary Revisions
Temporary revisions, printed on yellow paper, will be issued as necessary
to alert the customer of configuration differences and to provide temporary in-
struction prior to the next scheduled revision.
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AMM AIRCRAFT MAINTENANCE MANUAL

MM MAINTENANCE MANUAL
General PAGE IDENTIFICATION
The Maintenance manual contains the information necessary to enable the The four elements of page identification are:
mechanics to service, troubleshoot, functional check and repair all systems ( located at the lower page margin )
and equipment, installed in the airplane. It includes information necessary for
-- Chapter--Section--Subject Number
the mechanic to perform maintenance practices or make minor repairs to any
unit on the airplane, in the line or maintenance hangar. It covers the configura- -- Page Number
tion of the airplanes as delivered to the customer. -- Page Data
This Maintenance Manual does not contain information relative to work nor- -- Page Code Number
mally performed to units or assemblies away from the airplane.
SUBJECT NUMBERING The subjects are divided into reasonably small topics and subtopics to enable
the user to locate the desired information more rapidly.
The chapter of this manual are broken down into section and subjects. They
are numbered in a three--part subject--numbering system. The first number in The topics are:
the subject number is the CHAPTER number and serves to identify the major
-- Description and Operation,
functional system. The middle part of the number is the SECTION number and
serves to identify all of the coverage pertaining to a system, subsystem, or -- Troubleshooting and Maintenance Practices.
group of related assemblies, including all units that are functionally a part of
The subtopics are:
the system or related assemblies. The last part of the number is the SUBJECT
number and serves to identify all information relative to a specific unit, minor -- Servicing,
assemblies, simple system or simple circuit. -- Removal and Installation,
Complete system information is included in subjects, identified by the third part -- Adjustment Test,
of the subject number being a dash--zero (--0) number. The descriptions of -- Inspection Check,
units which comprise the system or subsystem are also included with the com- -- Cleaning and Painting
plete system information to the extent necessary for understanding how they
work in performing their function in the system. In those cases where the units -- Approved Repairs.
are sufficiently complex, additional description and operation type information The page blocks for these topics and subtopics are as follows:
is given at the unit level. TOPIC OR SUBTOPIC PAGE BLOCK
Description and Operation 1 to 100
Troubleshooting 101 to 200
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Maintenance Practices 201 to 300

Servicing 301 to 400
Removal and Installation 401 to 500
Adjustment / Test 501 to 600

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IPC ILLUSTRATED PARTS CATALOG

AIPC AIRCRAFT ILLUSTRATED PARTS CATALOG

The Illustrated Parts Catalog contains information for use in provisioning, re-
quisitioning, storing and issuing replaceable aircraft parts and units and in iden-
tifying parts.
SUBJECT NUMBERING
The subject numbering is the same as for the Maintenance Manual.
INDEX SYSTEM
The Numerical Index is a complete alpha--numerical listing of all part numbers,
contained in the Detailed Parts List of the Illustrated Parts catalog.
The index is divided into two sections :
-- Numerical Index--Alpha
-- Numerical Index--Numeric.
The Numerical Index also displays substitution information on interchangeable
standard parts numbers.
The Specification Cross Reference Index is divided into two sections and is
common to all customers.
The first section is titled ”Specification Number Sequence” cross--referencing
the Manufacturer Specifications to the vendor part number and vendor code.
The second section is titled ”Vendor Part Number Sequence” cross--referen-
cing the vendor part number and code to the Manufacturer specification.
The Airplane Customer, Manufacturing and Registry Number Index relates the
effectivity code shown in the Detailed Parts List to the corresponding:
-- airplane effectivity number,
-- manufacturing number
-- and registry number.
The Vendors Name and Addresses Index, with supply codes, is a list of ven-
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dors referenced in the Detailed Parts List and is common to all customers.
The list is arranged in vendor code number sequence. The Major Drawing
Number Index is an indentured breakdown denoting only the major airplane
sections and system installation drawing numbers.

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COMPONENT MAINTENANCE MANUAL (CMM )

General
The Manual describes maintenance on the component in the workshop. It does The necessary information for the description and operation, the disassembly,
not describe maintenance on the component when it is installed in the aircraft. cleaning, inspection / check, repair, assembly, fits and clearances, testing and
This manual contains technical data, maintenance and the repair procedure for fault isolation, storage instructions and the illustrated parts list.
the component. This information allows overhaul of the units, after their removal from the air-
The data and the figures of the component parts are given the separate IPC. craft, in specialized workshops.
The Aircraft Manufacturer’s Component Maintenance is comprised of
CMS Component Maintenance Sheet
-- A record of revisions,
This document is applicable to small items for which no CMM is required. The
-- A letter of transmittal, component maintenance sheet will include the following :
-- A list of effective pages not exclusive of topics corresponding to over- -- Description
haul able units,
-- Characteristics of the item
-- An introduction
-- Diagram
-- A list of chapters
-- Fits and clearances
-- An alpha--numerical index
-- Testing
-- A tab divider per chapter
-- Storage instructions
-- A table of contents per chapter
-- Illustrated parts list
-- A Component maintenance manual for specific items and a Component
maintenance sheet for specific items.

Component Maintenance Manuals For Specific Items

The revision service will be provided in accordance with the purchase agree-
ment between the Manufacturer and the customer.
Each component maintenance manual for a specific item comprises :
-- A title page
-- A record of revisions
-- A record of temporary revisions
-- A list of effective pages
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-- A list of temporary revisions

-- A service bulletin list
-- A list of approved repairers
-- A list of materials
-- A table of contents.

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IDENTIFICATION OF THE CMM/ CMS

General List Of Ata Chapter
The CMM and CMS are classified into systems ( Chapters ) and sub--systems 23 Communications
( Sections ) each unit is identified by its part-- number ( P/N ) and assigned an 25 Equipment and furnishings
ATA 100 reference.
27 Flight controls
Information concerning all units of a system is identified by the reference of
28 Fuel
that system.
30 Ice and rain protection
-- system ( Chapter ), 27 -- Flight Controls.
32 Landing gear
In each system, the information concerning all units of sub--system is identified
by the reference of that sub--system. Thus, all components relative to the aile- 33 Lights
rons and tabs of system, ( Chapter ) 27 --Flight Controls are included in sub-- 34 Navigation
system ( Section ) 10 --Aileron and Tab. 36 Pneumatic
How to use the CMM and CMS 49 Airborne aux. power
Using the ATA reference; the manuals are classified inside the chapters in 52 Doors
ascending numerical order. Using the unit reference, in the alpha--numerical 53 Fuselage
index, identify the ATA manual reference. 55 Stabilizers
The Alpha--numerical Index 56 Windows
This is the alpha--numerical index of units having specific component mainte- 57 Wings
nance manual or CMS within the document. 76 Engine control
It comprises two columns :
-- The first column gives the part number of the unit classified alphanume-
rically,
-- and the second, the references of the corresponding manuals.

The Table Of Contents

The table of contents gives a list of component maintenance manual and CMS
for specific items, classified in ascending numerical order according to their
ATA 100 reference.
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SECTION PAGE BLOCK NUMBERING

INTRODUCTION INTRO 1 and on ASSEMBLY 701 and on
General General
Revision Service Equipment and Materials
List of Abbreviations List of Procedures
Procedure
DESCRIPTION AND OPERATION 1 and on
Storage after Assembly
General
Description and Operation SPECIAL TOOLS, FIXTURES AND EQUIPMENT 901 and on
Special Tools.. Fixtures and Equipment List
TESTING AND FAULT ISOLATION 101 and on
General
Equipment and Materials
Procedure
DISASSEMBLY 301 and on
General
Equipment and Materials
List of Procedures
Procedure
CLEANING 401 and on
Equipment and Materials
Procedure
CHECK 501 and on
General
Procedure

REPAIR 601 and on

General
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Equipment and Materials

Normal Repair
Special Repair

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SRM - USAGE / BOEING

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INTRODUCTION
The manuals have been prepared by the commercial airplane manufacturers in
accordance with the Air Transport Association of America Specification Num-
ber 100, ”Specifications for Manufacturers Technical Data”.
The manuals contain the information necessary for personnel to properly ser-
vice, maintain and repair the airplanes.

TYPES OF MANUALS
The following manuals are supplied to the customer and reflect the customers
configuration:
Maintenance Manual
Wiring Diagram Manual
Overhaul Manual
Illustrated Parts Catalogue
The following manuals are supplied to the customer in a non-customized ver-
sion:
Structural Repair Manual
Illustrated Tool and Equipment List
For detailed usage of each manual, refer to the INTRODUCTION section in the
appropriate manual.
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Figure 1 Manual Overview

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CHAPTERIZATION
The subject matter in the manuals is divided into chapters and groups of chap-
ters to facilitate the location of information by the using personnel. This chap-
terization provides a functional breakdown of the entire airplane. Information on
all units comprising a system will be found in the chapter identified by the
name of that system or by a general name indicative of the several systems
which may be covered in this chapter.
Thus, all units relating to the generation and distribution of electrical power are
covered in the chapter 24, ELECTRICAL POWER, while electrically driven
pumps and valves serving the fuel system are covered in chapter 28, FUEL.
Also all units of the elevator control system, hydraulic, mechanical, and electri-
cal units, are included in chapter 27, FLIGHT CONTROLS.
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ATA CHAPTERS
Aircraft: Power Plant:
TIME LIMITS / MAINTENANCE CHECKS 5 POWER PLANT 71
DIMENSIONS AND AREAS 6 ENGINE 72
LIFTING AND SHORING 7 ENGINE FUEL AND CONTROL 73
LEVELLING AND WEIGHING 8 INDICATION 74
TOWING AND TAXIING 9 AIR 75
PARKING AND MOORING 10 ENGINE CONTROLS 76
SERVICING 12 ENGINE INDICATING 77
EXHAUST 78
Airframe Systems: OIL 79
STANDARD PRACTICES--AIRFRAME 20 STARTING 80
AIR CONDITIONING 21
AUTOFLIGHT 22
COMMUNICATIONS 23
ELECTRICAL POWER 24
EQUIPMENT / FURNISHING 25
FIRE PROTECTION 26
FLIGHT CONTROLS 27
FUEL 28
HYDRAULIC POWER 29
ICE AND RAIN PROTECTION 30
INSTRUMENTS 31
LANDING GEAR 32
LIGHTS 33
NAVIGATION 34
OXYGEN 35
PNEUMATIC 36
WATER / WASTE 38
AIRBORNE AUXILIARY POWER 49

Structure:
STRUCTURES 51
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DOORS 52
FUSELAGE 53
NACELLES/PYLONS 54
STABILIZERS 55
WINDOWS 56
WINGS 57

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EFFECTIVITY
The SRM is non-customized. Applicability is shown by descriptive title (e.g.,
airplanes with main cargo door) or by line number.
Data which have no effectivity designations are used to define configuration
differences between airplanes.

LIST OF EFFECTIVE PAGES

A list of effective pages is provided in each chapter in printed manuals. The list
is a numerical list of effective pages for the chapter and is located at the begin-
ning of the chapter. The pages are identified in the lower outside corner by the
words LIST OF EFFECTIVE PAGES and are numbered separately starting
with page 1.

NORMAL REVISION SERVICE

Revision service to this manual will be issued frequently. Pages that are re-
vised will be so indicated on the list of effective pages by an asterisk (*) and
identified by both a date and a page code. On each individual page, the re-
vised area is indicated by a revision bar on the left margin.

TEMPORARY REVISION SERVICE

Temporary revision, printed on yellow paper, will be issued as necessary to
alert the customer of configuration differences and to provide temporary
instruction prior to the next scheduled revision.
Temporary revisions will be also issued as a result of a customer request for
planned incorporation of a service bulletin.
Each temporary revision will apply to one subject only and will be keyed within
this manual so that the temporary revision will be filed adjacent to the affected
pages.
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Figure 2 SRM Effectivity

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INTRODUCTION CHAPTER 52 - 57
General Topics
The structural repair manual (SRM) has been prepared in accordance with Air Each chapter is sub-divided further into sections and subjects. Section num-
Transport Association Specification Number 100 (ATA Spec. 100). bers indicate a sud-division of a major area (e.g. fuselage section 41, wing
The SRM is available either as a printed manual or on microfilm. It will also be center section). The subject numbers are allocated to the structural elements
intruduced on CD-ROM in the near future. (e.g. skins, stringers, etc)

Coverage Chapter 52 - 57 contain three basic topics:

The purpose of the SRM is to provide data on the field repair of primary and Page Block 1 - 99 Structure Identification
secondary structure. Data in this manual which affects structural integrity is
Page Block 101 - 199 Allowable Damage
FAA approved prior to application.
Page Block 201 - 999 Repairs
Where repairs are not included, it does not follow that the structure concerned
is not repairable. Either it has not been found practicable to design a typical
repair, or service experience has not yet indicated a requirement.
Consider the following when typical repairs are not found:
Accomplish a repair in accordance with the general repair practices and
procedures provided in chapter 51 of the SRM
Replace the part
In some instances, an adequate repair design has to be prepared by engi-
neering and will require evaluation by the manufacturer.
Manual Arrangement
The manual is divided into the following chapters:
Chapter 51 - Structures, General
Chapter 52 - Doors
Chapter 53 - Fuselage
Chapter 54 - Nacelles and Pylons
Chapter 55 - Stabilizers
Chapter 56 - Windows
Chapter 57 - Wings
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Figure 3 Standard Number System

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SRM - CHAPTER 51
Chapter 51 deals with those subjects which are general in nature to the entire Cold Working
structure of the airplane. It contains the following subjects: Strength Values
General Information: Support of Airplane for Repair:
Major Assembly Breakdown Details of supports and loads which can be applied at various points on the
Principal Dimensions structure.
Structure Classification
Alignment or Symmetry Checks:
Abbreviations
Means of checking for significant deformation of the structure.
Damage Removal:
Composite Repair Instructions
Approved methods for damage clean-up.
Detailed repair instructions for all composite fabric components including
Aerodynamic Smoothness: wet lay-up repairs and hot bonding repairs to fibreglass, carbon fibre, ara-
mid fibre as well as hybrid fabric components and sandwich components.
Requirements and recommendations for flight safety and economic re-
asons.
Processes and Procedures:
General procedures such as protective treatment, hardness testing and fire
damage evaluation.
Materials:
Sheet Metal
Minimum Bend Radii
Extrusions and Formed Sections
Non-metallic Materials
Substitution Data
Fasteners:
Fastener Codes
Installation and Removal
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Substitution Data
Torque Values
Hole Sizes
Edge Margins
Countersinking

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Figure 4 Manual Number System

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Manual Arrangement and Number System (Continued)

In chapter 52 through 57 the data included in a CHAPTER-SECTION is divi-
ded into specified SUBJECT-NUMBERS :
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Figure 5 Manual Number System (Continued)

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MANUAL USAGE
The structural repair manual is divided into three topics :
Identification
Allowable Damage
Repair
The relevant procedures to find the applicable topic will be described on the
following pages.
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Figure 6 How to Use the Manual

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STRUCTURE IDENTIFICATION
The structure identification topics in chapters 52 - 57 illustrate significant struc-
tural components and provide details of material used for construction. They
also indicate effectivity to permit the reader to identify material on any specific
airplane. For more detailed information a drawing reference number is given in
each individual figure.
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Figure 7 Structure Identification

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ALLOWABLE DAMAGE
Allowable damage is that which is permitted without repair. Allowable damage
limitations may require minimal clean-up. Examples are blending out scratches
or the application of high speed tape. Normally the limitations are good for the
service life of the airplane. However, in some instances the damage must be
repaired after a specific time when degradation is considered to be possible.
Allowable damage data is contained in chapters 52 - 57 and is FAA approved.
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Figure 8 Allowable Damage

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Figure 9 Damage Dimension

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REPAIR INSTRUCTIONS
Ideally, repairs are designed to meet static and fatigue strength requirements
for the service life of the airplane. Practical solutions to repair problems some-
times require a repair which will not necessarily be permanent.
These are:
Time Limited Repair
Must be replaced after a specified time with a permanent repair.
Interim Repair
Must be inspected at specified intervals and replaced if there is deteriora-
tion.
Chapter 52 - 57 of the SRM cover typical repairs for general use and specific
repairs for known problems which are generally applicable to all operators. The
manual does not include specific repairs where a preventive modification is
provided in a service bulletin. Repairs in the manual are FAA approved.
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Figure 10 Repair Instructions

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Figure 11 Repair Instructions (Continued)

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DAMAGE CLASSIFICATION
General
Damages as considered in the manuals, is any cross--sectional area change or
permanent distorsion of a structural member.
Use good judgment in determining the type of significant damage to structural
material. The terms dent, crease, abrasion, gouge, nick, scratch, crack, corro-
sion, etc. referred to elsewhere in the manuals, are defined on the next pages
as a guide for this determination, particularly with respect to the external skin
of the airplane in panel areas.
Damages are classified in the following three categories:
1. Allowable Damage
Damage or distorsion which can be permitted to exist as it is or which may be
corrected by a simple procedure, such as stop drilling cracks or smoothing out
nicks is classified as allowable damage. The extent of allowable damage for
the major assemblies and component parts are defined in the corresponding
chapters of the Structural Repair Manual (SRM).
2. Repairable Damage
Damages which exceeds the ”Allowable Damage” limits be repaired by cutting
out the damaged area of structural component and inserting or attaching a re-
inforcing piece. These specific repairs are to be found in each chapter of the
SRM.

3. Replacement of the Part

Replacement of the entire part is suggested when repair of the part is not prac-
tical or economical. In some cases damage may necessitate replacement of
the part. These are specifically noted in other chapters of the manual. Replace-
ment is often advisable when damage to a complicated part is extensive or the
damaged part is less than 30 inches long.
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Figure 12 Damage Classification

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TYPES OF DAMAGE
Dent Corrosion
A dent is normally a damage area which is depressed with a normal contour. Corrosion is a damage area of any size and depth which results in a cross--
There is no cross--sectional area change. Its form is generally the result of sectional area change caused by chemical or electrochemical action. Depth of
contact with a smoothly contoured object. such pitting damage must be determined by a clean up operation.
Crease Debonding
A damage area which is depressed or folded back upon itself in such a manner Debonding is the separation of the face sheet from the core material or the rib
that its boundaries are sharp or well defined lines or ridges. Consider it to be flange, stringer, etc. usually caused by cycling/fatigue.
the equivalent of a crack.
Delamination
Abrasion Delamination is the separation of a laminate into its constituent layers.
An abrasion is a damage area of any size, which results in a cross--sectional
area change due to scuffing, rubbing, scraping or other surface erosion. It is Burn Marks (Lightning Strikes)
usually rough and irregular. Burn marks / lightning strikes are usually spot formed welded damages with
discolouration of the material.
Gouge
A gouge is a damage area of any size, which results in a cross--sectional area Hole
change. It is usually caused by contact with a relatively sharp object which pro- A hole constitutes a complete penetration of the surface. It is usually caused
duce a continuous sharp or smooth channel--like groove in the material. by impact of a sharp object.

Nick
A nick is a local gouge with sharp edges. Consider a series of nicks, in a line
pattern to be equivalent to a gouge.

Scratch
A scratch is a line of damage of any depth in the material and results in a
cross--sectional area change. It is usually caused by contact with a very sharp
object.
Crack
A crack is a partial fracture or complete break in the material with the most sig-
nificant cross--sectional area change. In appearance, it is usually an irregular
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line and is normally the result of fatigue failure.

Distorsion
Any twisting, bending or permanent strain which results in misalignment or
change of shape. May be caused by impact from a foreign object, but is usu-
ally result from vibration or movement of adjacent attached components.

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DELAMINATION
CRACK
NICK CREASE

DEBONDING (STRINGER)

SCRATCH GAUGE ABRAISON

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DENT BURNING MARKS HOLE DISTORSION

Figure 13 Types of Damages

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SRM - EXAMPLE / BOEING

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CLASSROOM EXAMPLE

DAMAGE DESCRIPTION:
Scratch at external skin panel at body station STA 370, between stringers
S-25 and S-26 left hand.
Scratch depth: 0,6 mm
Scratch length: 6 inches

Find the skin identification, allowable damages and, if applicable, the repair
instructions in accordance with the Structural Repair Manual.
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Section 43 Fuselage Skin Identification

Figure 14 Damage Location

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TABLE OF CONTENTS
Chapter 53 - Fuselage Page Blocks
Chapter 53 has to be selected as the appropriate SRM chapter for the damage Each section is further divided into the following page blocks:
location on a fuselage skin panel . The table of contents at the beginning of Page Block 1 - 99 Structure Identification
each chapter gives detailed information about the breakdown of the selected
Page Block 101 - 199 Allowable Damage
chapter.
Page Block 201 - 999 Repairs
Fuselage Sections
The Chapter 53 - Fuselage consists of the following sections:
53 - 00 Fuselage - General
53 - 10 Fuselage - Section 41
53 - 30 Fuselage - Section 43
53 - 40 Fuselage - Section 44/45
53 - 60 Fuselage - Section 46
53 - 70 Fuselage - Section 47
53 - 80 Fuselage - Section 48
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Figure 15 Table of Contents

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DAMAGE LOCATION
Section Identification
In order to select the right section of the fuselage chapter, it is neccessary to
locate the damaged fuselage skin in the fuselage station diagram. The different
sections of the fuselage can be seen on the bottom of the diagram.
For this example the damage is located at body station STA 370. This body
station is in the fuselage section 43, which runs from body station STA 360 to
body station STA 540. Section 43 of the fuselage refers to section 53-30 of the
fuselage chapter.
Subject Identification
In section 53-30 of the fuselage chapter, subject -01, fuselage skin has to be
selected as the right fuselage subject.
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Figure 16 Damage Location

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STRUCTURE IDENTIFICATION
Skin Identification
The fuselage subject 53-30-01, figure 1 shows a detailed drawing of the fuse-
lage skin of section 43. Here the individual skin panels are identified by item
numbers and a drawing reference number. This drawing reference number can
be used to refer to a manufacturers detail drawing of a particular skin panel.
The damage can be located on item number 4. This item is described as a
skin panel in the ”List of Material”-table of the same figure. It is manufactured
of cladded aluminum alloy 2024 - T3. The skin panel has a thickness of 0.080
of an inch and is chemically milled.
The last column of the table gives a reference to any effective applicabilities
that have to be considered on this particular item. The skin panel identified as
item number 4 has no restricted effectivity.
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Figure 17 Skin Identification

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Damage Area
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Figure 18 Skin Identification (Continued)

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ALLOWABLE DAMAGE
General Reference
In order to simplify the use of the manual all allowable damages are collected
in the general section 53-00 of the fuselage chapter and apply to all fuselage
sections.
The fuselage subject 53-30-01, figure 101 gives a reference to the general
section of the fuselage chapter, 53-00-01 for detailed information on allowable
damages to skin panels.
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Figure 19 Allowable Damage Reference

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FUSELAGE SKIN CLASSIFICATION

Fuselage Areas
In figure 101 of the fuselage subject 53-00-01, the entire fuselage is divided
into three major areas for damage classification. These areas are:
The Pressurized Crown Area from body station STA 259.5 to body station
STA 1016 and from stringer S-10 left hand over the top to stringer S-10
right hand ( ZONE 1 ).
The Pressurized Fuselage Cavity minus Crown Area ( ZONE 2 )
The Unpressurized Fuselage Cavity from body station STA 1016 to body
station STA 1217 (Section 48) ( ZONE 3 ).
For the example the damage is located between stringer S-25 and S-26 left
hand at body station STA 370 and therefore in the lower lobe.

Aerodynamic Smoothness
The critical aerodynamic area of the fuselage is identified from body station
STA 130 to body station STA 663.75 and can be of importance for the repair
selection in terms of aerodynamic smoothness. From body station STA 663.75
to the end of the fuselage the area is considered to be aerodynamically not
critical.
For the example the damage at body station STA 370 is located in the critical
aerodynamic area.
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Figure 20 Fuselage Skin Classification / FIGURE 102

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DAMAGE CLASSIFICATION
Types of Defects
The chart in figure 101 of the fuselage subject 53-00-01 gives all types of de-
fects that can be considered for a fuselage damage. These are:
Cracks
Nicks, Gouges and Corrosion
Dents
Holes
Wrinkles and Buckles
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” Knife Edges”
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Figure 21 Damage Classification

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Figure 22 Damage Classification (Continued) / FIGURE 103

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Figure 23 Damage Classification (Continued) / FIGURE 104

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Figure 24 Damage Classification (Continued)

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REPAIR SELECTION
General Reference
In order to simplify the use of the manual all repair instructions are collected in
the general section 53-00 of the fuselage chapter and apply to all fuselage sec-
tions.
The fuselage subject 53-30-01, figure 201 gives a reference to the general
subject 53-00-01. All repairs applicable to the fuselage skin are listed here in
figure 201.
For the example an EXTERNAL REPAIR for damage at a lower lobe lap splice
has to be selected.
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Figure 25 Repair Selection

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REPAIR INSTRUCTIONS
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Figure 26 Repair Instructions

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Figure 27 Repair Instructions (Continued)

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Figure 28 Repair Instructions (Continued)

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Figure 29 Repair Instructions (Continued)

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SRM - USAGE / AIRBUS

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INTRODUCTION
Manufacturers publish Structural Repair Manual (SRM) to provide data for the It is indented that, in the event of a major damage, the information included in
structural maintenance of commercial airplanes which have sustained structu- the manual be supplemented as required by direct liaison with the repair assi-
ral damage. gned Manufacturer Customer Support Representative.
The Manuals are approved by the Aircraft Manufacturers Aviation Authority, For ordering structural repair parts, see Spare Parts Identification,
for example : located in the 00-- Introduction Part.
D.G.A.C.: Direction Générale De L‘Aviation Civile ( France ) The manual will serve as a medium through which the airplane operators will
FAA : Federal Aviation Administration ( USA ) be advised of actual repairs with general-- interest nature, designed by the Ma-
They are available as hardcopy, microfilm or soon on CD-- ROM. nufacturer or by the airplane operator.
As originally issued, the Structural Repair Manual contains :
material identification for structure subject to field repair SERVICE BULLETINS
typical repairs general applicable to structural components of the airplane Service bulletins which have incorporated are listed in the
that are most likely to be damaged 00 -- Introduction section.
information relative to material substitution Service Bulletins are recommendations from Manufacturer, which are not ur-
fastener installation gent to put into action.
airplane alignment check procedure and a brief description of procedures
that must be performed concurrently with structural repair, such as protec-
tive treatment of repair parts and sealing of integral fuel tanks
Either it has not been found practicable to design a typical repair, or service
experience has not yet indicated a requirement. In some instances, an ade-
quate repair design will require evaluation by the Manufacturer.
Consider the following when typical repairs are not found :
Accomplish a repair in accordance with the general repair practices and
procedures provided in chapter 51 -- Structures General -- of the manual
Preparing a specific repair design for the damage not covered
Replacing of the damaged part
As service experience indicates a requirement, the manual will be revised to
include actual, specific repairs to both primary and secondary structures.
To ensure consistent handling of these revisions, index categories have been
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established for all known types of repairs, although some information which
falls within these categories will not be released until warranty service expe-
rience.

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Figure 30 Typical Microfilm

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REVISION SERVICE
List of effective pages
The SRM is provided with a List of Effective Pages. All pages are listed in se- Temporary revisions will not be revised if changes are required to an existing
quence, together with their latest revision date. In Airbus Manuals the list is temporary revision, the temporary revision will be reissued.
located in every ATA Chapter. ( Boeing provides it in the Manuals Introduction.)
The List of Effective Pages will be revised with each regular revision of the Ma-
nual.
Regular revision service
Revision service to the manual will be issued periodically.
Each manual takes a revision number and date of issue on the outside label,
to check the effectivity of the hole Manual by a document list.
Pages which are revised will be so indicated on the list of effective pages by an
asterisk (*) and identified by a date. A revised page may be dated prior to, or
as same as, the date of the revision cycle.
On each individual page the revised area is indicated by a revision bar on the
left margin. Those pages which have not been technically revised, but have
been reprinted due to recomposition, are also indicated by a revision bar be-
side the chapter / section and page number or date.
Temporary revision service
Temporary revision service to the manual will be issued as necessary to alert
the customer of configuration differences and to provide temporary instructions
prior to the next scheduled revision.
Temporary revision will also be issued as a result of a customer request for
planned incorporation of a service bulletin.
Each temporary revision will be incorporated into the manual within 90 days
from date of issuance, except from those temporary revisions, issued as a re-
sult of planned incorporation of a service bulletin.
These service bulletin temporary revisions will remain active until the
Manufacturer has been advised by the customer that incorporation of the ser-
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vice bulletin into the airplane has been completed.

Each temporary revision will apply to one subject only and will be keyed within
this manual, so that the temporary revision will be filed adjacent to the affected
pages.

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CHAPTERIZATION
In accordance with the ATA Specification No. 100, the material presented in
this manual is divided into seven chapters.

Chapter numbers
Chapter 51 Structures -- General
Chapter 52 Doors
Chapter 53 Fuselage
Chapter 54 Nacelles / Pylons
Chapter 55 Stabilizers
Chapter 56 Windows
Chapter 57 Wings

SECTION NUMBERING
Chapter numbers are sub-- divided into section numbers. In some instances
specific section number allocations are made to cater for structural variations
between model differences.

CHAPTER 51
Chapter 51 deals with those subjects which are general in nature to the entire
structure of the airplane. It is arranged to allow maximum utilization of common
data. The assigned section numbers are as follows:
Chapter Section
Number Nomenclature
51--00 General
51--10 Investigation, Clean up of Damage and
Aerodynamic Smoothness
51--20 Processes and Procedures
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51--30 Materials
51--40 Fasteners
51--50 Support of Airplane for Reparand Symmetry Check
51--60 Control Surface Balancing
51--70 Repairs

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Figure 31 Chapter 51 Content

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CHAPTER 52 -- 57
Chapters 52 thru 57 deal with major airplane components.
The section numbers are assigned for specific components with the major
grouping.
There are differences between old types of Structural Repair Manuals
and new types.
Old manual types, for example : Airbus A300 are containing a different
section numbering.
The Table of Contents in each ATA Chapter will show the specific section
numbering in accordance to the type of manual.

Example :

Airbus A 300
Chapter 53 Fuselage
53 -- 11 -- XX Nose Fuselage ( Section 11 / 12 )

Airbus A 320
Chapter 53 Fuselage
53 -- 10 -- XX Nose Fuselage ( Section 11 / 12 )
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SUBJECT NUMBERING
Subject numbers within the chapter/section structure of Chapter 51 will be as-
signed sequentially. 5X--XX --30 Auxiliary
In Chapter 52 thru 57 a consistent numbering system will be applied. --31 thru
The subject numbers that have been assigned are shown below. Each section --49 not used
will only use the subject numbers applicable to the structural elements that are --50 Floor Structure
described in the section. --52 Seat Tracks
This will mean that the subject numbers are not necessarily sequential, but it is --53 Cargo Compartment Special Structure
anticipated that regular manual users will become familiar with the consistent
--54 thru
number system and will be able to turn directly to their area of interest.
--69 not used
Subject numbers assignment --70 Fillets and Fairings, Skins and Plating
Chapters 52 thru 57 --72 Radomes and Antenna Fairings
--73 thru
5X--XX --00 General --89 not used
--01 Skins and Plates --90 Attachment Fittings
--02 Structure Complete --91 thru
--03 Stringers and Skin Stiffeners --99 not used
--04 Intercostals
--05 Longerons
--06 Formers
--07 Frames
--08 Bulkheads
--09 Ribs
--10 Spars
--11 Intermediate, Auxiliary and Subspars
--12 Keel Structure
--13 Beams
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--14 Landing Gear Support Structure

--15 Door Surround Structure
--16 Edge Members
--17 thru
--29 not used

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PAGE BLOCK ALLOCATION

In Chapters 52 thru 57 each subject represents a structural element. All of the
data concerning that element are covered within that subject. To provide topic
separation page blocks are used.

IDENTIFICATION : Page 1 to 99

ALLOWABLE DAMAGE : Page 101 to 199

REPAIRS : Page 201 to 999

Chapter 51 has no identifying page block. In this case a description page block
could extent up to page 199.

Note :
Structural Repair Manuals for airplane types, like Airbus A300 differ in the
page block:
The Airbus A300 SRM includes the following page blocks :
Description Page 1 to 100
Identification Page 101 to 500
Restricted Areas Page 501 to 600
Permissible Damage Page 601 to 700
Repairs Page 701 to 1000

Figure numbering
Figure numbers are to be allocated sequentially within page blocks. Figure
numbers in page block 1 thru 99 will start at Fig. 1, in page block 101 thru 199
at Fig. 101 and in page block 201 at Fig. 201.
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DAMAGE CLASSIFICATION
The term ’Damage’ includes any and every type of permanent deformation or
alteration to any cross--section of a structural component.
Deformation or alteration to the cross--section of a structural
component results from many causes, which can be generally categorized into
four main groups:
mechanical action
chemical or electrochemical reaction
thermal action or cycling
inherent metallurgical characteristics
Examination of damage
Examine the type and extent of the damage, to determine the damage cate-
gory.
Remove all unwanted material from the surface of the damaged component,
cut out all broken, bent, heated or badly damaged areas of the component,
remove all loose rivets.
In all forms of damage, particularly where shock has been sustained, secon-
dary damage is likely to exist. Therefore, a close examination of the structure
surrounding the initial damage must be made. Damage caused by transmis-
sion of force may be located some distance from the impact, resulting in struc-
ture deformation, drawn rivets or bolt holes.
If misalignment or twisting of the airplane structure is suspected,
alignment and/or leveling checks must be carried out.
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DAMAGE CATEGORIES
Non allowable damage
Damage which exceeds the ”Allowable Damage” limits can be repaired by cut- For example, in the case of corrosion, you first remove the corrosion and then
ting out the damaged area of a structural component and inserting or attaching examine the extent of the damage.
a reinforcing piece. These specific repairs are to be found in each chapter of
this manual. Compare the extent of the damage with the allowable damage limits.
Operating limits are defined as the limit for airplane operation with a damage
Non repairable damage beyond allowable damage defined above.
Non--repairable damage is defined as damage to structural components, which Example of acceptable airplane operation : before xx flight cycles.
cannot be repaired and where replacement of the complete component is re-
commended as a repair is not practical or economical.
Refer to Chapter 51 for ’Replacement of Structural Components’.
After cleaning and investigating the damage and surrounding area, the da-
mage must be classified into one of the following categories, also taking into
account the location of the damage.

Repairable damage
The damage must be classified either as ’Allowable Damage’ or as damage
which requires a repair.

Allowable damage
Allowable damage is defined as a minor damage which does not affect the
structural integrity or decrease the function of a component.
Allowable damage values specified in each chapter are by definition establis-
hed in such a way that damage within that limit does not require a structural
repair during the design life goal of the airplane, for example 48000 flight cy-
cles.
Although no structural repair is necessary, it does not mean that
no action has to be taken.
Minor repairs, such as blend out of a scratch or restoration of protective treat-
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ment is generally required.

Clean the area before examination in order to see if the damage is within allo-
wable limits.

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DEFINITION OF DAMAGE
Scratch
A scratch is a line of damage of any depth and length in the material which
causes a cross--sectional area change. A sharp object usually causes it. Corrosion
The destruction of metal by chemical or electro--chemical effect.
Gouge
A gouge is a damage area of any size which results in a cross--sectional area Abrasion
change. It is usually caused by contact with a relatively sharp object, which An abrasion is a damage area of all sizes which causes change in a cross--
produces a continuous, sharp or smooth channel -- like groove in the material. sectional area because of scuffing, rubbing, scraping or other surface erosion.
It is usually rough and irregular.
Mark
A mark is a damage area of all sizes were a concentration of scratches, nicks, Debonding
chips, burrs or gouges etc. is shown. You must prepare the damage as an area Debonding is when a separation of materials occurs due to an adhesive failure.
and not as a series of individual scratches, gouges etc.
Delamination
Crack Delamination is when the separation of plies occurs in a multi--laminate mate-
A crack is a partial fracture or complete break in the material. rial. This can be caused by the material being hit -- impact, or when there is a
resin failure for any other reason.
Dent
A dent is a damaged area which is pushed in, with respect to its usual contour. Fretting
There is no cross--sectional area change in the material, area edges are Surface damage at the interface between elements of the joints resulting from
smooth. very small angular or linear movements. Evidence of fretting is usually the pro-
duction of fine black powder staining.
Nick
A small decrease of material due to a knock at the edge of a member or skin.
Distortion
Any twisting, bending or permanent strain which results in misalignment or
change of shape. May be caused by impact from a foreign object, but usually
results from vibration or movement of adjacent attached components.
This group includes bending, buckling, deformation, imbalance, misalignment,
pinching and twisting.
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Figure 32 Damage Classifications

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PROCEDURE FOR MANUAL USAGE

The following procedure is recommended for the efficient use of the Structural
Repair Manual : Within every chapter, except 56, any subject which contains the word ”repair”,
Check for allowable damage. lists each repair figure number and title which is applicable to the specific sub-
ject.
From the Table of Contents of the manual find the chapter to which the dama-
ged part belongs. Look for all the Cross--References to the Maintenance Manual,
Process Specifications and Standard Practice Manuals.
Turn to the Table of Contents of the selected chapter, find subject number of
Allowable Damage.
Damage Classification-- General, to determine if the damage is allowable.
Identify the damaged part.
If it is found that the damage exceeds the allowable, the part must be identified
in order to determine the applicable repair figure.
From the Table of Contents of that chapter, find subject number of identification
figure, that includes the damaged part.
Find the item number of the damaged part from the identification figure .
Check modification status of the damaged part.
Turn to tabulation sheet of the identification figure. Find the applicable repair
figure number.
Apply repair figure to actual damage.
Turn to the repair figure mentioned above, read notes and instructions care-
fully, and perform the repair according to the figure.
Use the Table of Contents, at the beginning of each chapter, as a numerical
index to locate a specific subject within a specific section of a chapter.
Read all the text material, supporting figures and references within a specific
subject.
Chapter 51 lists the sections and subsections generally applicable
(except when limited) to the entire airplane.
Chapters 52,53, 54, 55, 56, and 57 list such sections and subjects which are
applicable respectively to those specific chapters only.
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The use of the table of contents to locate specific repairs, supplements the in-
formation given above.

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AIRPLANE EFFECTIVITY DESIGNATIONS

This non--customized Structural Repair Manual contains information applicable
to the airplanes, listed in the Airplane Effectivity Allocation List, located in the
Introduction part of the SRM.
They relate current operator code, airplane model series designation, manufac-
turers serial number (MSN), and customer abbreviation.
Pages that have no effectivity designation are applicable to all airplanes. Ef-
fectivity designations are used to define configuration differences between air-
planes.
Effectivity designation will appear in one of the following forms:
Use of the customer abbreviation code, such as AFR or DLH, indicates that
the information is applicable to all airplanes of that customer.
Use of the effectivities Manufacturers Serial Number, shown as (B) Before or
(A) After modification.
All modifications are shown in the Modification / Service Bulletin List.
Use of a generic designator which includes a readily identifiable feature.
For example :
for airplanes with optional forward airstairs,
or which is related to model, like : A 320

Airplane allocation list Airbus A320

Containing information about :
Aircraft Manufacturer Serial Number
Aircraft Type
Version Number
Customer
Customer Abbreviation
Registration Number
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Example, Key to figure 5

Containing informatins about:
Item number
Nomenclature
Specification
Partnumber
Action or repair
Modification status

Modification status
To find out the modification status, it is nessesary to check the
Modification / Service Bulletin list, located at the beginning of the applicable
chapter or subchapter.
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Figure 33 Modification Status

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INBOARD FLAP
Modification/Service Bulletin list
Structural arrangement
Identification scheme
Allowable damage
Repair limits
Repair instructions
Repair layout
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Figure 34 Structural Arrangement

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Figure 35 Modification Status

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INBOARD FLAP IDENTIFICATION SCHEME

(Refer to figure 1:)

Item Name Refer to

1 Skins and plating 57--52--11
2 Structure complete 57--52--21
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Figure 36 Inboard Flap Upper Skin (Fig.1)

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Figure 37 Inboard Flap Lower Skin (Fig.1)

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Figure 38 Key to Figure 1

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INBOARD FLAP -- ALLOWABLE DAMAGE

General
This topic contains the allowable damage and related data applicable to the Repair limits
inboard flap structure. The repair limits data gives the time limits in which to make temporary and per-
This data is necessary to find the correct repair procedure. manent repairs.
These time limits are given in flight hours (FH).
Damage evaluation The repair limits also tell if it is necessary to make a room temperature (RT) or
Before you repair the damage structure, you must do a damage evaluation. hot--bond repair.
Refer to 51--77--00, page block 101, Paragraph 4 for data. To find the above given repair limits data applicable to a damage area, you
Delamination damage must know the subsequent data:
The delamination damage which can occur to the composite structure is as the repair zone applicable to the damage area
follows: the area, length or depth (as applicable) of the damage to the structure
Impact delamination the type of structure (for example, monolithic or honeycomb)
This is when an object has through the plies and the honeycomb core and se- the type of damage (for example: scratches, abrasion, cracks, impact dela-
paration is usually caused between many of the plies. mination, delamination and debonding)
The repair limits for the inboard flap structure are in Figure 103 thru 133 in the
Distance between damaed areas sequence as follows:
There is a minimum permitted distance between areas of delamination and
between repair areas.
The dimension for this distance is given in the applicable allowable damage
and repair limits figure.
If you have less than the permitted distance between delaminated or repair
areas, work on them together as one large damage area.
Refer to Figure 102 to find out how to measure the distances between delami-
nated or repair areas.

Repair zones
Each of the components of the inboard flap structure is divided into repair zo-
nes.
These repair zones show the zones of different structural importance of the
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component. When you do a damage evaluation (Refer to Paragraph 2),

you must refer to the repair zone data.
The repair zone date for the inboard flap structure is in Figure 101,
sheet 1 and 2.

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Figure 39 Allowable Damage and Repair Limits

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Figure 40 Upper Surface inbd. Flap Repair Zones

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Immediate Immediate Temorary Repair: Temorary Repair: No

temporary or per- temporary or per- Bond with two layers of high speed tape for Permanent repair, refer to 51--77--12,
manent repair manent repair ferry flight only. paragraph 3.D.(2)

Temporary repair : Temporary repair :

Bond with high Bond with high Permanent repair, refer to 51--77--12,
speed tape. speed tape.
paragraph 3.D.(2)
Inspect every 100 Inspect every 20
FH FH

Permanent repair Permanent repair

after temporary after temporary
repair within 1000 repair within 1000
FH. FH.
Refer to Refer to
51--77--12 51--77--12
paragraph 3.D (2) paragraph 3.D (2)

DAMAGE
LENGTH

25mm 50mm 150mm mm

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(0.98in.) (1.97in.) (5.91in.) (in.)

Figure 41 Allowable Damage and Repair Limits Cracks Zone1

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DAMAGE
Depth
mm
(in.)

Refer to Fig. 105

0,35mm
(0.014in)
Immediate temporary or permanent repair. Temporary repair:
Temporary repair: Bond with high speed tape. Bond with two layers of high speed
Permanent repair after temporary repair within 100 FH, refer tape for ferry flight only.
to 51--77--12 Paragraph 3.D.(2) Permanent repair: refer to 51--77--12
Paragraph 3.D.(2)
0,25mm
(0.01in.)

0,1mm
(0.004in.)
Immediate temporary or permanent repair.
Temporary repair: Bond with high speed tape.
Permanent repair after temporary repair within 1000 FH. Fill
DAMAGE
scratches with resin.
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LENGTH
mm
25mm 50mm 150mm 200mm
(in.)
(0.98in.) (1.97in.) (5.90in.) (7.87in.)
Temporary repair not required.
Permanent repair within 1000 FH. Fill scratches with resin.

Figure 42 Scratches Zone 2

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DAMAGE
DEPTH Refer to Figure 126

70%

Temporary repair: Bond with 2 layers of high speed tape for Temporary repair: NO
ferry flight only. Permanent repair prior to next flight.
Permanent repair: refer to Page Block 201 Refer to Page Block 201

40%

Immediate temporary or permanent repair.

Temporary repair: Bond with high speed tape.
Permanent repair after temporary repair within 100 FH, refer
to Page Block 201

20%

Immediate
temporary or
10% permanent repair.
Temporary repair: Bond with high speed tape.
Permanent repair after temporary repair within 1000 FH.
Fill scratches with resin. DAMAGE
LENGTH
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50mm 150mm 200mm mm

25mm
(1.97in.) (5.90in.) (7.87in.) ( in.)
(0.98in.)
Temporary repair not required.
Permanent repair within 1000 FH. Fill scratches with resin.

Figure 43 Scratches Zone 5,6,7

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INBOARD FLAP REPAIRS

Repair index (paragraph1)

Specific repair procedure Paragraph Figure Permanent repairs

Skin repair -- Zone 1 11 A B C 201 There is one type of permanent repair for the inboard flap structure
Skin repair -- Zone 2 12 A B C 202 Laminate Repair
Skin and stringer repair -- Zone 3 13 A B C 203 To make a laminate repair you must do a hot--bond repair procedure.

Skin repair -- Zone 5,6,7 14 A B C 204 Preparation of repair parts

Skin repair -- Zone 5,6 15 A B C 205 The repair parts can be manufactured of pre--cured CFRP tape material or alu-
minum.
Skin and stringer repair -- Zone 5,6 16 A B C 206
To make a pre--cured type repair, you must manufacture the repair parts of
Skin and stringer repair -- Zone 5,6 17 A B C 207 pre--cured CFRP material.
Skin, stringer and rib repair -- Zone 7 18 A B C 208 To manufacture the repair parts made of CFRP tape you must cure them under
influence of heat (125°C/237°F) and pressure (80 % vacuum).
Refer to 51--77--11.
General These repair parts are then attached to the aircraft structure with fasteners and
This topic contains specific repair data and is applicable to the inboard flap adhesive.
structure (for general repair data applicable to composite structures, refer to
51--77--00). Note
The repair adhesive is used as shim material to a maximum thickness of
For specific repair procedures for the inboard flap structure refer to repair in-
0.5 mm (0.02 in.).
dex, paragraph 1.
Damage evaluation
Before you repair the damaged structure, you must do a damage evaluation.
Refer to 51--77--00, page block 101, paragraph 4 for data.
Types of repairs
There are three groups of repairs for the aircraft structure
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permanent repairs
temporary repairs
permanent repairs after temporary repairs

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TEMPORARY REPAIRS
You may make a temporary repair only when
flight safety is not affected adversely
you do not have the correct materials to make a permanent repair
you do not have the time to make a permanent repair
Temporary repair with high speed tape
This temporary repair procedure is in paragraph B of the specific repair proce-
dure.
Delamination repairs with fasteners
This type of temporary repair uses fasteners to hold the delaminated layers
inside the composite material together and prevent an increase in the delami-
nated area.
Refer to 51--77--13 for general data about delamination repairs.
Permanent repair after temporary repair
The permanent repair after temporary repair procedures are in paragraph C of
the specific repair procedures.
You must make a permanent repair after a temporary repair in the given flight
hour (FH) limit.
Refer to the aplicable allowable damage and repair limits data to find the FH
limits (refer to page block 101).

Special tools
To work with composite materials, it is necessary to use special tools.
Here are some examples
explosion--proof tools are necessary if you will cause CFRP dust.
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REPAIR INSTRUCTIONS
Skin Repair with CFRP tape of surface damage, Zones 5, 6 and 7
Note
Before you repair the damaged structure, you must do a damage evaluation. Fill the cavity with CFRP tape in the correct layer order until the skin thick-
Refer to 51--77--00, page block 101, paragraph 4 for data. ness is reached
For CFRP tape layer order, refer to figure 204 (sheet 1 or 2)
Permanent repair (refer to figure 204, sheet 1 or 2)
Remove any wrinkles or air bubbles with a roller or similar device
Caution make the last layer on the repair area of epoxy prepreg glass fabric
Only use a mechanical procedure to remove the surface protection. (refer to 51--33--00, item 41f)
Refer to 51--77--11, paragraph 2d. Cover with a parting film (refer to 51--33--00, item 75B) and allow to cure
Remove the surface protection from the repair area. under heat and pressure
The pressure may be applied using a vacuum bag
Warning (refer to 51--77--00, page block 201, paragraph 3.D)
The CFRP dust is dangerous. After the cure time, remove the parting film, the sticky tape and unwanted
Chamfer the damaged skin structure to the correct repair shape and dimen- adhesive from the repair area
sions (refer to figure 204, sheet 1 or 2). Use abrasive cloth to smooth the repair. Use 280 grade first and then finish
Remove the remaining rivets from the chamfer and make a drilling template with 400 grade
from stainless steel. If you have removed rivets in the chamfer, install the drilling template, drill
the holes with the correct dimensions for the new rivets and debur
Note
Remove the waste from the area with a vacuum cleaner
Abrade only the destroyed layers, but do not reduce the skin thickness to less
than given in figure 204 (sheet 1 or 2). Install the new rivets
Remove the waste from the area with a vacuum cleaner. Remaining rivets outside the chamfer but within the heated area must be
replaced
Warning
Cleaning agent (material number 11--003) is dangerous
Clean the repair area with cleaning agent (material number 11--003)
Put sticky tape around the outer edge of the overlap area
This will help you to remove unwanted adhesive from the repair area.
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Prepare the CFRP tape (refer to 51--33--00, item 66)

Cut the adhesive film (material number 08—042) to the correct dimensions
Apply the adhesive film (material number 08—042) to the repair area
Remove any wrinkles or air bubbles with a roller or similar device

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Note
It is only necessary to replace the rivets if they connect metal and CFRP parts.

Warning
Cleaning agent (material number 11--003) is dangerous.
Clean the repair area with the cleaning agent (material number 11--003)
Do an inspection of the repair
Restore the surface protection
Tell the inspection department to do an inspection every 6000 flight hours
Temporary repair
Warning
Cleaning agent (material number 11--003) is dangerous.
Clean the repair area with the cleaning agent (material number 11--003)
Put a protective layer of high--speed tape (HST)(material number 05--015C)
over the repair area
Smooth out from the center to remove air
Press the edges of the HST down tightly
Do an inspection of the repair
Tell the inspection department that persons must do a permanent repair
after the flight hours as given in the repair limits data list
(refer to page block 101)

Permanent repair after temporary repair

Remove the high--speed tape (HST)
Do all the repair steps in paragraph a (permanent repair)
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Figure 44 Skin Repair inbd. Flap Zone 5--7 (Fig. 204)

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Inhaltsverzeichnis
AIRCRAFT MANUALS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . 1 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DAMAGE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
TYPES OF MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 STRUCTURE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . 50
MANUAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3 ALLOWABLE DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ATA 100 (CHAPTER AND TITLE) . . . . . . . . . . . . . . . . . . . . 4 FUSELAGE SKIN CLASSIFICATION . . . . . . . . . . . . . . . . . 56
REVISION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DAMAGE CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . 58
AMM AIRCRAFT MAINTENANCE MANUAL . . . . . . . . . . 7 REPAIR SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
MM MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . . 7 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 68
IPC ILLUSTRATED PARTS CATALOG . . . . . . . . . . . . . . . 9 SRM - USAG E / AI RBUS ............................ 77
AIPC AIRCRAFT ILLUSTRATED PARTS CATALOG . . . 9 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
COMPONENT MAINTENANCE MANUAL (CMM ) . . . . . 10 REVISION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
IDENTIFICATION OF THE CMM/ CMS . . . . . . . . . . . . . . . 11 CHAPTERIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION PAGE BLOCK NUMBERING . . . . . . . . . . . . . . . 12 SECTION NUMBERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SRM - USAG E / BO EI NG ............................. 13 CHAPTER 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CHAPTER 52 -- 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
TYPES OF MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SUBJECT NUMBERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CHAPTERIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 PAGE BLOCK ALLOCATION . . . . . . . . . . . . . . . . . . . . . . . . 86
ATA CHAPTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DAMAGE CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . 87
EFFECTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DAMAGE CATEGORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
LIST OF EFFECTIVE PAGES . . . . . . . . . . . . . . . . . . . . . . . 18 DEFINITION OF DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 90
NORMAL REVISION SERVICE . . . . . . . . . . . . . . . . . . . . . . 18 PROCEDURE FOR MANUAL USAGE . . . . . . . . . . . . . . . . 92
TEMPORARY REVISION SERVICE . . . . . . . . . . . . . . . . . 18 AIRPLANE EFFECTIVITY DESIGNATIONS . . . . . . . . . . . 93
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SRM - EXAMPL E / AI RBUS ......................... 96
CHAPTER 52 - 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INBOARD FLAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
SRM - CHAPTER 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INBOARD FLAP IDENTIFICATION SCHEME . . . . . . . . . 101
MANUAL USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 INBOARD FLAP -- ALLOWABLE DAMAGE . . . . . . . . . . . 106
STRUCTURE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . 28 INBOARD FLAP REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ALLOWABLE DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TEMPORARY REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
DAMAGE CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . 38
TYPES OF DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SRM - EXAMPL E / BO EI NG ........................ 43
CLASSROOM EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DAMAGE DESCRIPTION: . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Bildverzeichnis
Figure 1 Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 36 Inboard Flap Upper Skin (Fig.1) . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 2 SRM Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Figure 37 Inboard Flap Lower Skin (Fig.1) . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 3 Standard Number System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Figure 38 Key to Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 4 Manual Number System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Figure 39 Allowable Damage and Repair Limits . . . . . . . . . . . . . . . . . . . . 107
Figure 5 Manual Number System (Continued) . . . . . . . . . . . . . . . . . . . . . . 25 Figure 40 Upper Surface inbd. Flap Repair Zones . . . . . . . . . . . . . . . . . . 108
Figure 6 How to Use the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Figure 41 Allowable Damage and Repair Limits Cracks Zone1 . . . . . . . 109
Figure 7 Structure Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 42 Scratches Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 8 Allowable Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 43 Scratches Zone 5,6,7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 9 Damage Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 44 Skin Repair inbd. Flap Zone 5--7 (Fig. 204) . . . . . . . . . . . . . . 118
Figure 10 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 11 Repair Instructions (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 12 Damage Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 13 Types of Damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 14 Damage Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 15 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 16 Damage Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 17 Skin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 18 Skin Identification (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 19 Allowable Damage Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 20 Fuselage Skin Classification / FIGURE 102 . . . . . . . . . . . . . . 57
Figure 21 Damage Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 22 Damage Classification (Continued) / FIGURE 103 . . . . . . . . . 61
Figure 23 Damage Classification (Continued) / FIGURE 104 . . . . . . . . . 63
Figure 24 Damage Classification (Continued) . . . . . . . . . . . . . . . . . . . . . . 65
Figure 25 Repair Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 26 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 27 Repair Instructions (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 28 Repair Instructions (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 29 Repair Instructions (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 30 Typical Microfilm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 31 Chapter 51 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 32 Damage Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 33 Modification Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 34 Structural Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 35 Modification Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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