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STRUCTURAL REPAIR MANUAL

INBOARD FLAP
1. General
These repairs are applicable for damage to the inboard flap. The repairs
are listed in Table 201 and are described in more detail in the text that
follows.
NOTE: For a detailed definition of repair categories, refer to Chapter
511114.
NOTE: For damage / repair data recording, refer to Chapter 511115.
2. Safety Precautions
WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL
MANUFACTURER INSTRUCTIONS AND YOUR LOCAL REGULATIONS.
WARNING: OBEY THE MANUFACTURERS INSTRUCTIONS WHEN YOU USE CLEANING AGENT,
PRETREATMENT FOR PAINTING, BONDING AND ADHESIVE COMPOUND, SEALANT
AND STRUCTURE PAINT. THESE MATERIALS ARE DANGEROUS.
WARNING: BE CAREFUL WHEN YOU DO WORK WITH COMPOSITE MATERIALS:
CARBON DUST IS ELECTRICALLY CONDUCTIVE AND CAN CAUSE AN EXPLO
SION. IMMEDIATELY REMOVE THE DUST WITH A VACUUM CLEANER
DO NOT USE THESE MATERIALS NEAR A FLAME, SPARKS OR SOURCES OF
HEAT
USE PROTECTIVE GLOVES, GOGGLES AND A FILTER MASK WHEN YOU CUT,
ABRADE OR DRILL CFRP MATERIALS
MAKE SURE THAT THERE IS A GOOD FLOW OF AIR THROUGH THE WORK
AREA
IF YOU GET THE DUST ON YOUR SKIN, REMOVE IT WITH SOAP AND A
FLOW OF CLEAN WATER
IF YOU GET THE DUST IN YOUR EYES, FLUSH IT AWAY WITH A FLOW OF
CLEAN WATER. GET MEDICAL AID
IF YOU GET THE DUST IN YOUR LUNGS, GO OUTDOORS IMMEDIATELY AND
BREATHE FRESH AIR. GET MEDICAL AID
OBEY THE MATERIAL MANUFACTURERS INSTRUCTIONS AND THE LOCAL REG
ULATIONS.
WARNING: BE CAREFUL WHEN YOU DO WORK WITH METALLIC MATERIALS:
USE PROTECTIVE GLOVES, GOGGLES AND A FILTER MASK WHEN YOU CUT,
ABRADE OR DRILL
OBEY THE MATERIAL MANUFACTURERS INSTRUCTIONS AND THE LOCAL REG

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ULATIONS.
CAUTION: USE ONLY SPECIFIED SOLVENTS AND CLEANING PRODUCTS, OR THEIR EQUIV
ALENTS. SOLVENTS AND CLEANING PRODUCTS THAT ARE NOT APPROVED CAN
CAUSE DAMAGE TO THE SURFACE PROTECTION.
CAUTION: MAKE SURE THAT YOU COVER THE AREA ADJACENT TO THE REPAIR WITH
PLASTIC FOIL MASKING TAPE. IF YOU DO NOT OBEY THIS INSTRUCTION,
YOU CAN CAUSE DAMAGE TO THE SURFACE PROTECTION AND TO THE MECHAN
ICAL AND ELECTRICAL SYSTEMS.
CAUTION: MAKE SURE THAT YOU OBEY THE REPAIR INSTRUCTIONS APPLICABLE TO YOUR
AIRCRAFT TYPE, WEIGHT VARIANT AND REPAIR AREA. THESE INSTRUCTIONS
ARE GIVEN IN THE APPLICABLE PARAGRAPH.
CAUTION: OBEY THE EFFECTIVITY BY MODIFICATION GIVEN IN THE RELEVANT PARA
GRAPH.
CAUTION: OBEY THE GIVEN INSPECTION INSTRUCTION REFERENCE (IIR) WHICH LEADS
TO THE APPLICABLE INSPECTION PROGRAM DEFINED IN THE STRUCTURAL RE
PAIR INSPECTIONS (SRI) OF THE SRM, IF NECESSARY.
CAUTION: FOR THE REPAIR EFFECTIVITY RELATED TO AIRCRAFT TYPE, REFER TO
PARAGRAPH 3. GIVEN IN THE INTRODUCTION OF THE SRM.
CAUTION: REPAIRS MUST NOT HINDER THE OPERATION OF MOVING COMPONENTS. IT IS
IMPORTANT TO MAKE SURE THAT ALL CLEARANCE DIMENSIONS FOR COM
PONENTS ARE KEPT WITHIN THE SPECIFIED LIMITS.
CAUTION: HIDDEN DAMAGE CAN LEAD TO A FAILURE OF THE REPAIR OR SURROUNDING
STRUCTURE.
3. Repair Scheme for Specific Repairs

PARAGRAPH

FIGURE

REPAIR
CATEGORY

INSPECTION
INSTRUCTION REF
ERENCE (IIR)

External Bonded Metal Dou


bler and Core Repair in
Zone E
This repair principle is
inactive since revision
dated Jul 01/11

4.A.
INACTIVE

201
INACTIVE

Upper and Lower Skin and


Core Repair in Zone E
This repair principle is
inactive since revision
dated Jul 01/11

4.B.
INACTIVE

202
INACTIVE

REPAIR PROCEDURE

Repairs Specific
Table 201

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STRUCTURAL REPAIR MANUAL

PARAGRAPH

FIGURE

REPAIR
CATEGORY

INSPECTION
INSTRUCTION REF
ERENCE (IIR)

Inboard Flap Trailing


Edge Replacement Procedure

4.C.

203

External Bonded Metal Dou


bler and Core Repair for
the Trailing Edge Zone E

4.D.

204

Upper and Lower Skin and


Core Repair for the Trail
ing Edge Zone E

4.E.

205

Replacement of Leading Edge


Covers

4.F.

206

Repair of Dents in the


Trailing Edge Zone E

4.G.

207

Skin between Two Stringers


Flush Repair

4.H.

208

Skin between Two Stringers


External Doubler Repair

4.I.

209

575400200100

Skin at Rib, between


Stringers Flush Repair

4.J.

210

Skin at Rib and Stringer


Flush Repair

4.K.

211

Skin at Rib and Stringer


External Doubler Repair

4.L.

212

575400200200

Rubbing Strip Temporary


Repair
This repair principle is
inactive since revision
dated Oct 01/11, it has
been moved to applicable
Chapter 575412 Page Block
201

4.M.
INACTIVE

213
INACTIVE

Rubbing Strip Permanent


Repair
This repair principle is
inactive since revision
dated Oct 01/11, it has
been moved to applicable
Chapter 575412 Page Block
201

4.N.
INACTIVE

214
INACTIVE

REPAIR PROCEDURE

Repairs Specific
Table 201

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REPAIR PROCEDURE

PARAGRAPH

FIGURE

REPAIR
CATEGORY

INSPECTION
INSTRUCTION REF
ERENCE (IIR)

Wear Resistant Paint Tem


porary Repair
This repair principle is
inactive since revision
dated Oct 01/11, it has
been moved to applicable
Chapter 575412 Page Block
201

4.O.
INACTIVE

215
INACTIVE

Wear Resistant Paint Per


manent Repair
This repair principle is
inactive since revision
dated Oct 01/11, it has
been moved to applicable
Chapter 575412 Page Block
201

4.P.
INACTIVE

216
INACTIVE

Repair of Rubbing Plate


Bonded Permanent Repair
This repair principle is
inactive since revision
dated Oct 01/11, it has
been moved to applicable
Chapter 575412 Page Block
201

4.Q.
INACTIVE

217
INACTIVE

Repair of Rubbing Plate


Riveted Permanent Repair
This repair principle is
inactive since revision
dated Oct 01/11, it has
been moved to applicable
Chapter 575412 Page Block
201

4.R.
INACTIVE

218
INACTIVE

Repairs Specific
Table 201

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4. Inboard Flap Repairs
CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS ALLOWABLE REWORK LIMITS INFORMATION IS APPLICABLE AS FOLLOWS:
BEFORE MODIFICATION 49008D42923
FOR THE EFFECTIVITY OF THE GIVEN MODIFICATION REFER TO MODIFI
CATION/SERVICE BULLETIN LIST GIVEN IN CHAPTER 575000 PAGE BLOCK
001.
A. External Bonded Metal Doubler and Core Repair in Zone E.
NOTE: This repair principle is inactive since revision dated Jul 01/11.
NOTE: This repair is applicable in Zone E when the upper or lower skin
and the honeycomb core is damaged and is valid as shown in Table
202.
AIRCRAFT

WEIGHT VARIANT

A330200

020, 021, 024, 025, 026, 027

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014
020, 024, 025

Effectivity per Weight Variant and Aircraft Type


Table 202
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
For this repair there are two different repair principles available, re
fer to the following Paragraph to get the relevant repair:
Paragraph 4.A.(2) describes a Permanent Repair at Room Temperature
(RT).
Paragraph 4.A.(3) describes a Permanent Repair Hot Bond Repair
NOTE: For the definition of the Repair Zones refer to Chapter 575400
Page Block 101.
NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710, Paragraph 3. for details and
procedure.

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(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

1
2

Doubler
Honeycomb Core
Special Material

Special Material

Special Material

Special Material

Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Sealant

Cleaning Agent

Cleaning Agent

Structure Paint

Structure Paint

Refer to Figure 201


Refer to Figure 201
AR Material No. 05007, refer to
Chapter 513500
AR Material No. 05033, refer to
Chapter 513500
AR Material No. 05089, refer to
Chapter 513500
AR Material No. 05097, refer to
Chapter 513500
AR Material No. 08001B, refer to
Chapter 513500
AR Material No. 08010, refer to
Chapter 513500
AR Material No. 08042, refer to
Chapter 513500
AR Material No. 08042A, refer to
Chapter 513500
AR Material No. 08047A, refer to
Chapter 513500
AR Material No. 08047B, refer to
Chapter 513500
AR Material No. 08055, refer to
Chapter 513500
AR Material No. 08070 (refer to
Chapter 513500
AR Material No. 08074, refer to
Chapter 513500
AR Material No. 08078, refer to
Chapter 513500
AR Material No. 09013, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
AR Material No. 11004, refer to
Chapter 513500
AR Material No. 16001, refer to
Chapter 513500
AR Material No. 16003, refer to
Chapter 513500

and Adhesive Com


and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com

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ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Structure Paint

Structure Paint

Emery Cloth

AR Material No. 16018A, refer to


Chapter 513500
AR Material No. 16021A, refer to
Chapter 513500
AR Grade 280/400, local purchase

(2) Repair Instruction Room Temperature (RT) Repair


(a) Mark the cutout according to Figure 201.
(b) Drill out all affected fastener if necessary.
(c) Cutout the damaged material. Cut the skin and the honeycomb into
a regular shape and deburr the edges.
(d) Carefully abrade the mating surface of the skin with emery cloth,
grade 400 to obtain a rough surface.
NOTE: Do not abrade the CAAlayer of the existing skin.
(e) Remove the waste from the repair area with a vacuum cleaner and
clean the repair area with cleaning agent (Material No. 11003)
or cleaning agent (Material No. 11004).
(f) Apply bonding and adhesive compound (Material No. 08074) (Mask
ing tape) around the outer edge of the overlap area. This will
help you to remove unwanted adhesive and sealant from the repair
area.
(g) Apply bonding and adhesive compound (Material No. 08055) to the
skin surface to protect the CAAlayer.
(h) Prepare the honeycomb core plug, refer to Chapter 517711, Para
graph 4.I. for details and procedure.
(i) Mix bonding and adhesive compound (Material No. 08010) or bond
ing and adhesive compound (Material No. 08078) with special ma
terial (Material No. 05089) and apply the mixed paste to the
faying surfaces of the core plug, refer to Chapter 517711,
Paragraph 5.F. for procedure.
(j) Install and fix the honeycomb core plug, let the mixed paste
cure for the defined cure cycle, refer to Chapter 517711,
Paragraph 6.B.(1) or manufacturer instructions for details.
(k) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.
(l) Prepare the repair doubler, refer to Figure 201.

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(m) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 201.
(n) Drill the required fastener holes and deburr the doubler.
NOTE: For countersinking refer to Chapter 514600.
(o) Clean the doubler and the repair area with cleaning agent (Mate
rial No. 11003) or cleaning agent (Material No. 11004).
(p) Apply bonding and adhesive compound (Material No. 08055) to the
doubler. Let bonding and adhesive compound cure according to
manufacturers instruction.
(q) Apply bonding and adhesive compound (Material No. 08001B) or
bonding and adhesive compound (Material No. 08078) to the faying
surface of the doubler.
(r) Position the doubler to the repair area and install the applica
ble fasteners if necessary, refer to Figure 201.
NOTE: Ensure that the fastener are installed during the curing
time of the bonding and adhesive compound.
(s) Let the repair cure for the defined cure cycle at RT (room tem
perature) and under pressure. To apply pressure use weights,
clamps or a vacuum bag, refer to Chapter 517711, Paragraph 5.D.
for additional information.
NOTE: The cure process can be accelerated by the use of heat,
refer to Chapter 517711, Paragraph 5.E. and 6.B.(1) for
details.
(t) Prepare special material (Material No. 05097) or bonding and
adhesive compound (Material No. 08070) (Lamination resin) and
apply a thin layer to the rear edge of the repair area if nec
essary, refer to Figure 201 and to Chapter 517711, Paragraph
6.B.(2) for mixing/curing details.
(u) Laminate the special material (Material No. 05007) or special
material (Material No. 05033) to the rear edge of the repair
area, refer to Figure 201 and to Chapter 517711, Paragraph 5.A.
for procedure and details.
NOTE: Step 4.A.(2)(t) and 4.A.(2)(u) are necessary only in case
of damage to the rear edge, refer to Figure 201.
(v) Apply sealant (Material No. 09013) to the circumferential edges
of the doubler, refer to Figure 201.
(w) Clean the repair area with cleaning agent (Material No. 11003)
or cleaning agent (Material No. 11004).
(x) Apply structure paint (Material No. 16003) or structure paint
(Material No. 16021A) to the sealant bead.

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STRUCTURAL REPAIR MANUAL


(y) Apply structure paint (Material No. 16001) to the repair area.
(z) Apply structure paint (Material No. 16018A) to the repair area
to match the surrounding structure.
(aa)Inspect the repair, refer to Chapter 517710, Paragraph 5. for
procedure and details.
(3) Repair Instruction Hot Bond Repair
(a) Carry out repair steps 4.A.(2)(a) thru 4.A.(2)(h) above.
(b) Wrap a layer of bonding and adhesive compound (Material No.
08047A) or bonding and adhesive compound (Material No. 08047B)
around the core plug and position the prepared core plug to the
cutout, refer to Chapter 517711, Paragraph 5.G. for installa
tion details.
(c) Install the required heating equipment and the vacuum bag, refer
to Chapter 517711, Paragraph 5.D. for details.
(d) Let the installed core plug cure for the defined temperature,
time and vacuum, refer to Chapter 517711, Paragraph 5.E. and
Paragraph 5.G. for details.
(e) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.
(f) Prepare the repair doubler, refer to Figure 201.
(g) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 201.
(h) Drill the required fastener holes and deburr the doubler.
(i) Clean the doubler and the repair area with cleaning agent (Mate
rial No. 11003) or cleaning agent (Material No. 11004).
(j) Apply bonding and adhesive compound (Material No. 08042) or
bonding and adhesive compound (Material No. 08042A) to the fay
ing surface of the repair area.
(k) Position the doubler to the repair area and install the required
heating equipment and the vacuum bag, refer to Chapter 517711,
Paragraph 5.D. for details.
NOTE: Fasteners inside the range of the heating blanket have to
be removed to avoid damage to the fasteners. In this case
drill out the fasteners in the heat affected area.
(l) Let the installed doubler cure for the defined temperature, time
and vacuum, refer to Chapter 517711, Paragraph 5.E. and Para
graph 5.G. for details.

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(m) If necessary, install the applicable fasteners to the doubler and
the adjacent area, refer to Figure 201.
(n) Continue with step 4.A.(2)(t) thru 4.A.(2)(aa).

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External Bonded Metal Doubler and Core Repair in Zone E


Figure 201 (sheet 1)

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External Bonded Metal Doubler and Core Repair in Zone E


Figure 201 (sheet 2)

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External Bonded Metal Doubler and Core Repair in Zone E


Figure 201 (sheet 3)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS ALLOWABLE REWORK LIMITS INFORMATION IS APPLICABLE AS FOLLOWS:
BEFORE MODIFICATION 49008D42923
FOR THE EFFECTIVITY OF THE GIVEN MODIFICATION REFER TO MODIFI
CATION/SERVICE BULLETIN LIST GIVEN IN CHAPTER 575000 PAGE BLOCK
001.
B. Upper and Lower Skin and Core Repair in Zone E
NOTE: This repair principle is inactive since revision dated Jul 01/11.
NOTE: This repair is applicable in Zone E when the upper and lower skin
and the honeycomb core is damaged and is valid as shown in Table
203.
AIRCRAFT

WEIGHT VARIANT

A330200

020, 021, 024, 025, 026, 027

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014
020, 024, 025

Effectivity per Weight Variant and Aircraft Type


Table 203
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
For this repair there are two different repair principles available, re
fer to the following Paragraph to get the relevant repair:
Paragraph 4.B.(2) describes a Permanent Repair at Room Temperature
(RT).
Paragraph 4.B.(3) describes a Permanent Repair Hot Bond Repair
NOTE: For the definition of the Repair Zones refer to Chapter 575400
Page Block 101.
NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710, Paragraph 3. for details and
procedure.

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STRUCTURAL REPAIR MANUAL


(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

1
2

Doubler
Honeycomb Core
Special Material

Special Material

Special Material

Special Material

Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Bonding
pound
Sealant

Cleaning Agent

Cleaning Agent

Structure Paint

Structure Paint

Refer to Figure 202


Refer to Figure 202
AR Material No. 05007, refer to
Chapter 513500
AR Material No. 05033, refer to
Chapter 513500
AR Material No. 05089, refer to
Chapter 513500
AR Material No. 05097, refer to
Chapter 513500
AR Material No. 08001B, refer to
Chapter 513500
AR Material No. 08010, refer to
Chapter 513500
AR Material No. 08042, refer to
Chapter 513500
AR Material No. 08042A, refer to
Chapter 513500
AR Material No. 08047A, refer to
Chapter 513500
AR Material No. 08047B, refer to
Chapter 513500
AR Material No. 08055, refer to
Chapter 513500
AR Material No. 08070 (refer to
Chapter 513500
AR Material No. 08074, refer to
Chapter 513500
AR Material No. 08078, refer to
Chapter 513500
AR Material No. 09013, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
AR Material No. 11004, refer to
Chapter 513500
AR Material No. 16001, refer to
Chapter 513500
AR Material No. 16003, refer to
Chapter 513500

and Adhesive Com


and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com
and Adhesive Com

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STRUCTURAL REPAIR MANUAL

ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Structure Paint

Structure Paint

Emery Cloth

AR Material No. 16018A, refer to


Chapter 513500
AR Material No. 16021A, refer to
Chapter 513500
AR Grade 280/400, local purchase

(2) Repair Instruction Room Temperature (RT) Repair


(a) Mark the cutout according to Figure 202.
(b) Drill out all affected fastener if necessary.
(c) Cutout the damaged material. Cut the skin and the honeycomb into
a regular shape and deburr the edges.
(d) Carefully abrade the mating surface of the skin with emery cloth,
grade 400 to obtain a rough surface.
NOTE: Do not abrade the CAAlayer of the existing skin.
(e) Remove the waste from the repair area with a vacuum cleaner and
clean the repair area with cleaning agent (Material No. 11003)
or cleaning agent (Material No. 11004).
(f) Apply bonding and adhesive compound (Material No. 08074) (Mask
ing tape) around the outer edge of the overlap area. This will
help you to remove unwanted adhesive and sealant from the repair
area.
(g) Apply bonding and adhesive compound (Material No. 08055) to the
skin surface to protect the CAAlayer.
(h) Prepare the honeycomb core plug, refer to Chapter 517711, Para
graph 4.I. for details and procedure.
(i) Mix bonding and adhesive compound (Material No. 08010) or bond
ing and adhesive compound (Material No. 08078) with special ma
terial (Material No. 05089) and apply the mixed paste to the
faying surfaces of the core plug, refer to Chapter 517711,
Paragraph 5.F. for procedure.
(j) Install and fix the honeycomb core plug, let the mixed paste
cure for the defined cure cycle, refer to Chapter 517711,
Paragraph 6.B.(1) or manufacturer instructions for details.
NOTE: Support the core plug during the curing process by an ap
propriate device.
(k) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.

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STRUCTURAL REPAIR MANUAL


(l) Prepare the repair doubler, refer to Figure 202.
(m) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 202.
(n) Drill the required fastener holes and deburr the doubler.
NOTE: For countersinking refer to Chapter 514600.
(o) Clean the doubler and the repair area with cleaning agent (Mate
rial No. 11003) or cleaning agent (Material No. 11004).
(p) Apply bonding and adhesive compound (Material No. 08055) to the
doubler. Let bonding and adhesive compound cure according to
manufacturers instruction.
(q) Apply bonding and adhesive compound (Material No. 08001B) or
bonding and adhesive compound (Material No. 08078) to the faying
surface of the doubler.
(r) Position the doubler to the repair area and install the applica
ble fasteners if necessary, refer to Figure 202.
NOTE: Ensure that the fastener are installed during the curing
time of the bonding and adhesive compound.
(s) Let the repair cure for the defined cure cycle at RT (room tem
perature) and under pressure. To apply pressure use weights,
clamps or a vacuum bag, refer to Chapter 517711, Paragraph 5.D.
for additional information.
NOTE: The cure process can be accelerated by the use of heat,
refer to Chapter 517711, Paragraph 5.E. and 6.B.(1) for
details.
(t) Prepare special material (Material No. 05097) or bonding and
adhesive compound (Material No. 08070) (Lamination resin) and
apply a thin layer to the rear edge of the repair area if nec
essary, refer to Figure 202, Sheet 2, Option 4 and to Chapter
517711, Paragraph 6.B.(2) for mixing/curing details.
(u) Laminate the special material (Material No. 05007) or special
material (Material No. 05033) to the rear edge of the repair
area, refer to Figure 202 and to Chapter 517711, Paragraph 5.A.
for procedure and details.
(v) Apply sealant (Material No. 09013) to the circumferential edges
of the doubler, refer to Figure 202.
(w) Clean the repair area with cleaning agent (Material No. 11003)
or cleaning agent (Material No. 11004).
(x) Apply structure paint (Material No. 16003) or structure paint
(Material No. 16021A) to the sealant bead.

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STRUCTURAL REPAIR MANUAL


(y) Apply structure paint (Material No. 16001) to the repair area.
(z) Apply structure paint (Material No. 16018A) to the repair area
to match the surrounding structure.
(aa)Inspect the repair, refer to Chapter 517710, Paragraph 5. for
procedure and details.
(3) Repair Instruction Hot Bond Repair
(a) Carry out repair steps 4.B.(2)(a) thru 4.B.(2)(h) above.
(b) Wrap a layer of bonding and adhesive compound (Material No.
08047A) or bonding and adhesive compound (Material No. 08047B)
around the core plug and position the prepared core plug to the
cutout, refer to Chapter 517711, Paragraph 5.G. for installa
tion details.
(c) Install the required heating equipment and the vacuum bag, refer
to Chapter 517711, Paragraph 5.D. for details.
(d) Let the installed core plug cure for the defined temperature,
time and vacuum, refer to Chapter 517711, Paragraph 5.E. and
Paragraph 5.G. for details.
NOTE: Support the core plug during the curing process by an ap
propriate device.
(e) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.
(f) Prepare the repair doubler, refer to Figure 202.
(g) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 202.
(h) Drill the required fastener holes and deburr the doubler.
(i) Clean the doubler and the repair area with cleaning agent (Mate
rial No. 11003) or cleaning agent (Material No. 11004).
(j) Apply bonding and adhesive compound (Material No. 08042) or
bonding and adhesive compound (Material No. 08042A) to the fay
ing surface of the repair area.
(k) Position the doubler to the repair area and install the required
heating equipment and the vacuum bag, refer to Chapter 517711,
Paragraph 5.D. for details.
NOTE: Fasteners inside the range of the heating blanket have to
be removed to avoid damage to the fasteners. In this case
drill out the fasteners in the heat affected area.

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STRUCTURAL REPAIR MANUAL


(l) Let the installed doubler cure for the defined temperature, time
and vacuum, refer to Chapter 517711, Paragraph 5.E. and Para
graph 5.G. for details.
(m) If necessary, install the applicable fasteners to the doubler and
the adjacent area, refer to Figure 202.
(n) Continue with step 4.B.(2)(t) thru 4.B.(2)(aa).

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Upper and Lower Skin and Core Repair in Zone E


Figure 202 (sheet 1)

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Upper and Lower Skin and Core Repair in Zone E


Figure 202 (sheet 2)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
C. Inboard Flap Trailing Edge Replacement
This repair is applicable for the trailing edge of the inboard flap.
NOTE: This replacement procedure is applicable for the inboard flap part
numbers F57570200XXX, F57585000XXX and G57570503XXX only.
AIRCRAFT

WEIGHT VARIANT

A330200

ALL

A330300

ALL

Effectivity per Weight Variant and Aircraft Type


Table 204
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.

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(1) Repair Material
ITEM
1
2
3
4
5
6

NOMENCLATURE

QTY MATERIAL/REMARKS

Trailing Edge Inner Part


Trailing Edge Outer Part
Rubbing Strip
Insert
Setscrew
Trailing Edge Installation
Jig
Fastener
Bonding and Adhesive Com
pound (Masking Tape)
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane Methyl Chloroform)
Pretreatment for Painting
(Chemical Conversion Coat
ing, Yellow Aluminum)
Storage Preservation (Cor
rosion Preventive, Tempo
rary Protective Compound)
Storage Preservation (Cor
rosion Preventive, Tempo
rary Protective Compound)
Structure Paint (AntiCor
rosion Primer)
Structure Paint (Polyure
thane Top Coat, Grey)
Structure Paint (Wash
Primer)
Chromic Acid Anodizing
(CAA)

1
1
1
2
2
2

Refer
Refer
Refer
Refer
Refer
Refer

to
to
to
to
to
to

Figure
Figure
Figure
Figure
Figure
Figure

203
203
203
203
203
203

AR Refer to Figure 203


AR Material No. 08074
Chapter 513500)
AR Material No. 09013
Chapter 513500)
AR Material No. 11003
Chapter 513500)
AR Material No. 11004
Chapter 513500)
AR Material No. 13002
Chapter 513500)

(Refer to
(Refer to
(Refer to
(Refer to
(Refer to

AR Material No. 15005A (Refer to


Chapter 513500)
AR Material No. 15007 (Refer to
Chapter 513500)
AR Material No. 16001 (Refer to
Chapter 513500)
AR Material No. 16002 (Refer to
Chapter 513500)
AR Material No. 16020 (Refer to
Chapter 513500)
AR Refer to Chapter 512111

(2) Repair Instructions, refer to Chapter 517211 and Figure 203.


(a) Remove the inboard flap assembly, refer to AMM Chapter 275471.
(b) Put the inboard flap assembly on a suitable support fixture.

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CAUTION: MAKE SURE YOU DO NOT DAMAGE THE FLAP DURING JIG MANUFAC
TURE.
CAUTION: YOU MUST MAKE THE TRAILING EDGE INSTALLATION JIGS BEFORE
YOU REMOVE THE DAMAGED TRAILING EDGE FROM THE INBOARD FLAP
ASSEMBLY.
(c) Make the trailing edge installation jigs to match the contour of
the inboard flap, refer to Figure 203, sheet 2.
(d) Install the jigs, refer to Figure 203, sheet 2.
1 Put the jigs on the flap and align with the rivet centers on
Rib 4 and Rib 8 and the trailing edge.
2 Identify a minimum of 3 rivet positions along the length of
Rib 4 and Rib 8 to attach the jigs.
3 Drill out the rivets and transfer the hole positions to the
jigs.
4 Drill the holes in the jigs for the same size fastener, refer
to Chapter 514400.
5 Deburr all holes and install the jigs with blind universalhead
rivets with the same size as the removed rivets.
6 Mark the exact position of the trailing edge on each jig.
(e) Drill out all affected rivets from the trailing edge for removal,
refer to Figure 203, sheet 3 thru 7.
(f) Remove the rubbing strip and attachment parts as necessary at Rib
1, refer to drawing F57570200, F57585000 or G57570503.
(g) Remove the attachment parts as necessary at Rib 13, refer to
drawing F57570200, F57585000 or G57570503.
(h) Mark the reference points on the inboard flap assembly as fol
lows, refer to Figure 203, sheet 8.
NOTE: The trailing edge flanges are cut from the damaged trailing
edge in step 4.C.(2)(j). These flanges are used as tem
plates to install the new trailing edge.
1 Apply masking tape (bonding and adhesive compound) (Material
No. 08074) along the length of the center box.
2 Mark a cross with a pencil every 500 mm (19.685 in) on the
masking tape.
3 Use a compass to mark arcs on the upper flange of the trailing
edge of a fixed radius with the circumference intersecting at a
tangent midway between the rear spar and the auxiliary spar.

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4 Mark several lines along the length of the flap with a pencil
from the centre box to the trailing edge flange.
5 Repeat work steps 4.C.(2)(h)1 thru 4.C.(2)(h)4 for the lower
flange of the trailing edge.
(i) Remove the trailing edge from the flap center box.
(j) Cut the upper and lower flanges (including rivet holes) from the
damaged trailing edge to use templates and deburr the edges, re
fer to Figure 203, sheet 9.
CAUTION: MAKE SURE THAT YOU DO NOT REMOVE THE PENCIL MARKS FROM THE
FLANGE TEMPLATES DURING CLEANING.
(k) Clean the upper and lower flange templates with cleaning agent
(methylethylketone) (Material No. 11003) or cleaning agent
(trichloroethane methyl chloroform) (Material No. 11004).
(l) Before you install new trailing edge on flap part numbers
F57570200XXX and F57585000XXX, make sure that you do the work
steps that follow:
1 Plug the two existing holes at joint of trailing edge with
fasteners. For fastener detail and location refer to Figure
203, sheet 11.
2 Drill four new fastener holes for trailing edge connection to
rear spar. Refer to Figure 203, sheet 11 and Chapter 514400.
(m) Temporarily install the new trailing edge.
(n) Align the trailing edge with the installation jigs to get the
correct contour position. You must obey the tolerances in drawing
F57570200, F57585000 or G57570503 as applicable.
(o) Attach the template flanges on the new trailing edge and align
the pencil marks from work step 4.C.(2)(h).

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CAUTION: YOU MUST NOT DRILL INTO THE REAR SPAR. DUE TO MANUFACTURING
TOLERANCES THE NEW AND OLD TRAILING EDGE ASSEMBLIES CAN BE
DIFFERENT DIMENSIONS. THERE CAN BE HOLE POSITION MIS
ALIGNMENT BETWEEN THE REAR SPAR AND THE FLANGE TEMPLATES.
BEFORE YOU DRILL THE FINISHED FASTENER HOLE SIZE, YOU MUST:
MAKE SURE THAT YOU USE A DRILL 0.2 MM (0.008 IN) SMALLER
IN DIAMETER THAN FINISHED HOLE SIZE TO TRANSFER DRILL.
DO A VISUAL INSPECTION TO MAKE SURE THAT THE HOLE IN THE
NEW TRAILING EDGE ALIGNS WITH THE HOLE IN THE REAR SPAR.
CAUTION: MAKE SURE THAT YOU DO NOT EXCEED A DRILL DEPTH OF MORE
THAN 2 MM (0.080 IN).
(p) Set the drill depth to 2 mm (0.080 in) and transfer drill the
trailing edge with a drill size 0.2 mm (0.008 in) smaller in di
ameter than the finished hole size, refer to Chapters 514300,
514400 and 514700.
(q) Do a visual inspection to make sure that the holes in the new
trailing edge and the rear spar align.
(r) Drill the finished hole size, refer to Chapters 514300,
514400 and 514700.
(s) Repeat work steps 4.C.(2)(p) thru 4.C.(2)(r) for all the fastener
holes.
(t) Remove the trailing edge assembly and deburr the holes.
(u) Clean the trailing edge and the repair area with cleaning agent
(Methylethylketone) (Material No. 11003) or cleaning agent
(trichloroethane methyl chloroform) (Material No. 11004).
(v) Pretreat all bare surfaces of the repair area and trailing edge
with pretreatment for painting (chromic acid anodizing (CAA) or
chemical conversion coating) (Material No. 13002) or structure
paint (wash primer) (Material No. 16020).
NOTE: For application of chemical conversion coating, refer to
Chapter 512111.
(w) Apply structure paint (anticorrosion primer) (Material No.
16001) to the repair area and trailing edge.
(x) Restore the paint finish around the repair area and trailing edge
with structure paint (polyurethane top coat, grey) (Material No.
16002).
WARNING: DO NOT APPLY STORAGE PRESERVATION (MATERIAL NO. 15005A) IN
AREAS OF OXYGEN EQUIPMENT AND OXYGEN PIPES.
(y) If necessary, apply a corrosion preventive temporary protective
compound to the repair area and trailing edge. First apply stor

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STRUCTURAL REPAIR MANUAL


age preservation (corrosion preventive, temporary protective com
pound) (Material No. 15005A) and after that storage preservation
(corrosion preventive, temporary protective compound) (Material
No. 15007).
NOTE: Allow storage preservation (corrosion preventive, temporary
protective compound) (Material No. 15005A) to cure for
approx. 1 hour before applying storage preservation (corro
sion preventive, temporary protective compound) (Material
No. 15007).
NOTE: This is a supplement and means to prevent corrosion in
areas where special protection required, refer to Chapter
512312 for information about these areas.
(z) Apply sealant (corrosion inhibiting brush consistency) (Material
No. 09013) to the mating surfaces, refer to Chapter 512400.
(aa)Temporarily install trailing edge inboard assembly (1) and align
with the installation jig.
(ab)Do a visual inspection to make sure that the trailing edge and
rear spar holes are aligned and make any adjustments as neces
sary.
(ac)Install the inboard trailing edge (1) rivets, refer to Chapters
514300, 514400 and 514700 and drawing F57570200, F57585000
or G57570503.
(ad)Repeat work steps 4.C.(2)(aa) thru 4.C.(2)(ac) for the outboard
assembly (2).
(ae)Install the rubbing strip between Rib 1 and Rib 2, refer to
Chapter 575412 and attachment parts as necessary, refer to
drawing F57570200, F57585000 or G57570503.
(af)Install the attachment parts as necessary at Rib 13, refer to
drawing F57570200, F57585000 or G57570503.
(ag)Drill out the blind head rivets and remove the trailing edge
installation jigs.
(ah)Reinstall the rivets removed in work step 4.C.(2)(d)2, refer to
Chapters 514300, 514400 and 514700.
(ai)Install the rigging points, refer to Figure 203, sheet 10 and
drawing G57570506.
NOTE: You can use the old trailing edge to make a template to
install the rigging points in the same position.
(aj)Install the inboard flap assembly, refer to AMM Chapter 275471.

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 1)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 2)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 3)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 4)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 5)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 6)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 7)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 8)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 9)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 10)

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Inboard Flap Trailing Edge Replacement


Figure 203 (sheet 11)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
D. External Bonded Metal Doubler and Core Repair for the Trailing Edge
Zone E
NOTE: This repair is applicable in Zone E when the upper or lower skin
and the honeycomb core is damaged and is effective as follows:
AIRCRAFT

A330200

WEIGHT VARIANT
020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

080, 081, 082, 083 <1>

A330300

000,
011,
024,
054,

001,
012,
025,
056,

002, 003, 004, 010,


013, 014, 020, 022,
050, 051, 052, 053,
057

080, 081, 082, 083 <1>


Effectivity per Weight Variant and Aircraft Type
Table 205
<1> Only applicable After Modification 49008D42923.
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
For this repair there are two different repair principles available, re
fer to the following paragraph to get the relevant repair:
Paragraph 4.D.(2) describes a permanent repair at room temperature
(RT).
Paragraph 4.D.(3) describes a permanent repair hot bond repair.
NOTE: For the definition of the repair zones, refer to Chapter 575400
Page Block 101.
NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710, Paragraph 3. for details and
procedure.
(1) Repair Materials
ITEM
1
2

NOMENCLATURE

QTY MATERIAL/REMARKS

Doubler
Honeycomb Core

AR Refer to Figure 204


AR Refer to Figure 204

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ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Special Material (Glass


Cloth for Laminates)
Special Material (Glass
Cloth)
Special Material (Thicken
ing Agent)
Special Material (Resin
(Epoxy))
Bonding and Adhesive Com
pound (Epoxy Resin and
Hardener Adhesive)
Bonding and Adhesive Com
pound (Adhesive Film)
Bonding and Adhesive Com
pound (Splice Adhesive Film
(120C) (248F))
Bonding and Adhesive Com
pound (Splice Adhesive Film
(120C) (248F))
Bonding and Adhesive Com
pound (Epoxy Resin)
Bonding and Adhesive Com
pound (Bonding Primer)
Bonding and Adhesive Com
pound (Composite Wet Lay
Up Resin)
Bonding and Adhesive Com
pound (Masking Tape)
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane (Methyl Chloroform))
Structure Paint (Anti Cor
rosion Primer Polyurethane)
Structure Paint (Polyure
thane Finish Paint)
Structure Paint (Flexible
Polyurethane)
Emery Cloth

AR Material No. 05007, refer to


Chapter 513500
AR Material No. 05033, refer to
Chapter 513500
AR Material No. 05089, refer to
Chapter 513500
AR Material No. 05097, refer to
Chapter 513500
AR Material No. 08010D, refer to
Chapter 513500
AR Material No. 08042, refer to
Chapter 513500
AR Material No. 08047A, refer to
Chapter 513500
AR Material No. 08047B, refer to
Chapter 513500
AR Material No. 08051, refer to
Chapter 513500
AR Material No. 08055, refer to
Chapter 513500
AR Material No. 08070, refer to
Chapter 513500
AR Material No. 08074, refer to
Chapter 513500
AR Material No. 09013, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
AR Material No. 11004, refer to
Chapter 513500
AR Material No. 16001, refer to
Chapter 513500
AR Material No. 16018A, refer to
Chapter 513500
AR Material No. 16021, refer to
Chapter 513500
AR Grade 280/400

(2) Repair Instructions Room Temperature (RT) Repair (Refer to Figure


204)

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(a) Mark the cutout according to Figure 204.
(b) Drill out all affected fasteners if necessary, refer to Chapter
514211.
(c) Cut out the damaged material. Cut the skin and the honeycomb
into a regular shape and deburr the edges.
(d) Carefully abrade the mating surface of the skin with emery cloth,
grade 400 to obtain a rough surface.
NOTE: Do not abrade the chromic acid anodizing (CAA) layer of
the existing skin.
(e) Remove the waste from the repair area with a vacuum cleaner and
clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane (methyl
chloroform)) (Material No. 11004).
(f) Apply bonding and adhesive compound (masking tape) (Material No.
08074) around the outer edge of the overlap area. This will
help you to remove unwanted adhesive and sealant from the repair
area.
(g) Apply bonding and adhesive compound (bonding primer) (Material
No. 08055) to the skin surface to protect the chromic acid an
odizing (CAA) layer.
(h) Prepare the honeycomb core plug, refer to Chapter 517711, Para
graph 4.I for the details and procedure.
(i) Mix bonding and adhesive compound (epoxy resin and hardener adhe
sive) (Material No. 08010D) or bonding and adhesive compound
(epoxy resin) (Material No. 08051) with special material (thick
ening agent) (Material No. 05089) and apply the mixed paste to
the faying surfaces of the core plug, refer to Chapter 517711.
(j) Install and fix the honeycomb core plug, let the mixed paste
cure for the defined cure cycle, refer to Chapter 517711.
(k) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.
(l) Prepare the repair doubler, refer to Figure 204.
(m) Clean the external doubler with cleaning agent (methylethylke
tone) (Material No. 11003) or cleaning agent (trichloroethane
(methyl chloroform)) (Material No. 11004).
(n) Treat and protect the external doubler with bonding and adhesive
compound (bonding primer) (Material No. 08055), refer to Chapter
517713 Paragraph 3.A.2.(b) or Paragraph 3.A.1.(b).(4) or Para
graph 3.A.1.(b).(5).

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(o) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 204.
(p) Drill the required fastener holes and deburr the doubler.
NOTE: For countersinking refer to Chapter 514600.
(q) Clean the doubler and the repair area with cleaning agent (meth
ylethylketone) (Material No. 11003) or cleaning agent (trichlo
roethane (methyl chloroform)) (Material No. 11004).
(r) Apply bonding and adhesive compound (epoxy resin and hardener
adhesive) (Material No. 08010D) or bonding and adhesive compound
(epoxy resin) (Material No. 08051) to the faying surface of the
doubler.
(s) Position the doubler to the repair area and install the applica
ble fasteners if necessary, refer to Figure 204.
NOTE: Ensure that the fastener are installed during the curing
time of the bonding and adhesive compound.
(t) Let the repair cure for the defined cure cycle at RT (room tem
perature) and under pressure. To apply pressure use weights,
clamps or a vacuum bag, refer to Chapter 517711 Paragraph 5.D.
NOTE: The cure process can be accelerated by the use of heat,
refer to Chapter 517711 Paragraph 5.E.(1).
(u) Prepare special material (resin (epoxy)) (Material No. 05097) or
bonding and adhesive compound (composite wet lay up resin) (Mate
rial No. 08070) and apply a thin layer to the rear edge of the
repair area if necessary, refer to Figure 204 and to Chapter
517711.
(v) Laminate the special material (glass cloth for laminates) (Mate
rial No. 05007) or special material (glass cloth) (Material No.
05033) to the rear edge of the repair area, refer to Figure 204
and to Chapter 517711.
NOTE: Step 4.D.(2)(u) and 4.D.(2)(v) are necessary only in case
of damage to the rear edge, refer to Figure 204.
(w) Apply sealant (corrosion inhibiting brush consistency) (Material
No. 09013) to the circumferential edges of the doubler, refer to
Figure 204.
(x) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane (methyl
chloroform)) (Material No. 11004).
(y) Apply structure paint (flexible polyurethane) (Material No.
16021) to the sealant bead.

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(z) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to the repair area.
(aa)Apply structure paint (polyurethane finish paint) (Material No.
16018A) to the repair area to match the surrounding structure.
(ab)Inspect the repair, refer to Chapter 517710.
(3) Repair Instructions Hot Bond Repair (Refer to Figure 204)
(a) Carry out repair steps 4.D.(2)(a) thru 4.D.(2)(h) above.
(b) Wrap a layer of bonding and adhesive compound (splice adhesive
film (120C) (248F)) (Material No. 08047A) or bonding and adhe
sive compound (splice adhesive film (120C) (248F)) (Material
No. 08047B) around the core plug and position the prepared core
plug to the cutout, refer to Chapter 517711.
(c) Install the required heating equipment and the vacuum bag, refer
to Chapter 517711.
(d) Let the installed core plug cure for the defined temperature,
time and vacuum, refer to Chapter 517711.
(e) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.
(f) Prepare the repair doubler, refer to Figure 204.
(g) Clean the external doubler with cleaning agent (methylethylke
tone) (Material No. 11003) or cleaning agent (trichloroethane
(methyl chloroform)) (Material No. 11004).
(h) Treat and protect the external doubler with bonding and adhesive
compound (bonding primer) (Material No. 08055), refer to Chapter
517713 Paragraph 4.A.2.(b) or Paragraph 4.A.1.(b).(4) or Para
graph 4.A.1.(b).(5).
(i) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 204.
(j) Drill the required fastener holes and deburr the doubler.
(k) Clean the doubler and the repair area with cleaning agent (meth
ylethylketone) (Material No. 11003) or cleaning agent (trichlo
roethane (methyl chloroform)) (Material No. 11004).
(l) Apply bonding and adhesive compound (adhesive film) (Material No.
08042) to the faying surface of the repair area.

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(m) Position the doubler to the repair area and install the required
heating equipment and the vacuum bag, refer to Chapter 517711.
NOTE: Fasteners inside the range of the heating blanket have to
be removed to avoid damage to the fasteners. In this case
drill out the fasteners in the heat affected area.
(n) Let the installed doubler cure for the defined temperature, time
and vacuum, refer to Chapter 517711.
(o) If necessary, install the applicable fasteners to the doubler and
the adjacent area, refer to Figure 204.
(p) Continue with step 4.D.(2)(u) thru 4.D.(2)(ab).

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External Bonded Metal Doubler and Core Repair for the Trailing Edge Zone E
Figure 204 (sheet 1)

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External Bonded Metal Doubler and Core Repair for the Trailing Edge Zone E
Figure 204 (sheet 2)

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External Bonded Metal Doubler and Core Repair for the Trailing Edge Zone E
Figure 204 (sheet 3)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
E. Upper and Lower Skin and Core Repair for the Trailing Edge Zone E
NOTE: This repair is applicable in Zone E when the upper and lower skin
and the honeycomb core is damaged and is effective as follows:
AIRCRAFT

A330200

WEIGHT VARIANT
020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

080, 081, 082, 083 <1>

A330300

000,
011,
024,
054,

001,
012,
025,
056,

002, 003, 004, 010,


013, 014, 020, 022,
050, 051, 052, 053,
057

080, 081, 082, 083 <1>


Effectivity per Weight Variant and Aircraft Type
Table 206
<1> Only applicable After Modification 49008D42923.
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
For this repair there are two different repair principles available, re
fer to the following Paragraph to get the relevant repair:
Paragraph 4.E.(2) describes a permanent repair at room temperature
(RT).
Paragraph 4.E.(3) describes a permanent repair hot bond repair.
NOTE: For the definition of the repair zones, refer to Chapter 575400
Page Block 101.
NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710, Paragraph 3. for details and
procedure.
(1) Repair Materials
ITEM
1
2

NOMENCLATURE

QTY MATERIAL/REMARKS

Doubler
Honeycomb Core

AR Refer to Figure 205


AR Refer to Figure 205

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ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Special Material (Glass


Cloth for Laminates)
Special Material (Glass
Cloth)
Special Material (Thicken
ing Agent)
Special Material (Resin
(Epoxy))
Bonding and Adhesive Com
pound (Epoxy Resin and
Hardener Adhesive)
Bonding and Adhesive Com
pound (Adhesive Film)
Bonding and Adhesive Com
pound (Splice Adhesive Film
(120C) (248F))
Bonding and Adhesive Com
pound (Splice Adhesive Film
(120C) (248F))
Bonding and Adhesive Com
pound (Epoxy Resin)
Bonding and Adhesive Com
pound (Bonding Primer)
Bonding and Adhesive Com
pound (Composite Wet Lay
Up Resin)
Bonding and Adhesive Com
pound (Masking Tape)
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane (Methyl Chloroform))
Structure Paint (Anti Cor
rosion Primer Polyurethane)
Structure Paint (Polyure
thane Finish Paint)
Structure Paint (Flexible
Polyurethane)
Emery Cloth

AR Material No. 05007, refer to


Chapter 513500
AR Material No. 05033, refer to
Chapter 513500
AR Material No. 05089, refer to
Chapter 513500
AR Material No. 05097, refer to
Chapter 513500
AR Material No. 08010D, refer to
Chapter 513500
AR Material No. 08042, refer to
Chapter 513500
AR Material No. 08047A, refer to
Chapter 513500
AR Material No. 08047B, refer to
Chapter 513500
AR Material No. 08051, refer to
Chapter 513500
AR Material No. 08055, refer to
Chapter 513500
AR Material No. 08070, refer to
Chapter 513500
AR Material No. 08074, refer to
Chapter 513500
AR Material No. 09013, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
AR Material No. 11004, refer to
Chapter 513500
AR Material No. 16001, refer to
Chapter 513500
AR Material No. 16018A, refer to
Chapter 513500
AR Material No. 16021, refer to
Chapter 513500
AR Grade 280/400

(2) Repair Instructions Room Temperature (RT) Repair (Refer to Figure


205)

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(a) Mark the cutout according to Figure 205.
(b) Drill out all affected fasteners if necessary, refer to Chapter
514211.
(c) Cut out the damaged material. Cut the skin and the honeycomb
into a regular shape and deburr the edges.
(d) Carefully abrade the mating surface of the skin with emery cloth,
grade 400 to obtain a rough surface.
NOTE: Do not abrade the chromic acid anodizing (CAA) layer of
the existing skin.
(e) Remove the waste from the repair area with a vacuum cleaner and
clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane (methyl
chloroform)) (Material No. 11004).
(f) Apply bonding and adhesive compound (masking tape) (Material No.
08074) around the outer edge of the overlap area. This will
help you to remove unwanted adhesive and sealant from the repair
area.
(g) Apply bonding and adhesive compound (bonding primer) (Material
No. 08055) to the skin surface to protect the chromic acid an
odizing (CAA) layer.
(h) Prepare the honeycomb core plug, refer to Chapter 517711 Para
graph 4.I. for details and procedure.
(i) Mix bonding and adhesive compound (epoxy resin and hardener adhe
sive) (Material No. 08010D) or bonding and adhesive compound
(epoxy resin) (Material No. 08051) with special material (thick
ening agent) (Material No. 05089) and apply the mixed paste to
the faying surfaces of the core plug, refer to Chapter 517711.
(j) Install and fix the honeycomb core plug, let the mixed paste
cure for the defined cure cycle, refer to Chapter 517711 Para
graph 6.B.(1).
NOTE: Support the core plug during the curing process by an ap
propriate device.
(k) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.
(l) Prepare the repair doubler, refer to Figure 205.
(m) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 205.
(n) Drill the required fastener holes and deburr the doubler.
NOTE: For countersinking refer to Chapter 514600.

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(o) Clean the doubler and the repair area with cleaning agent (meth
ylethylketone) (Material No. 11003) or cleaning agent (trichlo
roethane (methyl chloroform)) (Material No. 11004).
(p) Apply bonding and adhesive compound (bonding primer) (Material
No. 08055) to the doubler. Let bonding and adhesive compound
cure according to manufacturers instruction.
(q) Apply bonding and adhesive compound (epoxy resin and hardener
adhesive) (Material No. 08010D) or bonding and adhesive compound
(epoxy resin) (Material No. 08051) to the faying surface of the
doubler.
(r) Position the doubler to the repair area and install the applica
ble fasteners if necessary, refer to Figure 205.
NOTE: Ensure that the fastener are installed during the curing
time of the bonding and adhesive compound.
(s) Let the repair cure for the defined cure cycle at RT (room tem
perature) and under pressure. To apply pressure use weights,
clamps or a vacuum bag, refer to Chapter 517711.
NOTE: The cure process can be accelerated by the use of heat,
refer to Chapter 517711 Paragraph 5.D.
(t) Prepare special material (resin (epoxy)) (Material No. 05097) or
bonding and adhesive compound (composite wet lay up resin) (Mate
rial No. 08070) and apply a thin layer to the rear edge of the
repair area if necessary, refer to Figure 205 sheet 3 option 4
and Chapter 517711.
(u) Laminate the special material (glass cloth for laminates) (Mate
rial No. 05007) or special material (glass cloth) (Material No.
05033) to the rear edge of the repair area, refer to Figure 205
and Chapter 517711.
(v) Apply sealant (corrosion inhibiting brush consistency) (Material
No. 09013) to the circumferential edges of the doubler, refer to
Figure 205.
(w) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane (methyl
chloroform)) (Material No. 11004).
(x) Apply structure paint (flexible polyurethane) (Material No.
16021) to the sealant bead.
(y) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to the repair area.
(z) Apply structure paint (polyurethane finish paint) (Material No.
16018A) to the repair area to match the surrounding structure.
(aa)Inspect the repair, refer to Chapter 517710.

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(3) Repair Instructions Hot Bond Repair (Refer to Figure 205)
(a) Carry out repair steps 4.E.(2)(a) thru 4.E.(2)(h) above.
(b) Wrap a layer of bonding and adhesive compound (splice adhesive
film (120C) (248F)) (Material No. 08047A) or bonding and adhe
sive compound (splice adhesive film (120C) (248F)) (Material
No. 08047B) around the core plug and position the prepared core
plug to the cutout, refer to Chapter 517711 Paragraph 5.G.
(c) Install the required heating equipment and the vacuum bag, refer
to Chapter 517711 Paragraph 5.D.
(d) Let the installed core plug cure for the defined temperature,
time and vacuum, refer to Chapter 517711 Paragraph 5.E. and
5.G.
NOTE: Support the core plug during the curing process by an ap
propriate device.
(e) After the curing process, smooth the surface using emery cloth
grade 280 and finish with grade 400.
(f) Prepare the repair doubler, refer to Figure 205.
(g) If necessary position the doubler to the repair area and transfer
the existing fastener holes to the doubler, refer to Figure 205.
(h) Drill the required fastener holes and deburr the doubler.
(i) Clean the doubler and the repair area with cleaning agent (meth
ylethylketone) (Material No. 11003) or cleaning agent (trichlo
roethane (methyl chloroform)) (Material No. 11004).
(j) Apply bonding and adhesive compound (adhesive film) (Material No.
08042) to the faying surface of the repair area.
(k) Position the doubler to the repair area and install the required
heating equipment and the vacuum bag, refer to Chapter 517711.
NOTE: Fasteners inside the range of the heating blanket have to
be removed to avoid damage to the fasteners. In this case
drill out the fasteners in the heat affected area.
(l) Let the installed doubler cure for the defined temperature, time
and vacuum, refer to Chapter 517711.
(m) If necessary, install the applicable fasteners to the doubler and
the adjacent area, refer to Figure 205.
(n) Continue with step 4.E.(2)(t) thru 4.E.(2)(aa).

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Upper and Lower Skin and Core Repair for the Trailing Edge Zone E
Figure 205 (sheet 1)

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Upper and Lower Skin and Core Repair for the Trailing Edge Zone E
Figure 205 (sheet 2)

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Upper and Lower Skin and Core Repair for the Trailing Edge Zone E
Figure 205 (sheet 3)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
F. Replacement of Leading Edge Covers
NOTE: Before you repair the damaged structure, you must do a damage
evaluation. Refer to Chapter 517710.
NOTE: This repair is applicable for replacement of leading edge skin
only. STGR11 must remain installed and undamaged, if not contact
AIRBUS.
NOTE: This repair gives information about replacement of leading edge
covers in inboard flap and is effective as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021,
027,
055,
061,

022,
050,
056,
080,

023,
051,
057,
081,

024,
052,
058,
082,

025,
053,
059,
083

A330300

000,
011,
024,
054,

001,
012,
025,
056,

002,
013,
050,
057,

003,
014,
051,
080,

004,
020,
052,
081,

010,
022,
053,
082, 083

Effectivity per Weight Variant and Aircraft Type


Table 207
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Aluminum Templates
Bonding and Adhesive Com
pound (Masking Tape)
Sealant (Low Adhesion
Polysulfide Sealant)
Sealant (Low Adhesion
Polysulfide Sealant)
Cleaning Agent (Methyl
EthylKetone)

AR Refer to
AR Material
CML
AR Material
CML
AR Material
CML
AR Material
CML

Figure 206
No. 08074, refer to
No. 09018, refer to
No. 09019, refer to
No. 11003, refer to

(2) Repair Instructions (Refer to Figure 206)


(a) Remove the screws common to the leading edge and carefully remove
the leading edge skin.

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(b) Remove the sealant from the flap substructure and the leading
edge skin.
(c) Manufacture aluminum templates at each rib location to match the
outer surface contour of the existing leading edge skin. The
templates should pickup all holes common to the upper surface of
the skin and rib and be wide enough to pickup one hole on each
side of the rib to locate the template, refer to Figure 206,
sheet 1, step 1.
(d) Clamp the templates to the existing leading edge skin and back
drill the rib holes from the skin into the templates. Remove the
templates from the existing leading edge skin.
(e) Manufacture an upper surface template from the existing leading
edge skin by sawing off a spanwise section of the upper surface
with holes common to flap upper skin (refer to Figure 206, sheet
1, step 2). Maintain a three hole diameter distance from the
forward row of fastener holes.
(f) Manufacture a lower surface template similar to as given in
Paragraph 4.F.(2)(e) by using the lower surface of the existing
leading edge skin.
(g) Place new skin on flap and trim excess as required at upper and
lower surface aft edges to eliminate any interference with radius
(minimum of 1 mm (0.039 in) clearance) in rebate area of upper
and lower flap skins. Locate inboard and outboard to adjacent
leading edge skins and trim excess as required (minimum of 1 mm
(0.039 in) clearance).
(h) With the replacement leading edge skin removed, select four hole
locations in outer flap skin along the forward row of fastener
holes and the aft row to be index holes to locate the new lead
ing edge skin on the upper and lower flap skin, refer to Figure
206, sheet 1, step 3.
(i) Lay strips of bonding and adhesive compound (masking tape) (Mate
rial No. 08074) (about 127 mm (5 in) long) from the edge of
the hole extending through the rebate area onto the skin, refer
to Figure 206, sheet 1, step 3. The strips should be at an
angle to each other to form an intersection point at the center
of the hole. Using a straight edge draw a line on each piece of
masking tape from the center of the index hole. Leave the tape
in place.
(j) Place the new leading edge skin and locate in the proper posi
tion. Draw the index hole intersecting lines from the lines on
the bonding and adhesive compound (masking tape) (Material No.
08074) on the upper and lower surface of the new leading edge
skin, refer to Figure 206, sheet 1, step 4). At intersection
points drill and ream original fastener holes as shown in Figure
206, sheet 2, step 7.

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(k) Locate the template manufactured from the old leading edge upper
surface on the new leading edge along the upper fastener hole
row at index holes and wedge lock in place. Drill and ream fas
tener holes, refer to Figure 206, sheet 2, step 6.
(l) Relocate template manufactured from the old leading edge upper
surface on the new leading edge along the lower fastener hole
row at index holes and wedge lock in place. Drill and ream fas
tener holes, refer to Figure 206, sheet 2, step 6.
(m) Repeat the procedure given in Paragraphs 4.F.(2)(k) and
4.F.(2)(l) for the lower surface fasteners.
(n) Locate the aluminum templates for the ribs on the upper surface
of leading edge skin at index holes and wedge lock in place.
Drill and ream fastener holes, refer to Figure 206, sheet 2,
step 7.
(o) Countersink and edge radius bottom of countersink at all hole
locations.
(p) Deburr all holes. Place the new leading edge skin to check fit
and alignment of holes.
(q) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).
(r) Prepare leading edge and structure for sealing. Wipe area thor
oughly with a clean cloth moistened with the cleaning agent
(methylethylketone) (Material No. 11003). Finish with a dry,
clean cloth.
(s) Seal mating surfaces of skin and substructure with sealant (low
adhesion polysulfide sealant) (Material No. 09018) or (low adhe
sion polysulfide sealant) (Material No. 09019) and install new
leading edge.
(t) Wet install new fasteners with sealant (low adhesion polysulfide
sealant) (Material No. 09018) or (low adhesion polysulfide seal
ant) (Material No. 09019).
NOTE: It is important that all rivets are installed within the
work life of the sealant (low adhesion polysulfide sealant)
(Material No. 09018) or (low adhesion polysulfide sealant)
(Material No. 09019). If this is not possible, install ev
ery third rivet within the work life of the sealant. For
work life of the sealant, refer to the manufacturers
instructions.
(u) Fillet seal leading edge skin with sealant (low adhesion polysul
fide sealant) (Material No. 09018) or (low adhesion polysulfide
sealant) (Material No. 09019).
(v) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).

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(w) Replace the surface protection of the repair area, refer to
Chapter 517512.

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Replacement of Leading Edge Covers


Figure 206 (sheet 1)

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Replacement of Leading Edge Covers


Figure 206 (sheet 2)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
G. Repair of Dents in the Trailing Edge Zone E
NOTE: Before you repair the damaged structure, you must do a damage
evaluation. Refer to Chapter 517710.
NOTE: For repair size limitations, refer to Chapter 575400 Page Block
101, Paragraph 11.C. and Figure 106.
NOTE: This repair gives information about repair of dents in the trailing
edge of inboard flap in Zone E and is effective as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021,
027,
055,
061,

022,
050,
056,
080,

023,
051,
057,
081,

024,
052,
058,
082,

025,
053,
059,
083

A330300

000,
011,
024,
054,

001,
012,
025,
056,

002,
013,
050,
057,

003,
014,
051,
080,

004,
020,
052,
081,

010,
022,
053,
082, 083

Effectivity per Weight Variant and Aircraft Type


Table 208
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
Refer to Figure 207 and use the repair procedure as stated in Chapter
517713.
NOTE: It is recommended to use an adhesive with a low viscosity to ob
tain a good core filling, refer to Chapter 517711. For the dent
filling, use bonding and adhesive compound (adhesive structural
flexible) (Material No. 08017A) mixed with special material
(thickening agent) (Material No. 05089).

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Repair of Dents in the Trailing Edge Zone E


Figure 207

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: FOR BEFORE MODIFICATION 49008D42923, THIS TEMPORARY REPAIR MUST BE
REPLACED BY A PERMANENT REPAIR SOLUTION WITHIN 28 800 FC (FH NOT
RELEVANT).
CAUTION: FOR AFTER MODIFICATION 49008D42923, THIS TEMPORARY REPAIR MUST BE
REPLACED BY A PERMANENT REPAIR SOLUTION WITHIN 24 600 FC (FH NOT
RELEVANT).
H. Skin between Two Stringers Flush Repair
NOTE: This repair is applicable for damaged skin between two stringers
flush repair in Zone C (stringer undamaged) and is effective as
follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000,
011,
024,
054,

001, 002, 003, 004, 010,


012, 013, 014, 020, 022,
025, 050, 051, 052, 053,
056

Effectivity per Weight Variant and Aircraft Type


Table 209
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give the nec
essary data about all weight variants and their required informa
tion for allowable damage and repair applicability.

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(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

1
2

Repair Skin
Repair Doubler (Internal)
Shim
Sealant (Interfay Sealant)

AR

Sealant (Corrosion Inhibit


ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Pretreatment For Painting
(Chemical Conversion Coat
ing, Yellow Aluminum)
Structure Paint (Anti Cor
rosion Primer Polyurethane)
Structure Paint (Polyure
thane Top Coat, Grey)
Structure Paint (Polyure
thane Finish Paint)
Structure Paint (Wash
Primer)
Structure Paint (Flexible
Polyurethane)
Chromic Acid Anodizing
(CAA)

Refer to Figure 208


Refer to Figure 208
Refer to Figure 208
Material No. 09005,
Chapter 513500
AR Material No. 09013,
Chapter 513500
AR Material No. 11003,
Chapter 513500
AR Material No. 13002,
Chapter 513500

refer to
refer to
refer to
refer to

AR Material No. 16001, refer


Chapter 513500
AR Material No. 16002, refer
Chapter 513500
AR Material No. 16018, refer
Chapter 513500
AR Material No. 16020, refer
Chapter 513500
AR Material No. 16021, refer
Chapter 513500
AR Refer to Chapter 512111

to
to
to
to
to

(2) Repair Instructions (Refer to Figure 208)


(a) Mark the repair area.
CAUTION: MAKE SURE NOT TO DAMAGE INTERNAL STRUCTURE OR SYSTEM WHEN
DRILLING.
(b) Remove the existing fasteners in the repair area, refer to Chap
ter 514211.

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CAUTION: A METAL SHEET MUST BE PLACED UNDERNEATH THE CUTTING AREA TO
AVOID DAMAGE TO THE STRUCTURE.
(c) Cut out the damaged skin area and deburr the edges of the cut
out.
NOTE: The cutout must be parallel and perpendicular to the
stringer and in the shape of a rectangle.
NOTE: The cutout must not exceed the adjacent edge of the string
er.
(d) Clean the edges of the cutout with cleaning agent (methylethyl
ketone) (Material No. 11003).
(e) Treat the edges of the cutout with structure paint (wash primer)
(Material No. 16020), refer to Chapter 512300.
(f) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to the edges of the cutout, refer to Chapter
512300.
(g) Prepare the repair parts according to Figure 208.
NOTE: Precut the doubler to oversize.
NOTE: Adapt the repair parts to the flapcontour.
(h) Put the repair parts in position.
NOTE: For steps < 0.3 mm (0.012 in) no shim must be applied. For
steps 0.3 mm (0.012 in) and < 0.5 mm (0.02 in) apply
liquid shim (sealant (interfay sealant) (Material No.
09005) or sealant (corrosion inhibiting brush consistency)
(Material No. 09013)). For steps 0.5 mm (0.02 in) use
solid shim.
(i) Measure the step and determine if a liquid shim, solid shim or
no shim is required. Remove the repair parts.
(j) Prepare the solid shim if required.
CAUTION: MAKE SURE NOT TO DAMAGE INTERNAL STRUCTURE OR SYSTEM WHEN
DRILLING.
(k) Put the repair parts in position, transfer drill the existing
fastener holes, drill the additional fastener holes and drill the
inspection hole (if required).
(l) Make the countersinks for the fasteners in the repair skin, refer
to Chapter 514611.
(m) Remove the repair parts and deburr the fastener holes.
(n) Cut the repair doubler (internal) to size and deburr.

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(o) Clean the repair parts and repair area with cleaning agent
(methylethylketone) (Material No. 11003) and treat repair parts
with chromic acid anodizing (CAA) or pretreatment for painting
(chemical conversion coating, yellow aluminum) (Material No.
13002), refer to Chapter 512111.
(p) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to the repair parts, refer to Chapter 512300.
(q) Apply sealant (interfay sealant) (Material No. 09005) or sealant
(corrosion inhibiting brush consistency) (Material No. 09013) to
the mating surfaces of the repair parts, refer to Chapter
517611.
(r) Put the repair parts in position including the liquid shim if
required and install all fasteners with wet sealant (interfay
sealant) (Material No. 09005) or sealant (corrosion inhibiting
brush consistency) (Material No. 09013), refer to Chapter
514211 and Chapter 517611.
NOTE: For fastener installation and layout dimensions, refer to
Figure 208, sheet 2.
NOTE: Make sure that the installation process is completed, or at
least one fastener is set in every third hole, during the
curing time of the sealant (interfay sealant) (Material No.
09005) or sealant (corrosion inhibiting brush consistency)
(Material No. 09013), refer to Chapter 517600.
(s) Fill the gap between skin and repair skin (1 mm 2 mm (0.039
in 0.079 in)) with sealant (corrosion inhibiting brush consis
tency) (Material No. 09013).
(t) Seal the edges of the repair parts with sealant (interfay seal
ant) (Material No. 09005) or sealant (corrosion inhibiting brush
consistency) (Material No. 09013), refer to Chapter 517611.
(u) Apply structure paint (flexible polyurethane) (Material No.
16021) to the sealant bead, refer to Chapter 512300.
(v) Apply structure paint (polyurethane top coat, grey) (Material No.
16002) to the internal surface of repair area, refer to Chapter
512300.
(w) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the external surface of repair area to match the sur
rounding structure, refer to Chapter 512300.

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STRUCTURAL REPAIR MANUAL

Skin between Two Stringers Flush Repair


Figure 208 (sheet 1)

Printed in Germany

575400 PagesApr283/284
01/15

STRUCTURAL REPAIR MANUAL

Skin between Two Stringers Flush Repair


Figure 208 (sheet 2)

Printed in Germany

575400 PagesApr285/286
01/15

STRUCTURAL REPAIR MANUAL


CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR MUST BE INSPECTED AT DEFINED INTERVALS. THE INSPECTION
INSTRUCTION REFERENCE (IIR) IS 575400200100 AND IS DESCRIBED
IN THE STRUCTURAL REPAIR INSPECTIONS (SRI) SECTION OF THE SRM. IN
FORM YOUR PLANNING DEPARTMENT AND PROVIDE THEM WITH THE NECESSARY
INFORMATION.
I. Skin between Two Stringers External Doubler Repair
NOTE: This repair is applicable for damaged skin between two stringers
external doubler repair in Zone C (skin damage only) and is effec
tive as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000,
011,
024,
054,

001, 002, 003, 004, 010,


012, 013, 014, 020, 022,
025, 050, 051, 052, 053,
056

Effectivity per Weight Variant and Aircraft Type


Table 210
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give the nec
essary data about all weight variants and their required informa
tion for allowable damage and repair applicability.

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STRUCTURAL REPAIR MANUAL


(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

External Doubler
Sealant (Interfay Sealant)

Sealant (Corrosion Inhibit


ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Pretreatment for Painting
(Chemical Conversion Coat
ing, Yellow Aluminum)
Structure Paint (Anti Cor
rosion Primer Polyurethane)
Structure Paint (Polyure
thane Top Coat, Grey)
Structure Paint (Polyure
thane Finish Paint)
Structure Paint (Wash
Primer)
Structure Paint (Flexible
Polyurethane)
Chromic Acid Anodizing
(CAA)

Refer to Figure 209


AR Material No. 09005,
Chapter 513500
AR Material No. 09013,
Chapter 513500
AR Material No. 11003,
Chapter 513500
AR Material No. 13002,
Chapter 513500

refer to
refer to
refer to
refer to

AR Material No. 16001, refer


Chapter 513500
AR Material No. 16002, refer
Chapter 513500
AR Material No. 16018, refer
Chapter 513500
AR Material No. 16020, refer
Chapter 513500
AR Material No. 16021, refer
Chapter 513500
AR Refer to Chapter 512111

to
to
to
to
to

(2) Repair Instructions (Refer to Figure 209)


NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710.
(a) Mark the repair area, according to Figure 209.
CAUTION: MAKE SURE YOU DO NOT DAMAGE INTERNAL STRUCTURE OR SYSTEM
WHEN DRILLING.
(b) Remove the existing fasteners in the repair area, refer to Chap
ter 514211.

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STRUCTURAL REPAIR MANUAL


CAUTION: A METAL SHEET MUST BE PLACED UNDERNEATH THE CUTTING AREA TO
AVOID DAMAGE TO THE STRUCTURE.
(c) Cut out the damaged skin area and deburr the edges of the cut
out.
NOTE: The cutout must be parallel and perpendicular to the
stringer and in the shape of a rectangle.
NOTE: The cutout must not exceed the adjacent edge of the string
er.
(d) Clean the edges of the cutout with the cleaning agent (methyl
ethylketone) (Material No. 11003).
(e) Treat the edges of the cutout with structure paint (wash primer)
(Material No. 16020), refer to Chapter 512300.
(f) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to the edges of the cutout, refer to Chapter
512300.
(g) Prepare the repair part (external doubler).
NOTE: Precut the doubler to oversize.
NOTE: Adapt the repair part (external doubler) to the flapcon
tour.
(h) Put the repair part (external doubler) in position, transfer
drill the existing fastener holes, drill the required additional
fastener holes and drill the inspection hole (if required).
(i) Make the countersinks for the fasteners in the doubler, refer to
Chapter 514611.
(j) Remove the repair part (external doubler) from the repair area
and deburr the fastener holes.
(k) Cut the external doubler to size and deburr.
(l) Chamfer the external doubler, refer to Chapter 514700.
(m) Clean the repair part (external doubler) with the cleaning agent
(methylethylketone) (Material No. 11003) and treat with chromic
acid anodizing (CAA) or pretreatment for painting (chemical con
version coating, yellow aluminum) (Material No. 13002), refer to
Chapter 512111.
(n) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to the repair part (external doubler), refer to
Chapter 512300.
(o) Fill existing countersinks with repair washers if necessary, re
fer to Chapter 517115.

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STRUCTURAL REPAIR MANUAL


(p) Apply sealant (interfay sealant) (Material No. 09005) or sealant
(corrosion inhibiting brush consistency) (Material No. 09013) to
the mating surfaces of the repair part (external doubler), refer
to Chapter 517611.
(q) Put the repair part (external doubler) in position and install
all fasteners with wet sealant (interfay sealant) (Material No.
09005) or sealant (corrosion inhibiting brush consistency) (Mate
rial No. 09013), refer to Chapter 514211 and Chapter 517611.
NOTE: For fastener layout dimensions, refer to Figure 209, sheet
2.
NOTE: For fastener installation, refer to Figure 209, sheet 3.
NOTE: Make sure that the installation process is completed, or at
least one fastener is set in every third hole, during the
curing time of the sealant (interfay sealant) (Material No.
09005) or sealant (corrosion inhibiting brush consistency)
(Material No. 09013).
(r) Seal the edges of the external doubler with sealant (interfay
sealant) (Material No. 09005) or sealant (corrosion inhibiting
brush consistency) (Material No. 09013), refer to Chapter
517611.
(s) Apply structure paint (flexible polyurethane) (Material No.
16021) to the sealant bead, refer to Chapter 512300.
(t) Apply structure paint (polyurethane top coat, grey) (Material No.
16002) to the internal surface of repair area, refer to Chapter
512300.
(u) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the external surface of repair area to match the sur
rounding structure, refer to Chapter 512300.

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STRUCTURAL REPAIR MANUAL

Skin between Two Stringers External Doubler Repair


Figure 209 (sheet 1)

Printed in Germany

575400 PagesApr291/292
01/15

STRUCTURAL REPAIR MANUAL

Skin between Two Stringers External Doubler Repair


Figure 209 (sheet 2)

Printed in Germany

575400 PagesApr293/294
01/15

STRUCTURAL REPAIR MANUAL

Skin between Two Stringers External Doubler Repair


Figure 209 (sheet 3)

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Page 295
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STRUCTURAL REPAIR MANUAL


CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: FOR BEFORE MODIFICATION 49008D42923, THIS TEMPORARY REPAIR MUST BE
REPLACED BY A PERMANENT REPAIR SOLUTION WITHIN 28 800 FC (FH NOT
RELEVANT).
CAUTION: FOR AFTER MODIFICATION 49008D42923, THIS TEMPORARY REPAIR MUST BE
REPLACED BY A PERMANENT REPAIR SOLUTION WITHIN 24 600 FC (FH NOT
RELEVANT).
J. Skin at Rib, between Stringers Flush Repair
NOTE: This repair is applicable for skin and rib damage between stringers
flush repair in Zone C (stringer undamaged) and is effective as
follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000,
011,
024,
054,

001, 002, 003, 004, 010,


012, 013, 014, 020, 022,
025, 050, 051, 052, 053,
056

Effectivity per Weight Variant and Aircraft Type


Table 211
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give the nec
essary data about all weight variants and their required informa
tion for allowable damage and repair applicability.

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STRUCTURAL REPAIR MANUAL


(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

1
2
3
4

Repair Skin
Repair Doubler (Internal)
Repair Angle (Rib Foot)
Shim
Sealant (Interfay Sealant)

AR

Sealant (Corrosion Inhibit


ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Pretreatment For Painting
(Chemical Conversion Coat
ing, Yellow Aluminum)
Structure Paint (Anti Cor
rosion Primer Polyurethane)
Structure Paint (Polyure
thane Top Coat, Grey)
Structure Paint (Polyure
thane Finish Paint)
Structure Paint (Wash
Primer)
Structure Paint (Flexible
Polyurethane)
Chromic Acid Anodizing
(CAA)

Refer to Figure 210


Refer to Figure 210
Refer to Figure 210
Refer to Figure 210
Material No. 09005,
Chapter 513500
AR Material No. 09013,
Chapter 513500
AR Material No. 11003,
Chapter 513500
AR Material No. 13002,
Chapter 513500

refer to
refer to
refer to
refer to

AR Material No. 16001, refer


Chapter 513500
AR Material No. 16002, refer
Chapter 513500
AR Material No. 16018, refer
Chapter 513500
AR Material No. 16020, refer
Chapter 513500
AR Material No. 16021, refer
Chapter 513500
AR Refer to Chapter 512111

to
to
to
to
to

(2) Repair Instructions (Refer to Figure 210)


NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710.
CAUTION: ONLY USE A MECHANICAL PROCEDURE TO REMOVE THE SURFACE
PROTECTION. REFER TO CHAPTER 517511.
(a) Remove paint and surface protection from the repair area.
(b) Mark the repair area, refer to Figure 210.
CAUTION: MAKE SURE YOU DO NOT DAMAGE INTERNAL STRUCTURE OR SYSTEM
WHEN DRILLING.
(c) Remove the existing fasteners in the repair area, refer to Chap
ter 514211.

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STRUCTURAL REPAIR MANUAL


CAUTION: A METAL SHEET MUST BE PLACED UNDERNEATH THE CUTTING AREA TO
AVOID DAMAGE TO THE STRUCTURE.
CAUTION: FOR REPAIR CUTOUT LIMITATIONS, REFER TO FIGURE 210, SHEET
1).
(d) Cut out the damaged skin area and deburr the edges of the cut
out.
NOTE: The cutout must be parallel and perpendicular to the
stringer and in shape of a rectangle.
(e) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).
(f) Measure all skin, stringer thickness and all stringer distances
of the whole repair area.
(g) Prepare the repair parts according to Figure 210.
(h) Measure the steps and determine if liquid shims and solid shims
are required.
(i) Prepare the solid shims, if required.
NOTE: For steps < 0.3 mm (0.012 in) no shim must be applied. For
steps 0.3 mm (0.012 in) and < 0.5 mm (0.02 in) apply
liquid shim (sealant (interfay sealant) (Material No.
09005) or sealant (corrosion inhibiting brush consistency)
(Material No. 09013)). For steps 0.5 mm (0.02 in) use
solid shim (3.1364T3 / T42, clad 2024T3 / T42).
CAUTION: MAKE SURE YOU DO NOT DAMAGE INTERNAL STRUCTURE OR SYSTEM
WHEN DRILLING.
(j) Put the repair parts in position and transfer drill existing
holes, drill the additional fastener holes and the inspection
hole (if required).
NOTE: For fastener layout dimensions, refer to Figure 210, sheet
4).
(k) If necessary make the countersinks for the fasteners, refer to
Chapter 514611.
(l) Remove all repair parts.
(m) Deburr the repair fasteners holes and the inspection hole (if
required).
(n) Cut the repair parts to size and deburr.
(o) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).

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STRUCTURAL REPAIR MANUAL


(p) Apply pretreatment for painting (chemical conversion coating, yel
low aluminum) (Material No. 13002) to the repair parts or treat
with chromic acid anodizing (CAA), refer to Chapter 512111.
(q) Apply structure paint (wash primer) (Material No. 16020) to the
edges of the cutout, refer to Chapter 512300.
(r) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to repair parts and edges of the cutout, refer
to Chapter 512300.
(s) Apply structure paint (polyurethane top coat, grey) (Material No.
16002) to repair parts and edges of the cutout, refer to Chap
ter 512300.
(t) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).
(u) Put the repair parts in position.
(v) Install all fasteners in the repair area with sealant (interfay
sealant) (Material No. 09005) or sealant (corrosion inhibiting
brush consistency) (Material No. 09013), refer to Chapter
514211 and Chapter 517611.
NOTE: It is important that all fasteners are installed within the
work life of the sealant (interfay sealant) (Material No.
09005) or sealant (corrosion inhibiting brush consistency)
(Material No. 09013). If this is not possible, install ev
ery third rivet within the work life of the sealant. For
work life of the sealant refer to the manufacturers
instruction.
(w) Fill all gaps of the repair area with sealant (corrosion inhib
iting brush consistency) (Material No. 09013) and remove excess
sealant, refer to Chapter 517611.
(x) Apply structure paint (flexible polyurethane) (Material No.
16021) to the sealant bead, refer to Chapter 512300.
(y) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the external surface of the repair area to match the
surrounding structure, refer to Chapter 512300.

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575400 PagesApr299/300
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib, between Stringers Flush Repair


Figure 210 (sheet 1)

Printed in Germany

575400 PagesApr301/302
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib, between Stringers Flush Repair


Figure 210 (sheet 2)

Printed in Germany

575400 PagesApr303/304
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib, between Stringers Flush Repair


Figure 210 (sheet 3)

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575400 PagesApr305/306
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib, between Stringers Flush Repair


Figure 210 (sheet 4)

Printed in Germany

575400 PagesApr307/308
01/15

STRUCTURAL REPAIR MANUAL


CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: FOR BEFORE MODIFICATION 49008D42923, THIS TEMPORARY REPAIR MUST BE
REPLACED BY A PERMANENT REPAIR SOLUTION WITHIN 28 800 FC (FH NOT
RELEVANT).
CAUTION: FOR AFTER MODIFICATION 49008D42923, THIS TEMPORARY REPAIR MUST BE
REPLACED BY A PERMANENT REPAIR SOLUTION WITHIN 24 600 FC (FH NOT
RELEVANT).
K. Skin at Rib and Stringer Flush Repair
NOTE: This repair is applicable for skin, rib and stringer damage
flush repair in Zone C and is effective as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000,
011,
024,
054,

001, 002, 003, 004, 010,


012, 013, 014, 020, 022,
025, 050, 051, 052, 053,
056

Effectivity per Weight Variant and Aircraft Type


Table 212
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give the nec
essary data about all weight variants and their required informa
tion for allowable damage and repair applicability.

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STRUCTURAL REPAIR MANUAL


(1) Repair Materials
ITEM

NOMENCLATURE

1
2
3
4
5
6
7
8
9
10

QTY MATERIAL/REMARKS

Repair Skin
Repair Doubler (Internal)
Repair Angle (Rib Foot)
Repair Stringer (Lower
Skin)
Repair Stringer (LProfile,
Upper Skin)
Stringer Splice (Lower
Skin)
Stringer Splice (LProfile,
Upper Skin)
Stringer Section (Lower
Skin)
Stringer Section (LPro
file, Upper Skin)
Shim
Sealant (Interfay Sealant)
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Pretreatment For Painting
(Chemical Conversion Coat
ing, Yellow Aluminum)
Structure Paint (Anti Cor
rosion Primer Polyurethane)
Structure Paint (Polyure
thane Finish Paint)
Structure Paint (Wash
Primer)
Structure Paint (Flexible
Polyurethane)
Chromic Acid Anodizing
(CAA)

Refer
Refer
Refer
Refer

to
to
to
to

Figure
Figure
Figure
Figure

211
211
211
211

Refer to Figure 211

Refer to Figure 211

Refer to Figure 211

Refer to Figure 211

Refer to Figure 211

Refer to Figure 211


AR Material No. 09005,
Chapter 513500
AR Material No. 09013,
Chapter 513500
AR Material No. 11003,
Chapter 513500
AR Material No. 13002,
Chapter 513500

refer to
refer to
refer to
refer to

AR Material No. 16001, refer


Chapter 513500
AR Material No. 16018, refer
Chapter 513500
AR Material No. 16020, refer
Chapter 513500
AR Material No. 16021, refer
Chapter 513500
AR Refer to Chapter 512111

to
to
to
to

(2) Repair Instructions (Refer to Figure 211)


NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710.

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Page 310
575400 Apr
01/15

STRUCTURAL REPAIR MANUAL


CAUTION: ONLY USE A MECHANICAL PROCEDURE TO REMOVE THE SURFACE
PROTECTION. REFER TO CHAPTER 517511.
(a) Remove paint and surface protection from the repair area.
(b) Mark the repair area, refer to Figure 211.
CAUTION: MAKE SURE YOU DO NOT DAMAGE INTERNAL STRUCTURE OR SYSTEM
WHEN DRILLING.
(c) Remove the existing fasteners in the repair area, refer to Chap
ter 514211.
CAUTION: A METAL SHEET MUST BE PLACED UNDERNEATH THE CUTTING AREA TO
AVOID DAMAGE TO THE STRUCTURE.
CAUTION: FOR REPAIR CUTOUT LIMITATIONS, REFER TO FIGURE 211, SHEET
1).
(d) Cut out the damaged skin area and deburr the edges of the cut
out.
NOTE: The cutout must be parallel and perpendicular to the
stringer and in shape of a rectangle.
(e) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).
(f) Measure all skin, stringer thickness and all stringer distances
of the whole repair area.
(g) Prepare the repair parts according to Figure 211.
NOTE: Precut the doubler to oversize.
NOTE: Adapt the repair parts to the flapcontour.
(h) Measure the steps and determine if liquid shims and solid shims
are required.
(i) Prepare the solid shims if required.
NOTE: For steps < 0.3 mm (0.012 in) no shim must be applied. For
steps 0.3 mm (0.012 in) and < 0.5 mm (0.02 in) apply
liquid shim (sealant (interfay sealant) (Material No.
09005) or sealant (corrosion inhibiting brush consistency)
(Material No. 09013)). For steps 0.5 mm (0.02 in) use
solid shim (3.1364T3 / T42, clad 2024T3 / T42).
CAUTION: MAKE SURE YOU DO NOT DAMAGE INTERNAL STRUCTURE OR SYSTEM
WHEN DRILLING.
(j) Put the repair parts in position as follows:

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STRUCTURAL REPAIR MANUAL


1 Put the rib repair parts in position and transfer drill exist
ing holes.
For before Modification 49008D42923 lower skin area, refer to
Figure 211, sheet 3,
For after Modification 49008D42923 lower skin area, refer to
Figure 211, sheet 4,
For upper skin area, refer to Figure 211, sheet 5.
NOTE: For fastener layout dimensions, refer to Figure 211,
sheet 6.
2 Put the stringer repair parts in position and transfer drill
existing holes.
For before Modification 49008D42923, damaged stringer replaced
by repair stringer, refer to Figure 211, sheet 5.
For after Modification 49008D42923, splice repair, refer to
Figure 211, sheet 5.
NOTE: For fastener layout dimensions, refer to Figure 211,
sheet 6.
(k) Drill the inspection hole (if required) and the additional re
quired fastener holes in the skin and in the repair skin.
(l) If necessary make the countersinks for the fasteners in the skin
and repair skin, refer to Chapter 514611.
(m) Remove all the repair parts from the repair area.
(n) Deburr the repair fasteners holes and the inspection hole (if
required).
(o) Cut the repair parts to size and deburr.
(p) Apply pretreatment for painting (chemical conversion coating, yel
low aluminum) (Material No. 13002) to the repair parts or treat
with chromic acid anodizing (CAA), refer to Chapter 512111.
(q) Apply structure paint (wash primer) (Material No. 16020) to the
edges of the cutout, refer to Chapter 512300.
(r) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to repair parts and edges of the cutout, refer
to Chapter 512300.
(s) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).
(t) Coat the connecting surfaces of the repair parts with sealant
(interfay sealant) (Material No. 09005) or sealant (corrosion
inhibiting brush consistency) (Material No. 09013), refer to
Chapter 517611.

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STRUCTURAL REPAIR MANUAL


(u) Put the repair parts in position.
(v) Install all fasteners in the repair area with sealant (interfay
sealant) (Material No. 09005) or sealant (corrosion inhibiting
brush consistency) (Material No. 09013), refer to Chapter
514211 and Chapter 517611.
(w) Fill all gaps of the repair area with sealant (interfay sealant)
(Material No. 09005) or sealant (corrosion inhibiting brush con
sistency) (Material No. 09013) and remove excess sealant, refer
to Chapter 517611.
(x) Apply structure paint (flexible polyurethane) (Material No.
16021) to the sealant bead, refer to Chapter 512300.
(y) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the external surface of the repair area to match the
surrounding structure, refer to Chapter 512300.

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575400 PagesApr313/314
01/15

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Skin at Rib and Stringer Flush Repair


Figure 211 (sheet 1)

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575400 PagesApr315/316
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib and Stringer Flush Repair


Figure 211 (sheet 2)

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575400 PagesApr317/318
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib and Stringer Flush Repair


Figure 211 (sheet 3)

Printed in Germany

575400 PagesApr319/320
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib and Stringer Flush Repair


Figure 211 (sheet 4)

Printed in Germany

575400 PagesApr321/322
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib and Stringer Flush Repair


Figure 211 (sheet 5)

Printed in Germany

575400 PagesApr323/324
01/15

STRUCTURAL REPAIR MANUAL

Skin at Rib and Stringer Flush Repair


Figure 211 (sheet 6)

Printed in Germany

575400 PagesApr325/326
01/15

STRUCTURAL REPAIR MANUAL


CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR MUST BE INSPECTED AT DEFINED INTERVALS. THE INSPECTION
INSTRUCTION REFERENCE (IIR) IS 575400200200 AND IS DESCRIBED
IN THE STRUCTURAL REPAIR INSPECTIONS (SRI) SECTION OF THE SRM. IN
FORM YOUR PLANNING DEPARTMENT AND PROVIDE THEM WITH THE NECESSARY
INFORMATION.
L. Skin at Rib and Stringer External Doubler Repair
NOTE: This repair is applicable for skin, rib and stringer damage ex
ternal doubler repair in Zone C and is effective as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000,
011,
024,
054,

001, 002, 003, 004, 010,


012, 013, 014, 020, 022,
025, 050, 051, 052, 053,
056

Effectivity per Weight Variant and Aircraft Type


Table 213
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give the nec
essary data about all weight variants and their required informa
tion for allowable damage and repair applicability.

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STRUCTURAL REPAIR MANUAL


(1) Repair Materials
ITEM
1
2
3
4
5
6
7
8
9
10
11
12

NOMENCLATURE

QTY MATERIAL/REMARKS

Repair Doubler (External)


Repair Angle (Rib Foot,
Straight)
Repair Angle (Rib Foot,
Joggled)
Repair Stringer (Lower
Skin)
Repair Stringer (LProfile,
Upper Skin)
Stringer Splice (Lower
Skin)
Stringer Splice (LProfile,
Upper Skin)
Stringer Section (Lower
Skin)
Stringer Section (LPro
file, Upper Skin)
Shim
Shim
Shim
Sealant (Interfay Sealant)
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Pretreatment for Painting
(Chemical Conversion Coat
ing, Yellow Aluminum)
Structure Paint (Anti Cor
rosion Primer Polyurethane)
Structure Paint (Polyure
thane Finish Paint)
Structure Paint (Wash
Primer)
Structure Paint (Flexible
Polyurethane)
Chromic Acid Anodizing
(CAA)

Refer to Figure 212


Refer to Figure 212

Refer to Figure 212

Refer to Figure 212

Refer to Figure 212

Refer to Figure 212

Refer to Figure 212

Refer to Figure 212

Refer to Figure 212

AR

Refer to Figure 212


Refer to Figure 212
Refer to Figure 212
Material No. 09005,
Chapter 513500
AR Material No. 09013,
Chapter 513500
AR Material No. 11003,
Chapter 513500
AR Material No. 13002,
Chapter 513500

refer to
refer to
refer to
refer to

AR Material No. 16001, refer


Chapter 513500
AR Material No. 16018, refer
Chapter 513500
AR Material No. 16020, refer
Chapter 513500
AR Material No. 16021, refer
Chapter 513500
AR Refer to Chapter 512111

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to
to
to
to

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STRUCTURAL REPAIR MANUAL


(2) Repair Instructions (Refer to Figure 212)
NOTE: Before you repair the damaged structure, you must do a damage
evaluation, refer to Chapter 517710.
(a) Mark the repair area.
CAUTION: MAKE SURE YOU DO NOT DAMAGE INTERNAL STRUCTURE OR SYSTEM
WHEN DRILLING.
(b) Remove the existing fasteners in the repair area, refer to Chap
ter 514211.
CAUTION: A METAL SHEET MUST BE PLACED UNDERNEATH THE CUTTING AREA TO
AVOID DAMAGE TO THE STRUCTURE.
CAUTION: FOR REPAIR CUTOUT LIMITATIONS, REFER TO FIGURE 212, SHEET
1).
(c) Cut out the damaged skin area and deburr the edges of the cut
out.
NOTE: The cutout must be parallel and perpendicular to the
stringer and in the shape of a rectangle.
(d) Clean the edges of the cutout with the cleaning agent (methyl
ethylketone) (Material No. 11003).
(e) Measure all skin, stringer thickness and all stringer distances
of the whole repair area.
(f) Prepare the repair parts according to Figure 212.
NOTE: Precut the doubler to oversize.
NOTE: Adapt the repair parts to the flapcontour.
CAUTION: MAKE SURE YOU DO NOT DAMAGE INTERNAL STRUCTURE OR SYSTEM
WHEN DRILLING.
(g) Put the repair parts in position as follows:
1 Put the rib repair parts in position and transfer drill exist
ing holes.
For before Modification upper and lower skin areas, refer to
Figure 212, sheet 3,
For after Modification lower skin area, refer to Figure 212,
sheet 5.
NOTE: Use repair parts for upper and lower skin areas as ap
plicable.
NOTE: For fastener layout dimensions, refer to Figure 212,
sheet 7.

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STRUCTURAL REPAIR MANUAL


2 Put the stringer repair parts in position and transfer drill
existing holes.
For before Modification, damaged stringer replaced by one re
pair stringer, refer to Figure 212, sheet 4,
For After Modification, damaged stringer replaced by a splice
repair, refer to Figure 212, sheet 5.
NOTE: Use repair parts for upper and lower skin areas as ap
plicable.
NOTE: For fastener layout dimensions, refer to Figure 212,
sheet 7.
(h) Drill the inspection hole (if required).
(i) Position the repair doubler and transfer drill existing holes and
drill the additional required holes in the doubler.
NOTE: Pay attention to the correct sequence installation of the
repair parts.
(j) If necessary make the countersinks for the fasteners in the dou
bler, refer to Chapter 514611.
(k) Remove all the repair parts from the repair area and deburr all
holes.
(l) Apply pretreatment for painting (chemical conversion coating, yel
low aluminum) (Material No. 13002) to the repair parts or treat
with chromic acid anodizing (CAA), refer to Chapter 512111.
(m) Apply structure paint (wash primer) (Material No. 16020) to the
edges of the cutout, refer to Chapter 512300.
(n) Apply structure paint (anti corrosion primer polyurethane) (Mate
rial No. 16001) to repair parts and edges of the cutout, refer
to Chapter 512300.
(o) Clean the repair area with the cleaning agent (methylethylke
tone) (Material No. 11003).
(p) Fill existing countersinks with repair washers if necessary, re
fer to Chapter 517115.
(q) Coat the connecting surfaces of the repair parts with sealant
(interfay sealant) (Material No. 09005) or sealant (corrosion
inhibiting brush consistency) (Material No. 09013), refer to
Chapter 517611.
(r) Put the repair parts in position.
(s) Install all fasteners in the repair area with sealant (interfay
sealant) (Material No. 09005) or sealant (corrosion inhibiting

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STRUCTURAL REPAIR MANUAL


brush consistency) (Material No. 09013), refer to Chapter
514211 and Chapter 517611.
(t) Fill all gaps of the repair area with sealant (interfay sealant)
(Material No. 09005) or sealant (corrosion inhibiting brush con
sistency) (Material No. 09013) and remove excess sealant, refer
to Chapter 517611.
(u) Apply structure paint (flexible polyurethane) (Material No.
16021) to the sealant bead, refer to Chapter 512300.
(v) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the external surface of the repair area to match the
surrounding structure, refer to Chapter 512300.

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Skin at Rib and Stringer External Doubler Repair


Figure 212 (sheet 1)

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STRUCTURAL REPAIR MANUAL

Skin at Rib and Stringer External Doubler Repair


Figure 212 (sheet 2)

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Skin at Rib and Stringer External Doubler Repair


Figure 212 (sheet 3)

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Skin at Rib and Stringer External Doubler Repair


Figure 212 (sheet 4)

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Skin at Rib and Stringer External Doubler Repair


Figure 212 (sheet 5)

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STRUCTURAL REPAIR MANUAL

Skin at Rib and Stringer External Doubler Repair


Figure 212 (sheet 6)

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Skin at Rib and Stringer External Doubler Repair


Figure 212 (sheet 7)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR INFORMATION IS ONLY APPLICABLE BEFORE MODIFICATION
55884D46413.
CAUTION: THIS TEMPORARY REPAIR MUST BE REPLACED BY A PERMANENT REPAIR WITH
IN 30 MONTHS (FC AND FH NOT RELEVANT). REFER TO PARAGRAPH 4.N.
FOR RUBBING STRIP PERMANENT REPAIR.
M. Rubbing Strip Temporary Repair
NOTE: This repair principle is inactive since revision dated Oct 01/11,
it has been moved to applicable Chapter 575412 Page Block 201.
NOTE: This temporary repair is applicable for damage to the rubbing strip
of the inboard flap as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014, 020, 022,
024, 025, 050, 051, 052, 053

Effectivity per Weight Variant and Aircraft Type


Table 214
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Bonding and Adhesive Com


pound (Self Adhesive Alu
minum Tape)
Bonding and Adhesive Com
pound (Masking Tape)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane Methyl Chloroform)
Emery Cloth

AR Material No. 08052, refer to


Chapter 513500
AR Material No. 08074, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
AR Material No. 11004, refer to
Chapter 513500
AR Grade 240, Local Purchase

(2) Repair Instructions (Refer to Figure 213)

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STRUCTURAL REPAIR MANUAL


(a) Mark the repair area according to Figure 213 and cover the adja
cent area with bonding and adhesive compound (masking tape) (Ma
terial No.08074). This will help you to protect adjacent skin
surface.
CAUTION: TAKE CARE NOT TO DAMAGE THE FLAP SKIN PANEL. FURTHERMORE DO
NOT CAUSE ANY DEBONDING AT THE EDGE OF THE REMAINING RUB
BING STRIP PORTION.
(b) Remove the damaged rubbing strip.
(c) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
NOTE: For cleaning with cleaning agent (methylethylketone) (Ma
terial No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004) use paper or purecotton
cloths only. Do not use fabrics containing synthetic mate
rials. Synthetics are dissolved by cold solvents and form
an oil film which produces a nonadhesive surface.
(d) Lightly abrade the designated repair area with emery cloth (grade
240).
(e) Carefully clean the inboard flap with cleaning agent (methyl
ethylketone) (Material No. 11003) or cleaning agent (trichloroe
thane methyl chloroform) (Material No. 11004).
(f) Allow the cleaning agent to evaporate.
(g) To build up the damaged area of the rubbing strip, it is neces
sary to prepare three layers of bonding and adhesive compound
(self adhesive aluminum tape) (Material No. 08052), refer to
Figure 213, sheet 2.
(h) Position the prepared bonding and adhesive compound (self adhe
sive aluminum tape) (Material No. 08052) to the repair area,
refer to Figure 213, sheet 2. The strips must be laid in the
direction of the flap drive (direction of the flap travel).
NOTE: If the damage is greater than the width of the tape, pre
pare sufficient strips to be laid with a butt joint between
the strips.
(i) Smooth out the layers from the center to remove air and
wrinkles.
NOTE: Repeat this step after each layer is applied.
NOTE: If the position of the bonding and adhesive compound (self
adhesive aluminum tape) (Material No. 08052) is not correct
or if there is any indication of air bubbles, remove all
the strips and fix again.

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STRUCTURAL REPAIR MANUAL


(j) Remove all bonding and adhesive compound (masking tape) (Material
No. 08074).

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Rubbing Strip Temporary Repair


Figure 213 (sheet 1)

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Rubbing Strip Temporary Repair


Figure 213 (sheet 2)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR INFORMATION IS ONLY APPLICABLE BEFORE MODIFICATION
55884D46413.
N. Rubbing Strip Permanent Repair
NOTE: This repair principle is inactive since revision dated Oct 01/11,
it has been moved to applicable Chapter 575412 Page Block 201.
For this repair there are two repair principles available, refer to the
following paragraphs to get the relevant repair:
Paragraph 4.N.(2) describes a
bonding and adhesive compound
rial No. 08066)
Paragraph 4.N.(3) describes a
sealant (corrosion inhibiting

permanent repair of rubbing strip with


(acrylic pressure sensitive tape) (Mate
permanent repair of rubbing strip with
brush consistency) (Material No. 09013).

NOTE: This permanent repair is applicable for damage to the rubbing strip
of the inboard flap as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014, 020, 022,
024, 025, 050, 051, 052, 053

Effectivity per Weight Variant and Aircraft Type


Table 215
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.

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(1) Repair Materials
ITEM
1

NOMENCLATURE

QTY MATERIAL/REMARKS

Rubbing Strip
Bonding and Adhesive Com
pound (Acrylic Pressure
Sensitive Tape)
Bonding and Adhesive Com
pound (Masking Tape)
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane Methyl Chloroform)
Structure Paint (Polyure
thane Finish Paint)
Emery Cloth

Refer to Figure 214


AR Material No. 08066, refer to
Chapter 513500
AR Material No. 08074,
Chapter 513500
AR Material No. 09013,
Chapter 513500
AR Material No. 11003,
Chapter 513500
AR Material No. 11004,
Chapter 513500
Material No. 16018,
Chapter 513500
AR Grade 240/320, Local

refer to
refer to
refer to
refer to
refer to
Purchase

(2) Repair Instructions of Rubbing Strip with Adhesive Film (Refer to


Figure 214)
(a) Mark the repair area according to Figure 214 and cover the adja
cent area with bonding and adhesive compound (masking tape) (Ma
terial No.08074). This will help you to protect adjacent skin
surface.
(b) Remove the damaged rubbing strip, adhesive film and sealant using
a wooden spatula.
(c) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
NOTE: For cleaning with cleaning agent (methylethylketone) (Ma
terial No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004) use paper or purecotton
cloths only. Do not use fabrics containing synthetic mate
rials. Synthetics are dissolved by cold solvents and form
an oil film which produces a nonadhesive surface.
(d) Lightly abrade the designated repair area with emery cloth (grade
320).
(e) Prepare the new rubbing strip according to the original.

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CAUTION: CARE MUST BE TAKEN DURING GRINDING AND CLEANING OPERATIONS
TO AVOID DEFORMATION OF THE RUBBING STRIPS AS THEY HAVE
MINIMAL THICKNESS VALUES.
(f) Roughen the mating surface of the new rubbing strip with emery
cloth (grade 240).
(g) Carefully clean the mating surface of the rubbing strip and in
board flap with cleaning agent (methylethylketone) (Material No.
11003) or cleaning agent (trichloroethane methyl chloroform) (Ma
terial No. 11004).
(h) Allow the cleaning agent to evaporate.
(i) Cut the amount of bonding and adhesive compound (acrylic pressure
sensitive tape) (Material No. 08066) necessary for each rubbing
strip approximately 20 mm (0.787 in) longer.
(j) Remove the release paper from one side of the bonding and adhe
sive compound (acrylic pressure sensitive tape) (adhesive film)
(Material No. 08066) and apply the adhesive film immediately to
the mating surface of the rubbing strip. Ensure that the adhesive
film is correctly positioned and free of air bubbles.
NOTE: The adhesive film must be positioned to cover the rubbing
strip exactly. The width of the adhesive film must be the
same as the width of the rubbing strip.
(k) Remove the release paper from the other side of the adhesive
film.
(l) Install the rubbing strip to the inboard flap. Smooth out from
the center to remove air.
NOTE: If any position of the rubbing strip is not correct or if
there is any indication of air bubbles, the entire rubbing
strip must be removed and reaffixed.
(m) Apply bonding and adhesive compound (masking tape) (Material No.
08074) to the rubbing strip and to the adjacent area to give an
unmasked area of 5 mm (0.197 in) from the edge of the rubbing
strip, refer to Figure 214 sheet 2. This will help you to remove
unwanted sealant from the rubbing strip.
(n) Apply sealant (corrosion inhibiting brush consistency) (Material
No. 09013) to the circumferential edge of the rubbing strip,
refer to Figure 214 sheet 2. Let the sealant cure according to
manufacturers instruction.
(o) Carefully remove the bonding and adhesive compound (masking tape)
(Material No. 08074) only from the rubbing strip and the adja
cent area.
(p) Apply bonding and adhesive compound (masking tape) (Material No.
08074) to the rubbing strip and to the adjacent area to give an

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STRUCTURAL REPAIR MANUAL


unmasked area of 3 mm (0.118 in) thru 5 mm (0.197 in) from the
sealant, refer to Figure 214 sheet 2.
(q) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the unmasked repair area, refer to Figure 214, sheet
2.
(r) Remove all bonding and adhesive compound (masking tape) (Material
No. 08074).
(3) Repair Instructions of Rubbing Strip with Sealant (Refer to Figure
214)
(a) Mark the repair area according to Figure 214 and cover the adja
cent area with bonding and adhesive compound (masking tape) (Ma
terial No. 08074). This will help you to protect adjacent skin
surface.
(b) Remove the damaged rubbing strip, adhesive film and sealant using
a wooden spatula.
(c) Roughen the repair area with emery cloth (grade 240).
(d) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
NOTE: For cleaning with cleaning agent (methylethylketone) (Ma
terial No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004) use paper or purecotton
cloths only. Do not use fabrics containing synthetic mate
rials. Synthetics are dissolved by cold solvents and form
an oil film which produces a nonadhesive surface.
(e) Prepare the new rubbing strip according to the original.
CAUTION: CARE MUST BE TAKEN DURING GRINDING AND CLEANING OPERATIONS
TO AVOID DEFORMATION OF THE RUBBING STRIPS AS THEY HAVE
MINIMAL THICKNESS VALUES.
(f) Roughen the mating surface of the new rubbing strip with emery
cloth (grade 240).
(g) Clean the rubbing strip with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
(h) Apply an even coat of sealant (corrosion inhibiting brush consis
tency) (Material No. 09013) 0.25 mm (0.01 in) thick to both
mating surfaces.
(i) Install the rubbing strip to the inboard flap. Smooth out from
the center to remove air.

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STRUCTURAL REPAIR MANUAL


(j) Apply a uniform and constant pressure to the rubbing strip with
a vacuum bag or other suitable means. If a vacuum bag is used,
maintain a pressure of between 0.4 and 0.6 bar (5.8 and 9.66
psi).
NOTE: Let the sealant cure according to manufacturers instruction.
NOTE: If position of the rubbing strip is not correct or if
bubbles appear, the entire rubbing strip must be removed
and reaffixed.
(k) Apply bonding and adhesive compound (masking tape) (Material No.
08074) to the rubbing strip and to the adjacent area to give an
unmasked area of 5 mm (0.197 in) from the edge of the rubbing
strip, refer to Figure 214 sheet 2. This will help you to remove
unwanted sealant from the rubbing strip.
(l) Apply sealant (corrosion inhibiting brush consistency) (Material
No. 09013) to the circumferential edge of the rubbing strip,
refer to Figure 214 sheet 2. Let the sealant cure according to
manufacturers instruction.
(m) Carefully remove the bonding and adhesive compound (masking tape)
(Material No. 08074) only from the rubbing strip and the adja
cent area.
(n) Apply bonding and adhesive compound (masking tape) (Material No.
08074) to the rubbing strip and to the adjacent area to give an
unmasked area of 3 mm (0.118 in) thru 5 mm (0.197 in) from the
sealant, refer to Figure 214 sheet 2.
(o) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the unmasked repair area, refer to Figure 214, sheet
2.
(p) Remove all bonding and adhesive compound (masking tape) (Material
No. 08074).

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Rubbing Strip Permanent Repair


Figure 214 (sheet 1)

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Rubbing Strip Permanent Repair


Figure 214 (sheet 2)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR INFORMATION IS ONLY APPLICABLE AFTER MODIFICATION
55884D46413.
CAUTION: THIS TEMPORARY REPAIR MUST BE REPLACED BY A PERMANENT REPAIR WITH
IN 30 MONTHS (FC AND FH NOT RELEVANT). REFER TO PARAGRAPH 4.P.
FOR WEAR RESISTANT PAINT PERMANENT REPAIR.
O. Wear Resistant Paint Temporary Repair
NOTE: This repair principle is inactive since revision dated Oct 01/11,
it has been moved to applicable Chapter 575412 Page Block 201.
NOTE: This temporary repair is applicable for damage to the wear resis
tant paint of the inboard flap as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014, 020, 022,
024, 025, 050, 051, 052, 053

Effectivity per Weight Variant and Aircraft Type


Table 216
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Bonding and Adhesive Com


pound (Self Adhesive Alu
minum Tape)
Bonding and Adhesive Com
pound (Masking Tape)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane Methyl Chloroform)
Emery Cloth

AR Material No. 08052, refer to


Chapter 513500
AR Material No. 08074, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
AR Material No. 11004, refer to
Chapter 513500
AR Grade 240, Local Purchase

(2) Repair Instructions (Refer to Figure 215)

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STRUCTURAL REPAIR MANUAL


(a) Mark the repair area according to Figure 215 and cover the adja
cent area with bonding and adhesive compound (masking tape) (Ma
terial No.08074). This will help you to protect adjacent skin
surface.
(b) Remove the damaged wear resistant paint.
(c) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
NOTE: For cleaning with cleaning agent (methylethylketone) (Ma
terial No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004) use paper or purecotton
cloths only. Do not use fabrics containing synthetic mate
rials. Synthetics are dissolved by cold solvents and form
an oil film which produces a nonadhesive surface.
(d) Lightly abrade the designated repair area with emery cloth (grade
240).
(e) Carefully clean the inboard flap with cleaning agent (methyl
ethylketone) (Material No. 11003) or cleaning agent (trichloroe
thane methyl chloroform) (Material No. 11004).
(f) Allow the cleaning agent to evaporate.
(g) To build up the damaged area of the wear resistant paint, it is
necessary to prepare three layers of bonding and adhesive com
pound (self adhesive aluminum tape) (Material No. 08052), refer
to Figure 215, sheet 2.
(h) Position the prepared bonding and adhesive compound (self adhe
sive aluminum tape) (Material No. 08052) to the repair area,
refer to Figure 215, sheet 2. The strips must be laid in the
direction of the flap drive (direction of the flap travel).
(i) Smooth out the layers from the center to remove air and
wrinkles.
NOTE: Repeat this step after each layer is applied.
NOTE: If the position of the bonding and adhesive compound (self
adhesive aluminum tape) (Material No. 08052) is not correct
or if there is any indication of air bubbles, remove the
all strips and fix again.
(j) Remove all bonding and adhesive compound (masking tape) (Material
No. 08074).

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Wear Resistant Paint Temporary Repair


Figure 215 (sheet 1)

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Wear Resistant Paint Temporary Repair


Figure 215 (sheet 2)

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR INFORMATION IS ONLY APPLICABLE AFTER MODIFICATION
55884D46413.
P. Wear Resistant Paint Permanent Repair
NOTE: This repair principle is inactive since revision dated Oct 01/11,
it has been moved to applicable Chapter 575412 Page Block 201.
NOTE: For wear resistant paint damage you can do a partial repair or a
complete repair to the wear resistant paint area as necessary.
NOTE: This permanent repair is applicable for damage to the wear resis
tant paint of the inboard flap as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014, 020, 022,
024, 025, 050, 051, 052, 053

Effectivity per Weight Variant and Aircraft Type


Table 217
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
(1) Repair Materials
ITEM

NOMENCLATURE

QTY MATERIAL/REMARKS

Wear Resistant Paint

Bonding and Adhesive Com


pound (Masking Tape)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane Methyl Chloroform)
Emery Cloth

AR BAC707 In Accordance to
AIMS0404027
AR Material No. 08074, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
AR Material No. 11004, refer to
Chapter 513500
AR Grade 240, Local Purchase

(2) Repair Instructions (Refer to Figure 216)

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STRUCTURAL REPAIR MANUAL


(a) Mark the repair area according to Figure 216 and cover the adja
cent area with bonding and adhesive compound (masking tape) (Ma
terial No. 08074) as necessary depending on the type of repair
(partial repair or complete repair). This will help you to pro
tect adjacent skin surface.
(b) Remove the damaged wear resistant paint.
(c) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
NOTE: For cleaning with cleaning agent (methylethylketone) (Ma
terial No.11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No.11004) use paper or purecotton
cloths only. Do not use fabrics containing synthetic mate
rials. Synthetics are dissolved by cold solvents and form
an oil film which produces a nonadhesive surface.
(d) Lightly abrade the designated repair area with emery cloth (grade
240).
(e) Carefully clean the inboard flap with cleaning agent (methyl
ethylketone) (Material No. 11003) or cleaning agent (trichloroe
thane methyl chloroform) (Material No. 11004).
(f) Allow the cleaning agent to evaporate.
(g) Apply the wear resistant paint (item 1) on the repair area as
necessary depending on the type of repair (partial repair or
complete repair).
(h) Remove all bonding and adhesive compound (masking tape) (Material
No. 08074).

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Wear Resistant Paint Permanent Repair


Figure 216

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CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR INFORMATION IS APPLICABLE BEFORE AND AFTER MODIFICATION
55884D46413.
Q. Repair of Rubbing Plate Bonded Permanent Repair
NOTE: This repair principle is inactive since revision dated Oct 01/11,
it has been moved to applicable Chapter 575412 Page Block 201.
NOTE: This permanent repair is applicable for damage to the bonded rub
bing plate of the inboard flap as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014, 020, 022,
024, 025, 050, 051, 052, 053

Effectivity per Weight Variant and Aircraft Type


Table 218
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.

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(1) Repair Materials
ITEM
1

NOMENCLATURE

QTY MATERIAL/REMARKS

Rubbing Plate
Bonding and Adhesive Com
pound (Acrylic Pressure
Sensitive Tape)
Bonding and Adhesive Com
pound (Masking Tape)
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Cleaning Agent (Trichloroe
thane Methyl Chloroform)
Structure Paint (Polyure
thane Finish Paint)
Emery cloth

AR Refer to Figure 217


AR Material No. 08066, refer to
Chapter 513500
AR Material No. 08074, refer
Chapter 513500
AR Material No. 09013, refer
Chapter 513500
AR Material No. 11003, refer
Chapter 513500
AR Material No. 11004, refer
Chapter 513500
Material No. 16018, refer
Chapter 513500
AR Grade 240, Local Purchase

to
to
to
to
to

(2) Repair Instructions (Refer to Figure 217)


NOTE: This is a typical repair to be carried out on detached or torn
rubbing plate.
(a) Mark the repair area in accordance with Figure 217.
(b) Remove damaged rubbing plate and sealant up to normal interfaces
using wooden spatula.
(c) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
NOTE: For cleaning with cleaning agent (methylethylketone) (Ma
terial No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004) use paper or purecotton
cloths only. Do not use fabrics containing synthetic mate
rials. Synthetics are dissolved by cold solvents and form
an oil film which produces a nonadhesive surface.
(d) Prepare new rubbing plate (item 1) according to the original.
(e) Roughen mating surface of new rubbing plate (item 1) using emery
cloth (grade 240).
(f) Clean the new rubbing plate (item 1) with cleaning agent (methyl
ethylketone) (Material No. 11003) or cleaning agent (trichloroe
thane methyl chloroform) (Material No. 11004).

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(g) If you are using bonding and adhesive compound (acrylic pressure
sensitive tape) (adhesive film) (Material No. 08066), install
the rubbing plate (item 1) with (adhesive film) as follows:
1 Cut the amount of bonding and adhesive compound (acrylic pres
sure sensitive tape) (Material No. 08066) necessary for the
rubbing plate (item 1) approximately 20 mm (0.787 in) longer.
2 Remove the release paper from one side of the bonding and
adhesive compound (acrylic pressure sensitive tape) (adhesive
film) (Material No. 08066) and apply the adhesive film immedi
ately to the mating surface of the rubbing plate (item 1). En
sure that the adhesive film is correctly positioned and free of
air bubbles.
NOTE: The adhesive film must be positioned to cover the rubbing
plate (item 1) exactly. The width of the adhesive film
must be the same as the width of the rubbing plate (item
1).
3 Remove the release paper from the other side of the adhesive
film.
4 Install the rubbing plate (item 1) to the inboard flap. Smooth
out from the center to remove air.
NOTE: If any position of the rubbing plate (item 1) is not
correct or if there is any indication of air bubbles, the
entire rubbing strip must be removed and reaffixed.
(h) If you are using sealant (corrosion inhibiting brush consistency)
(Material No. 09013), install the rubbing plate (item 1) with
sealant as follows:
1 Apply an even coat of sealant (corrosion inhibiting brush con
sistency) (Material No. 09013) 0.25 mm (0.01 in) thick to both
mating surfaces.
2 Install the rubbing plate (item 1) to the inboard flap. Smooth
out from the center to remove air.
3 Apply a uniform and constant pressure to the rubbing plate
(item 1) with a vacuum bag or other suitable means. If a vacu
um bag is used, maintain a pressure of between 0.4 and 0.6 bar
(5.8 and 9.66 psi).
NOTE: Let the sealant cure according to manufacturers instruc
tion.
NOTE: If position of the rubbing strip is not correct or if
bubbles appear, the entire rubbing strip must be removed
and reaffixed.
(i) Seal the edges of the rubbing plate (item 1) with sealant (cor
rosion inhibiting brush consistency) (Material No. 09013), refer

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STRUCTURAL REPAIR MANUAL


to Figure 217. Let sealant (corrosion inhibiting brush consisten
cy) (Material No. 09013) cure according to manufacturers
instruction.
(j) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003) or cleaning agent (trichloroethane methyl
chloroform) (Material No. 11004).
(k) Apply bonding and adhesive compound (masking tape) (Material No.
08074) to the rubbing plate (item 1) to give an unmasked area
of 3 mm (0.118 in) 1 mm (0.039 in) on the trailing edge and 5
mm (0.197 in) 1 mm (0.039 in) on the upper surface, refer to
Figure 217, sheet 2.
(l) Apply structure paint (polyurethane finish paint) (Material No.
16018) to the unmasked repair area, refer to Figure 217, sheet
2.
(m) Remove all bonding and adhesive compound (masking tape) (Material
No. 08074).

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Repair of Rubbing Plate Bonded


Figure 217 (sheet 1)

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Repair of Rubbing Plate Bonded


Figure 217 (sheet 2)

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STRUCTURAL REPAIR MANUAL


CAUTION: OBEY THE REPAIR EFFECTIVITY PER WEIGHT VARIANT AND AIRCRAFT TYPE
GIVEN IN THE RELEVANT TABLE.
CAUTION: THIS REPAIR INFORMATION IS APPLICABLE BEFORE AND AFTER MODIFICATION
55884D46413.
R. Repair of Rubbing Plate Riveted Permanent Repair
NOTE: This repair principle is inactive since revision dated Oct 01/11,
it has been moved to applicable Chapter 575412 Page Block 201.
NOTE: This permanent repair is applicable for damage to the riveted rub
bing plate of the inboard flap as follows:
AIRCRAFT

WEIGHT VARIANT

A330200

020,
026,
054,
060,

021, 022, 023, 024, 025,


027, 050, 051, 052, 053,
055, 056, 057, 058, 059,
061

A330300

000, 001, 002, 003, 004, 010,


011, 012, 013, 014, 020, 022,
024, 025, 050, 051, 052, 053

Effectivity per Weight Variant and Aircraft Type


Table 219
NOTE: Refer to Paragraph 22. Weight Variant Information in the
INTRODUCTION of the SRM. Tables in the subparagraphs give necessary
data about all weight variants and their required information for
allowable damage and repair applicability.
(1) Repair Materials
ITEM
1

NOMENCLATURE

QTY MATERIAL/REMARKS

Rubbing Plate
Sealant (Corrosion Inhibit
ing Brush Consistency)
Cleaning Agent (Methyl
EthylKetone)
Structure Paint (Polyure
thane Finish Paint)

AR Refer to Figure 218


AR Material No. 09013, refer to
Chapter 513500
AR Material No. 11003, refer to
Chapter 513500
Material No. 16018, refer to
Chapter 513500

(2) Repair Instructions (Refer to Figure 218)


NOTE: This is a typical repair to be carried out on detached or torn
rubbing plate.
(a) Drill out the rivets from the damaged rubbing plate.
(b) Detach the damaged rubbing plate and remove sealant from the re
pair area using a wooden spatula.

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STRUCTURAL REPAIR MANUAL


(c) Clean the repair area using cleaning agent (methylethylketone)
(Material No. 11003).
(d) Prepare the new rubbing plate (item 1) according to the original
and adapt to the flap contour.
(e) Transfer the existing fastener holes to the new rubbing plate
(item 1) and drill the required diameter.
NOTE: For fastener hole and drill data, refer to Chapter
514411.
(f) Make the countersinks for the fasteners, refer to Chapter
514611.
(g) Deburr all rivet holes.
(h) Clean the rubbing plate (item 1) and the repair area with clean
ing agent (methylethylketone) (Material No. 11003).
(i) Apply sealant (corrosion inhibiting brush consistency) (Material
No. 09013) to the contacting surface of the rubbing plate (item
1), refer to Chapter 517611.
(j) Position the rubbing plate (item 1) and install the applicable
rivets, refer to Figure 218 sheet 1, 2 and 3.
(k) Install all rivets wet with sealant (corrosion inhibiting brush
consistency) (Material No. 09013), refer to Chapter 517611.
NOTE: It is important that all rivets are installed within the
work life of the sealant (corrosion inhibiting brush con
sistency) (Material No. 09013). If this is not possible,
install every third rivet within the work life of the seal
ant (corrosion inhibiting brush consistency) (Material No.
09013). For work life of the sealant (corrosion inhibiting
brush consistency) refer to the manufacturers instruction.
(l) Seal the edges of the rubbing plate (item 1) with sealant (cor
rosion inhibiting brush consistency), (Material No. 09013), refer
to Chapter 517611.
(m) Clean the repair area with cleaning agent (methylethylketone)
(Material No. 11003).
(n) Apply structure paint (polyurethane finish paint) (Material No.
16018) according to Figure 218, sheet 3.

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Repair of Rubbing Plate Riveted


Figure 218 (sheet 1)

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Repair of Rubbing Plate Riveted


Figure 218 (sheet 2)

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Repair of Rubbing Plate Riveted


Figure 218 (sheet 3)

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