TO 1-1-3 TECHNICAL MANUAL INSPECTION AND REPAIR OF AIRCRAFT INTEGRAL TANKS AND FUEL CELLS
CESSNA 310F · Other Documents
Overview
This document is a technical manual focused on the inspection and repair of integral tanks and fuel cells in aircraft. It is published under the authority of the Secretary of the Air Force and is intended for use by personnel involved in aircraft maintenance and repair. The manual provides detailed procedures, safety information, and guidelines necessary for ensuring the integrity and functionality of fuel systems in military aircraft. It includes a comprehensive list of changes made since the previous version, indicating modifications and updates to the content, ensuring that users have the most current information available.
- This document is not related to the Cessna 310F; it focuses on military aircraft fuel systems.
- Published on 28 March 2022, it supersedes a previous version from February 2019.
- The manual includes detailed safety summaries and responsibilities for personnel involved in aircraft maintenance.
- It emphasizes the importance of following safety protocols during inspections and repairs of fuel systems.
- The manual contains a comprehensive list of changes to ensure users have the most current information.
Document
Source
Originally published by www.robins.af.mil. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type
- Other Documents
- Year
- 2022
- Pages
- 266
- File size
- 4.4 MB
- Publisher
- www.robins.af.mil
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In this document
Introduction
The introduction outlines the purpose of the manual, which is to provide guidance on the inspection and repair of integral tanks and fuel cells in aircraft. It emphasizes the importance of adhering to safety and operational standards.
Safety Summary
This section highlights critical safety measures that must be observed during maintenance operations. It includes information on personal protective equipment, hazard identification, and emergency procedures.
Responsibilities, Qualifications, and Training
This chapter details the responsibilities of personnel involved in the maintenance process, including required qualifications and training to ensure compliance with safety and operational standards.
General Requirements
This section outlines the general requirements for conducting inspections and repairs on fuel systems, including necessary tools, materials, and procedures.
Hazards
The hazards section identifies potential risks associated with fuel system maintenance, including static electricity, confined spaces, and chemical exposure, along with recommended safety practices.
Safety notes
- Always wear appropriate personal protective equipment when working with fuel systems.
- Be aware of hazards associated with confined spaces and static electricity during maintenance operations.
Full document text
TO 1-1-3 TECHNICAL MANUAL INSPECTION AND REPAIR OF AIRCRAFT INTEGRAL TANKS AND FUEL CELLS This manual supersedes TO 1-1-3 dated 1 February 2019. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PA Case Number 04-11-87. Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFRL/ RXSS. Published Under Authority of the Secretary of the Air Force 28 MARCH 2022 Dates of issue for original and changed pages are: Original . . . . . . . . 0 . . . . . 28 March 2022 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 266, CONSISTING OF THE FOLLOWING: Page *Change Page *Change Page *Change No. No. No. No. No. No. Title . . . . . . . . . . . . . . . . . . . . 0 A - H . . . . . . . . . . . . . . . . . . . 0 I Blank. . . . . . . . . . . . . . . . . . .0 i - xxii . . . . . . . . . . . . . . . . . . 0 1-1 - 1-8 . . . . . . . . . . . . . . . . . 0 2-1 - 2-27 . . . . . . . . . . . . . . . . 0 2-28 Blank . . . . . . . . . . . . . . . . 0 3-1 - 3-5 . . . . . . . . . . . . . . . . . 0 3-6 Blank . . . . . . . . . . . . . . . . . 0 4-1 - 4-11 . . . . . . . . . . . . . . . . 0 4-12 Blank . . . . . . . . . . . . . . . . 0 5-1 - 5-22 . . . . . . . . . . . . . . . . 0 6-1 - 6-50 . . . . . . . . . . . . . . . . 0 7-1 - 7-14 . . . . . . . . . . . . . . . . 0 8-1 - 8-21 . . . . . . . . . . . . . . . . 0 8-22 Blank . . . . . . . . . . . . . . . . 0 9-1 - 9-56 . . . . . . . . . . . . . . . . 0 A-1 . . . . . . . . . . . . . . . . . . . . . 0 A-2 Blank. . . . . . . . . . . . . . . . .0 B-1 - B-5 . . . . . . . . . . . . . . . . 0 B-6 Blank. . . . . . . . . . . . . . . . .0 Glossary 1 - Glossary 7 . . . . . . . 0 Glossary 8 Blank . . . . . . . . . . . . 0 TO 1-1-3 LIST OF EFFECTIVE PAGES A USAF * Zero in this column indicates an original page. INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands. 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Glossary Added Added Information Content in Glossary Added Added Information Content in Glossary Deleted Deleted Information TO 1-1-3 H/(I blank) TABLE OF CONTENTS Chapter Page LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . xiv LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . xv INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . xvii SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . xxi 1 RESPONSIBILITIES, QUALIFICATIONS AND TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.1 REPAIR RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.2 AUTHORITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.2.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.3 CONFLICT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.3.2 Conflict with Air Force Occupational Safety and Health (AFOSH)/OSHA Standard, Air Force Manual (AFMAN) 91-203 or Federal Directive . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.3.3 Conflict with State or Local Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.3.4 Conflict with General Series TOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.3.5 Conflict with Weapons System TOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.3.6 Application of Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1 1.4 PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-2 1.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-2 1.4.2 Common Duty Titles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-2 1.5 TRAINING AND QUALIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-2 1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-2 1.5.2 Personnel/Office Responsibilities, Training and Qualifications . . . . . . . . . . . . . . . . . . .. . . . . 1-2 1.5.2.1 MXG/CC - Production Division Chief Responsibilities . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-2 1.5.2.2 Safety Office Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3 1.5.2.3 BEF Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3 1.5.2.4 Fire Protection Services Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3 1.5.2.5 Fuel Systems Section Chief/RPA Mech Section Chief . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3 1.5.2.5.1 Fuel Systems Section Chief/RPA Mech Section Chief Responsibilities . . . . . . . . . . . . . .. . . . . 1-3 1.5.2.6 Entry Authority/Supervisor/Designated Alternate . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4 1.5.2.6.1 Entry Authority/Supervisor/Designated Alternate Responsibilities . . . . . . . . . . . . . . . .. . . . . 1-4 1.5.2.7 Entrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4 1.5.2.7.1 Entrant Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5 1.5.2.7.2 Entrant Training and Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5 1.5.2.8 Attendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5 1.5.2.8.1 Attendant Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5 1.5.2.8.2 Attendant Training and Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6 1.5.2.9 Equipment Monitor/Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6 1.5.2.9.1 Equipment Monitor/Runner Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6 1.5.2.9.2 Equipment Monitor/Runner Training and Qualification Requirements . . . . . . . . . . . . . .. . . . . 1-7 1.5.2.10 Quality Assurance Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-7 1.5.2.10.1 Quality Assurance Training and Qualification Requirements . . . . . . . . . . . . . . . . . . . .. . . . . 1-7 1.5.2.11 Environmental Management Office Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-7 1.5.2.12 Base Medical Officer Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-7 1.5.2.13 Aircraft Program Office Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-7 1.5.2.14 Base Weather Officer Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-8 1.5.2.15 MAJCOM Aircraft Fuel Systems Functional Manager/Superintendent Responsibilities . . .. . . . . 1-8 1.5.2.16 TO 1-1-3 OPR Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-8 TO 1-1-3 i 2 SAFETY, HEALTH AND ENVIRONMENTAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.2.1 Minimum Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.2.2 Acceptable Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.3 ASSUMPTIONS AND ALTERNATIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.4 HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.4.1 Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.4.2 Confined Spaces and Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.4.3 Hot Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1 2.4.4 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2 2.4.5 Radar and Communications Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2 2.4.6 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2 2.4.7 Ancillary Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3 2.4.8 Environmental Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3 2.4.9 Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3 2.4.9.1 Climatic Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3 2.4.9.2 Severe Weather Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3 2.5 MEDICAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.5.1 Physical Examinations and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.5.2 Medical Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6 PROTECTIVE CLOTHING AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1 Personal Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.1 Coveralls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.1.1 Tri-Layer Coveralls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.1.2 White Cotton Coveralls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.1.3 Utility Coveralls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.2 Undergarments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.3 Chemical-Resistant Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.4 Footwear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4 2.6.1.5 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.1.6 Head Coverings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.2.1 Respirators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.2.2 Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.2.3 Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.2.4 Padding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.2.5 Aprons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5 2.6.3 Authorized Monitoring Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6 2.6.4 Emergency Rescue and Retrieval Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6 2.7 SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6 2.7.1 Controlling Access to a Fuel Systems Repair Area . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6 2.7.2 Personal Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6 2.7.3 Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6 2.7.4 Support and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7 2.7.4.3 Powered Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7 2.7.4.4 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7 2.7.4.5 Tools and Tool Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8 2.7.4.6 Fuel Collection Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8 2.7.5 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8 2.7.5.1 Aircraft Radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8 2.7.5.4 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8 2.7.5.5 Electronic/Video Personnel Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8 2.7.5.6 Other Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9 TO 1-1-3 ii TABLE OF CONTENTS - CONTINUED Chapter Page 2.7.6 Communication and Visual Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9 2.7.6.1 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9 2.7.6.3 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9 2.7.6.4 Caps, Plugs, and Streamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9 2.7.6.5 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10 2.7.6.6 Rope, Chain, Cable or Marking Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10 2.7.6.7 Fuel system Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10 2.7.7 Munitions, Explosive and Pyrotechnic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10 2.7.8 Aircraft Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10 2.7.9 Externally-Mounted Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10 2.7.10 Grounding/Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11 2.7.11 Temporary Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11 2.8 CONFINED SPACE FUEL TANK/CELL ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12 2.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12 2.8.2 Emergency Response and Rescue Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-13 2.8.3 MEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-15 2.8.4 Entry Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-16 2.9 AIRCRAFT AND FACILITIES PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-17 2.9.1 Servicing and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-17 2.9.1.1 JP-5, JP-8, Jet A, and Jet A-1 Serviced Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-17 2.9.1.2 JP-4 Serviced Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-17 2.9.2 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-17 2.9.3 Aircraft Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-17 2.9.3.1 Batteries, External Power, Fuel Management Panel . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-18 2.9.3.2 Fuel Quantity Wiring Harness Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-18 2.9.3.3 Fuel Probe Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-18 3 AIRCRAFT FUEL SYSTEMS REPAIR FACILITIES AND AREAS . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1.1 Permitted Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1.2 Repair Facility/Area Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1.3 Repair Facility/Area Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1.3.1 Primary Repair Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1.3.2 Alternate Repair Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1.3.3 Open (Outside) Repair Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.1.3.4 Temporary Repair Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.2 FUEL SYSTEMS REPAIR FACILITY AND AREA REQUIREMENTS . . . . . . . . . . . .. . . . . 3-1 3.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1 3.2.2 New Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-2 3.2.3 Existing Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-3 3.2.4 Open (Outside) Fuel Systems Repair Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-5 3.2.5 Temporary Repair Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-5 4 FUEL LEAK EVALUATION, CLASSIFICATION AND TEMPORARY REPAIRS . . . . . . . . . . . . . . . .. . . . . 4-1 4.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.2.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.2.2 Chasing a Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.2.3 Cosmetic Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.3 POSSIBLE CAUSES OF FUEL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.4 FUEL CELL LEAK EVALUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.5 LOCATING AND EVALUATING FUEL LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 TO 1-1-3 iii TABLE OF CONTENTS - CONTINUED Chapter Page 4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.5.2 Approved Methods to Locate a Leak Exit Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.5.2.1 Leak Detection Powder Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.5.2.1.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-1 4.5.2.1.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-2 4.5.2.2 Torn Paper Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-2 4.5.2.2.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-2 4.5.2.2.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-2 4.5.2.3 Leak Detection Helium Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-2 4.5.2.3.1 Integral Fuel Tank Pressurization Leak Test with Helium . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-2 4.5.2.3.1.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-2 4.5.2.3.1.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-3 4.5.2.4 Hydrogen-Nitrogen Leak Detection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-3 4.5.2.4.1 Integral Fuel Tank Pressurization Leak Test With Hydrogen-Nitrogen Mixture . . . . . . . . .. . . . . 4-3 4.5.2.4.1.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-3 4.6 INTEGRAL FUEL TANK LEAK CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-4 4.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-4 4.6.2 Leak Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-4 4.6.3 Leak Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-4 4.6.4 Conditions and Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-4 4.6.5 Determining Which Tank is Leaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-5 4.7 INTEGRAL FUEL TANK TEMPORARY REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-5 4.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-5 4.7.2 Loose Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-6 4.7.3 Temporary Repairs Accomplished at Depot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-6 4.7.4 Approved Temporary Repair Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-6 4.7.5 Hardman Extra-Fast Setting Epoxy with Aluminum Foil Patch . . . . . . . . . . . . . . . . . . .. . . . . 4-6 4.7.5.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-6 4.7.5.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-6 4.7.5.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-6 4.7.6 Aluminum Foil Patch Bonded with Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-7 4.7.6.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-7 4.7.6.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-7 4.7.6.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-7 4.7.7 Epoxy Tabs or Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-7 4.7.7.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-7 4.7.7.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.7.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.8 Click Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.8.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.8.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.8.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.9 Sealant without Aluminum Foil Patch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.9.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-8 4.7.9.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-9 4.7.9.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-9 4.7.10 Hardman Extra-Fast Setting Epoxy without Aluminum Foil Patch . . . . . . . . . . . . . . . . .. . . . . 4-9 4.7.10.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-9 4.7.10.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-9 4.7.10.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-9 4.7.11 Comp Air D236 Injector Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-10 4.7.11.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-10 4.7.11.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-10 4.7.12 Oyltite Stik . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-11 4.7.12.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-11 TO 1-1-3 iv TABLE OF CONTENTS - CONTINUED Chapter Page 4.7.12.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-11 4.7.12.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-11 5 PREPARATION FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-1 5.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-1 5.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-1 5.3 CHECKING VOLATILE ORGANIC COMPOUND (VOC) PARTS PER MILLION (PPM) (LOWER EXPLOSIVE LIMIT (LEL)) LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-1 5.3.1 Using Atmospheric Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-1 5.4 CHECKLISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-2 5.4.1 General Checklist for Fuel Systems Repair Facilities/Areas . . . . . . . . . . . . . . . . . . . . .. . . . . 5-2 5.4.2 General Checklist for Fuel Tank/Cell Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-2 5.5 PURGING AND VENTILATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1.1 Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1.2 MA-1 Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1.3 Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1.3.1 H-1 Heater or New Generation Heater (NGH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1.3.2 Rapid Curing Device (RCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1.3.3 HDU/13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-3 5.5.1.3.4 Plenum Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.1.4 Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.1.5 Portable Electric- or Pneumatic-Powered Ambient Air Breathing Pumps . . . . . . . . . . . . .. . . . . 5-4 5.5.1.6 Portable Electric- or Pneumatic-Powered Fans and Blowers . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.1.7 Air Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.1.8 Shot Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.1.9 Fuel Cell/Tank Servicing Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.1.10 Fuel Foam Storage Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.1.11 Ventilation Duct Air Movers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-4 5.5.3 Combination Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-5 5.5.3.1 Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-5 5.5.3.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-5 5.6 BAFFLE AND INERTING MATERIAL (Commonly referred to as fuel foam) . . . . . . . .. . . . . 5-6 5.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-6 5.6.1.1 MIL-DTL-83054C Baffle and Inerting Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-6 5.6.1.2 MIL-PRF-87260A Baffle and Inerting Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-6 5.6.2 Fuel Foam Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.3 Fuel Foam Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.3.1 Legibility of Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.3.2 Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.3.3 Burning or Singeing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.3.4 Deterioration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.3.5 Tears or Punctures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.4 Fuel Foam Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.4.1 Indoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-7 5.6.4.2 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.6.5 Fuel Foam Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.6.6 Fuel Foam Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.7 DEPUDDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.7.1 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.7.1.1 Vacuum Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.7.1.2 Rubber Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.7.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 TO 1-1-3 v TABLE OF CONTENTS - CONTINUED Chapter Page 5.7.2.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.7.2.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-8 5.8 COMPONENT PURGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-9 5.8.1 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-9 5.8.1.1 Air Chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-9 5.8.1.2 Rubber Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-9 5.8.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-9 5.8.2.1 Required Equipment, Materials and PPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-9 5.8.2.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 5-9 6 INTEGRAL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.2.1 Integral Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.3 FUEL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.3.2 Leak Path Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.3.3 General Troubleshooting and Repair Sequence of Events . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-1 6.4 LEAK EXIT POINT DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.1 Caps, Plugs and Cover Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.2 Tank Pressurization System (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.3 Ultraviolet Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.4 Leakage Tracing Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.4.1 Vacuum Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.4.2 Double Cup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.4.3 Hollow Bolt Dye Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.5 Pressure Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.6 Pressure and Vacuum Tank Leakage Test Control Panel . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.1.7 Manometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.2 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-2 6.4.2.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-3 6.4.2.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-3 6.5 FUEL TANK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-4 6.5.1 Free Water and Microbial Growth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-4 6.5.2 Condition of Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-5 6.5.3 Condition of Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-5 6.6 LOCATING A LEAK SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-5 6.6.1 Pressure Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-5 6.6.2 Helium Detection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-5 6.6.3 Hydrogen-Nitrogen Detection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-5 6.6.4 Vacuum Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-6 6.6.5 Aircraft Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-6 6.6.6 Blow Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-6 6.6.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-6 6.6.6.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-6 6.6.6.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-6 6.6.7 Helium Detection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-7 6.6.7.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-7 6.6.7.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-7 6.6.8 Pressure Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-7 6.6.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-7 6.6.8.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-7 TO 1-1-3 vi TABLE OF CONTENTS - CONTINUED Chapter Page 6.6.8.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-7 6.6.9 Pressure Box and Dye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-8 6.6.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-8 6.6.9.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-8 6.6.9.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-8 6.6.10 Double Cup and Dye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-9 6.6.10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-9 6.6.10.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-9 6.6.10.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-9 6.6.11 Hollow Bolt and Dye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.11.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.11.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.12 Vacuum Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.12.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.12.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-10 6.6.13 Vacuum Dye Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-11 6.6.13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-11 6.6.13.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-11 6.6.13.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-11 6.7 FUEL TANK SEALING METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-12 6.7.1 Access Door Types and Sealing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-12 6.7.2 Fastener Types and Sealing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.2.1 Fastener Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.2.2 Fastener Sealing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.3 Fuel Tank Boundary Sealing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.3.1 Non-Curing Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.3.2 Curing Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.3.3 Structural Adhesive Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.3.4 Vacuum Sealant Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.3.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-13 6.7.3.4.2 Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-14 6.7.3.4.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-14 6.8 SEALANT HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-15 6.8.1 Sealant Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-15 6.8.2 Mixing of Curing-Type Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-15 6.8.3 Application (Working) Life of Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-15 6.8.4 Tack-Free Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-15 6.8.5 Sealant Cure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-15 6.8.5.1 Sealant Cure Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-15 6.8.6 Sealant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-17 6.8.6.3 Sealant Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-18 6.8.7 Shelf-life Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-19 6.8.8 Freezing Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-19 6.8.9 Thawing Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-19 6.9 FUEL LEAK REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-20 6.9.1 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-20 6.9.1.1 Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-20 6.9.1.2 Gun and Mixing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-20 6.9.1.2.1 Sealant Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-20 6.9.1.2.2 Filleting Gun Cartridge Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-20 6.9.1.3 Filleting Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.4 Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.5 Cartridge Sealant Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 TO 1-1-3 vii TABLE OF CONTENTS - CONTINUED Chapter Page 6.9.1.6 Injection Nozzle Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.7 Curing-Type Sealant Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.8 Non-Curing Type Sealant Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.9 Sealant Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.9.1 Sealant Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.9.2 Manual Desealing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.9.3 Rapid Desealing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.1.9.4 Powered Sealant Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.2 Non-Curing Type Sealant Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.2.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-21 6.9.2.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-22 6.9.3 Curing-Type Sealant Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-23 6.9.3.1 Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-23 6.9.3.1.1 Remove Damaged Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-23 6.9.3.1.2 Repair Structural Damage and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-23 6.9.3.1.3 Clean Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-23 6.9.3.1.4 Apply Adhesion Promoter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-23 6.9.3.1.5 Sealant Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2 Sealant Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.1 Application of Pre-packed Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.2 Application of Injection Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.2.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.2.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.3 Application of Faying Surface Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.3.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.3.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-24 6.9.3.2.4 Application of Brush Coat Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25 6.9.3.2.4.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25 6.9.3.2.4.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25 6.9.3.2.5 Application of Fillet Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25 6.9.3.2.5.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25 6.9.3.2.5.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25 6.9.3.2.6 Repair of Chalking Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.3.2.6.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.3.2.6.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4 Fastener Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.1 Self-Sealing Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.2 Fasteners Located in Sealant Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.3 Fasteners Sealed with Dome Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.4 Fasteners Sealed with Sealing Washers or O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.5 Fasteners Sealed by Brush-Coat and Fillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.5.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.5.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26 6.9.4.6 Wet Installed Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.4.6.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.4.6.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.4.7 Access Door/Panel Fastener Leak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.4.7.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.4.7.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.5 Access Door/Panel Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.5.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.5.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27 6.9.6 Using Desealant, Specification MIL-R-81294 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-28 TO 1-1-3 viii TABLE OF CONTENTS - CONTINUED Chapter Page 7 AIR LOGISTICS COMPLEX (ALC) AND AEROSPACE MAINTENANCE AND REGENERATION GROUP (AMARG) REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.1.2 Applicability of Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.1.2.2 Contract Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.2 ALC/AMARG PERSONNEL RESPONSIBILITIES, QUALIFICATIONS AND TRAIN- ING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.2.1 First-Level Supervisor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.2.1.1 First-Level Supervisor Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-1 7.2.2 Entry Authority/Supervisor/Designated Alternate . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-2 7.2.2.1 Entry Authority/Supervisor/Designated Alternate Responsibilities . . . . . . . . . . . . . . . .. . . . . 7-2 7.2.3 Entrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-2 7.2.3.1 Entrant Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-3 7.2.3.2 Entrant Training and Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-3 7.2.4 Attendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-3 7.2.4.1 Attendant Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-3 7.2.4.2 Attendant Training and Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-4 7.2.5 Equipment Monitor/Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-4 7.2.5.2 Equipment Monitor/Runner Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-4 7.2.5.3 Equipment Monitor/Runner Training and Qualification Requirements (Minimum) . . . . . .. . . . . 7-5 7.2.6 Documentation of Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-5 7.3 SAFETY AND HEALTH REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-5 7.3.1 Fluid Purged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-5 7.3.2 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-5 7.3.3 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-5 7.3.4 Fuel Systems Repair Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-6 7.3.5 Fuel Systems Repair Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-6 7.3.6 Personal Protective Clothing and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-6 7.3.7 Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-6 7.3.7.1 Climatic Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-6 7.3.7.2 Severe Weather Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-6 7.4 ATMOSPHERIC MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-7 7.4.1 Using the PID Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-7 7.5 CONFINED SPACE FUEL TANK/CELL ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-7 7.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-7 7.5.2 Emergency Response and Rescue Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-8 7.5.3 MEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-9 7.5.4 Entry Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-11 7.6 FLUID PURGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-11 7.6.1 Fluid Purging Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-11 7.6.1.1 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-11 7.6.1.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-11 7.7 AIRCRAFT PREPARATION FOR FUEL SYSTEMS MAINTENANCE . . . . . . . . . . . .. . . . . 7-12 7.8 AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-12 7.8.1 Combination Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-12 7.8.1.1 Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-12 7.8.1.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-12 7.9 AIRCRAFT FUEL SYSTEMS INSPECTION REQUIREMENTS . . . . . . . . . . . . . . . .. . . . . 7-14 7.9.1 Inspections and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 7-14 8 EQUIPMENT AND MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-1 8.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-1 TO 1-1-3 ix TABLE OF CONTENTS - CONTINUED Chapter Page 8.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-1 8.3 EQUIPMENT AND MATERIAL SUBSTITUTION . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-1 8.4 SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-1 8.4.1 Air Purifier Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-1 8.4.2 Water Manometer Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-1 8.5 MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 8-2 9 FUEL CELLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-1 9.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-1 9.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-1 9.2.1 Item Unique Identification (IUID) Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-1 9.3 FUEL CELL CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-1 9.3.1 Self-Sealing Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-1 9.3.2 Bladder Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-1 9.3.3 Combination Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-2 9.3.4 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-2 9.3.4.1 Rubber Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-2 9.3.4.2 Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-2 9.3.4.3 Metal-to-Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-2 9.4 FUEL CELL HANDLING, PRESERVATION, PACKAGING AND STORAGE . . . . . . .. . . . . 9-2 9.4.1 Fuel Cell Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-2 9.4.2 Fuel Cell Preservation, Packaging and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-2 9.5 FUEL CELL DIAGNOSTIC INFORMATION, CLEANING, AND INSPECTION . . . . .. . . . . 9-3 9.5.1 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-3 9.5.2 Cleaning Prior to Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-3 9.5.3 Fuel Cell Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6 FUEL CELL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6.2 Fuel Cell Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6.2.2 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6.2.3 Tank Pressurization System 2 (TPS2) Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6.2.4 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6.2.5 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-4 9.6.3 Self-Sealing Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-5 9.6.4 Bladder Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-5 9.6.5 Chemical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-5 9.6.5.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-5 9.6.5.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-5 9.6.6 Soap Suds Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-6 9.6.6.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-6 9.6.6.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.6.3 Helium Leak Detection Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.6.4 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.6.5 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.6.6 Hydrogen-Nitrogen Leak Detection Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.7 Blow Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.7.2 Required Equipment and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-7 9.6.7.3 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-8 9.7 FUEL CELL REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-8 9.7.1 Repair of Installed Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-8 9.7.2 Repair Capability Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-8 9.8 APPLICATION OF LACQUER FINISH COAT . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-9 9.8.1 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-9 TO 1-1-3 x TABLE OF CONTENTS - CONTINUED Chapter Page 9.8.2 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-9 9.9 FUEL CELLS REPAIRED BY AN APPROVED CONTRACTOR . . . . . . . . . . . . . . . .. . . . . 9-9 9.10 FUEL CELL CAVITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-9 9.10.1 Lacing Cords and Knots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-10 9.11 FUEL CELL DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-10 9.12 INSPECTION AND REPAIR OF BLADDER CELLS . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-10 9.12.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-10 9.12.1.1 Interior Inspection Criteria for New/Removed Cells . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-10 9.12.1.2 Exterior Inspection Criteria for New/Removed Cells . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-11 9.12.1.3 Interior Inspection Criteria for Installed Bladder Cells . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-12 9.12.1.4 Exterior Inspection Criteria for Installed Bladder Cells . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-13 9.12.2 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-13 9.12.2.1 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-13 9.12.2.1.1 Buffing Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-13 9.12.2.1.2 Fuel Cell Buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-13 9.12.2.1.3 Buffing Stone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-13 9.12.2.1.4 Horizontal Offset Stitcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.1.5 Roller Stitcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.1.6 Vertical Offset Stitcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.1.7 Hot Knife Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.2 Types of Damages and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.2.1 Pinhole Type Damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.2.2 Repairing Weather-Ozone Checked Inner-Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.2.3 Blister Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.2.4 Corner Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.2.2.5 Inside/Outside Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.3 Required Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.4 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-14 9.12.5 Vulcanizing (Hot Patch) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-15 9.12.6 Vacuum Seal Patch Installation Using Cold Cure Method (Nitrile and Vithane Bladder Cells) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-16 9.13 INSPECTION AND REPAIR OF SELF-SEALING CELLS . . . . . . . . . . . . . . . . . . . .. . . . . 9-16 9.13.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-16 9.13.1.1 Interior Inspection Criteria for New/Removed Cells . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-16 9.13.1.2 Exterior Inspection Criteria for New/Removed Cells . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-17 9.13.1.3 Interior Inspection Criteria for Installed Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-18 9.13.1.4 Exterior Inspection Criteria for Installed Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-18 9.13.2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-19 9.13.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-19 9.13.2.2 Inside Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-19 9.13.3 Repair of Separation that Extends into Fitting Area . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-20 9.13.4 Repair of Hole-Type Damage Less Than Three Inches in Diameter . . . . . . . . . . . . . . . .. . . . . 9-20 9.13.5 Laying and Rolling Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-20 9.13.6 Reinforcing Wrap for Tubular Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-21 9.14 INSPECTION AND REPAIR OF VITHANE FUEL CELL . . . . . . . . . . . . . . . . . . . . .. . . . . 9-21 9.14.1 Inspection Criteria for New/Removed Vithane Bladder Cells . . . . . . . . . . . . . . . . . . . .. . . . . 9-21 9.14.2 Vithane Cell Exterior Inspection (Installed Cells) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-21 9.14.3 Application of Cover Patches over Fitting Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15 REPAIR OF GOODYEAR (VITHANE) CELLS . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.2 Vithane Fuel Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.3 Types of Damages and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.3.1 Separations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.3.2 Holes, Punctures, Cuts, Tears or Abraded Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.3.3 Loose Edges or Loose Fitting Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 TO 1-1-3 xi TABLE OF CONTENTS - CONTINUED Chapter Page 9.15.3.4 Missing Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.3.5 Metal Sealing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.3.6 Accessory Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-22 9.15.3.7 Activated Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-23 9.15.4 Repair Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-23 9.15.5 Vithane Bladder Cells Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9-23 9.15.5.1 Air-Cure Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What's in the CESSNA 310F TCDS
A Type Certificate Data Sheet (TCDS) is the FAA's record of what an aircraft type was approved as. It is the source of truth for weights, seating, fuel and the rules the design was certified against. Expand any line to see what it means.
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