飞机维修手册.pdf

STRUCTURAL REPAIR MANUAL Page 1 511000 Printed in Germany Aug 01/10 INVESTIGATION CLEANUP AND AERODYNAMIC SMOOTHNESS 1. General NOTE: The tolerances contained within this chapter can be used to determine the general aerodynamic smoothness requirements. These limits are derived for the aircraft in cruise condition and may be exceeded when measured on the ground. In this case the tolerances on the installa? tion drawings must be used. A. For a high aircraft performance it is necessary that the aircraft has an aerodynamically clean shape and a smooth external surface. Damage not re paired, dents not filled and repairs which change the contour or rough? ens the surface can reduce the performance. B. The aerodynamic smoothness of the external surface is divided into three tolerance areas. You can find these tolerance areas under the heading Degree of Smoothness. Refer to Figure 2 and Figure 3 and Tables 1 thru 15 (1) Description of the tolerance areas (Refer to Figure 2 and 3): (a) Area A: Surface areas with very good aerodynamic qualities and requiring close tolerances. (b) Area A1: Surface areas which are parts of area A. They are subject to further detailed improvements concerning fastener stan? dards. (c) Area B: Surface areas with tolerances usually larger than area A. (2) You must take precautions to protect the surface from damage when you work on it. You must wear softsoled shoes and cover the area with rubber mats. 2. Aerodynamic Smoothness Requirements A. Fuselage (1) Refer to : Figure 1, Figure 2, Figure 4, Figure 5, Figure 6, Figure 7 and Figure 8 and also to Tables 1, 5 and 6 for details of fuselage smoothness requirements. NOTE: For aerodynamic requirements in the region of static ports, angle of attack sensors, pitot probes and total air temperature probes refer to Chapter 530011, Page Block 101, in which specific aerodynamic tolerances are included. B. Belly Fairing STRUCTURAL REPAIR MANUAL Page 2 511000 Printed in Germany Aug 01/10 (1) Refer to : Figure 1, Figure 2, Figure 4, Figure 5, Figure 6, Figure 7 and Figure 9 and also to Tables 1, 7 and 8. for details of belly fairing smoothness requirements. C. Wing (1) Refer to : Figure 1, Figure 3, Figure 4, Figure 5, Figure 6, Figure 10 and Figure 11 and also to Tables 2, 3, 4, 9 and 10. for details of wing smoothness requirements. D. Stabilizers (1) Refer to : Figure 1, Figure 4, Figure 5, Figure 6, Figure 7, Figure 11 and Figure 12 and also to Tables 1, 11, 12 and 13. for details of stabilizer smoothness requirements. E. Pylon and nacelle (1) Refer to : Figure 1, Figure 4, Figure 5, Figure 6, Figure 7 and Figure 13 and also to Tables 2, 3, 4, 14 and 15. for details of pylon and nacelle smoothness requirements. 3. Aerodynamic Smoothness Fasteners A. All fasteners on external surfaces must be flush. This does not include section 19Tail Cone lower shell and end cover. (1) Sign convention: + = protruding above surface = recessed below surface STRUCTURAL REPAIR MANUAL Page 3 511000 Printed in Germany Aug 01/10 RIVET TYPEDEGREE OF SMOOTHNESS CRITICAL AREANORMAL TOLERANCEPERMISSIBLE TOLERANCE ON 10% mmin.mmin. COUNTERSUNK SOLID RIVETS A STABILIZER+0.10 to 0 +0.004 to 0 +0.15 to 0 +0.006 to 0 A FUSELAGE+0.15 to 0 +0.006 to 0 +0.20 to 0 +0.008 to 0 A 1 STABILIZER+0.10 to 0 +0.004 to 0 B +0.20 to 0 +0.008 to 0 +0.20 to 0 +0.008 to 0 COUNTERSUNK BLIND RIVETS AND BOLTS (FOR EXAMPLE A +0.13 to 0.10 +0.005 to 0.004 +0.20 to 0.10 +0.008 to 0.004 (FOR EXAMPLE HILOK, TAPER LOK, BOLTS, LOCKBOLT A 1 STABILIZER+0.13 to 0.10 +0.005 to 0.004 LOCKBOLT, CHERRYMAX, COMPOSILOK) B +0.13 to 0.30 +0.005 to 0.012 +0.20 to 0.30 +0.008 to 0.012 Flushness of Fasteners Fuselage, Stabilizer and Pylons Table 1 On pylon primary structure 0.3 mm (0.012 in.) NOTE: On angled surfaces the Normal tolerances apply at the lowest intersec? tion (Refer to Figure 1). RIVET TYPEDEGREE OF SMOOTHNESS CRITICAL AREANORMAL TOLERANCEPERMISSIBLE TOLERANCE ON 10% mmin.mmin. COUNTERSUNK SOL? ID RIVETS A +0.08 to 0 +0.003 to 0 +0.12 to 0 +0.005 to 0 A 1 +0.08 to 0 +0.003 to 0 B +0.15 to 0 +0.006 to 0 +0.20 to 0 +0.008 to 0 Flushness of Fasteners Wing and Nacelle Table 2 NOTE: On angled surfaces the Normal tolerances apply at the lowest intersec? tion (Refer to Figure 1) STRUCTURAL REPAIR MANUAL Page 4 51-10-00 Printed in Germany Feb 01/03 RIVET TYPEDEGREE OF SMOOTHNESS CRITICAL AREANORMAL TOLERANCEPERMISSIBLE TOLERANCE ON 10% mmin.mmin. COUNTERSUNK BLIND RIVETS AND BOLTS (FOR EXAM A +0.08 to -0.08 +0.003 to -0.003 +0.15 to -0.08 +0.006 to -0.003 BOLTS (FOR EXAM PLE HI-LOK, TA PER-LOK, LOCK BOLTBOLTS A 1 +0.08 to -0.08 +0.003 to -0.003 - BOLT, BOLTS, CHERRYMAX, COM POSI-LOK) B +0.08 to -0.20 +0.003 to -0.008 +0.18 to -0.20 +0.007 to -0.008 Flushness of Fasteners - Wing and Nacelle Table 3 Applicable up to aircraft (MSN) 11. NOTE: On angled surfaces the Normal tolerances apply at the lowest intersec tion (Refer to Figure 1). NOTE: The fastener flushness requirements for the pylon pickup fitting to wing top skin bolting is +0.1 mm (0.004 in.) to -0.6 mm (0.024 in.). RIVET TYPEDEGREE OF SMOOTHNESS CRITICAL AREANORMAL TOLERANCEPERMISSIBLE TOLERANCE ON 5% mmin.mmin. COUNTERSUNK BLIND RIVETS AND BOLTS (FOR EXAM A +0.05 to -0.18 +0.002 to -0.007 +0.13 to -0.18 +0.005 to -0.007 BOLTS (FOR EXAM PLE HI-LOK, TA PER-LOK, LOCK BOLTBOLTS A 1 +0.05 to -0.18 +0.002 to -0.007 - BOLT, BOLTS, CHERRYMAX, COM POSI-LOK) B +0.05 to -0.18 +0.002 to -0.007 +0.13 to -0.18 +0.005 to -0.007 Flushness of Fasteners - Wing and Nacelle Table 4 Applicable to aircraft (MSN) 12 onward. NOTE: On angled surfaces the Normal tolerances apply at the lowest intersec tion (Refer to Figure 1). NOTE: The fastener flushness requirements for the pylon pickup fitting to wing top skin bolting is +0.1 mm (0.004 in.) to -0.6 mm (0.024 in.). STRUCTURAL REPAIR MANUAL Page 5 51-10-00 Printed in Germany Feb 01/03 Flushness of Fasteners / Special Washers Figure 1 B. Angled surfaces (1) On angled surfaces the Normal tolerances apply at the lowest inter- section (Refer to Figure 1). C. Special Washers (1) For the tolerances applicable in particular to washers under bolts on composite surfaces refer to Figure 1. 4. Abbreviations A. The following special abbreviations are used in this Chapter: - IN LOF = in line of flight - A LOF= across line of flight STRUCTURAL REPAIR MANUAL Page 6 51-10-00 Printed in Germany Feb 01/02 Aerodynamic Smoothness - Tolerance Areas Figure 2 STRUCTURAL REPAIR MANUAL Page 7 51-10-00 Printed in Germany Feb 01/02 Aerodynamic Smoothness - Tolerance Areas Figure 3 STRUCTURAL REPAIR MANUAL Page 8 51-10-00 Printed in Germany Feb 01/02 Definitions and Sign Conventions Figure 4 (sheet 1) STRUCTURAL REPAIR MANUAL Page 9 51-10-00 Printed in Germany Feb 01/02 Definitions and Sign Conventions Figure 4 (sheet 2) STRUCTURAL REPAIR MANUAL Page 10 511000 Printed in Germany Aug 01/06 General Measures Fixed Structure Figure 5 STRUCTURAL REPAIR MANUAL Page 11 511000 Printed in Germany May 01/07 General Measures Hinged Doors etc. Figure 6 Aerodynamic Smoothness Filling of Gaps Figure 7 STRUCTURAL REPAIR MANUAL Page 12 51-10-00 Printed in Germany Feb 01/02 Skin Waviness - Fuselage General Surface Figure 8 STRUCTURAL REPAIR MANUAL Page 13 51-10-00 Printed in Germany Feb 01/02 CRITICAL AREADEGREE OF SMOOTHNESS IN LOF (excluding seam joints)A LOF POSITIVE STEPNEGATIVE STEPPOSITIVE STEPNEGATIVE STEP mmin.mmin.mmin.mmin. AREA A+0.8+0.031-0.8-0.031+0.5+0.020-0.5-0.020 AREA A (FOR 10% RE LAXATION) -+0.7+0.028-0.7-0.028 AREA B+1.0+0.039-1.0-0.039+0.7+0.028-0.7-0.028 Permissible Mismatch - Fuselage (Fixed Structure) Table 5 NOTE: For definition and general measures refer to Figure 4 and Figure 5. NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for filler smoothness tolerances. CRITICAL AREADEGREE OF SMOOTHNESSGAPS IN LOF and A LOFIN LOF and A LOF POSITIVE STEPNEGATIVE STEPMAX.MIN. mmin.mmin.mmin.mmin. AREA A+0.8+0.031-0.8-0.0313.00.1181.00.039 AREA B+1.0+0.039-1.0-0.0395.00.1971.00.039 Permissible Mismatch - Fuselage (Access Panels, surface installed Equipment, Rapid Access Doors) Table 6 NOTE: For definition and general measures refer to Figure 4 and Figure 6. STRUCTURAL REPAIR MANUAL Page 14 51-10-00 Printed in Germany Feb 01/02 Skin Waviness - Belly Fairing General Surfaces Figure 9 STRUCTURAL REPAIR MANUAL Page 15 51-10-00 Printed in Germany Feb 01/02 CRITICAL AREADEGREE OF SMOOTHNESS IN LOFA LOF POSITIVE STEPNEGATIVE STEPPOSITIVE STEPNEGATIVE STEP mmin.mmin.mmin.mmin. AREA A and B+1.5+0.059-1.5-0.059+1.0+0.039-1.0-0.039 Permissible Mismatch/Gaps - Belly Fairing - Removable Parts (Access panels, rapid access doors, surface installed Equipment) Table 7 NOTE: For definition and general measures refer to Figure 4 and Figure 5. CRITICAL AREAPERIPHERAL GAPSPERMISSABLE TOLERANCE ON 10% OF LENGTH IN LOF AND A LOFIN LOF AND A LOF MAX.MIN.MAX.MIN. mmin.mmin.mmin.mmin. AREA A3.00.1181.00.039 AREA B5.00.21.00.0396.50.2561.50.059 Permissible Mismatch/Gaps - Belly Fairing - Removable Parts (Access panels, rapid access doors, surface installed Equipment) Table 8 NOTE: For general surface smoothness requirements refer to Figure 8. STRUCTURAL REPAIR MANUAL Page 16 51-10-00 Printed in Germany Feb 01/02 Skin Waviness - Wing General Surfaces Figure 10 STRUCTURAL REPAIR MANUAL Page 17 51-10-00 Printed in Germany Feb 01/02 CRITICAL AREADEGREE OF SMOOTHNESS IN LOFA LOF POSITIVE STEPNEGATIVE STEPPOSITIVE STEPNEGATIVE STEP mmin.mmin.mmin.mmin. AREA A+0.6+0.024-0.6-0.024+0.3+0.012-0.3-0.012 AREA B+1.0+0.039-1.0-0.039+0.5+0.020-0.5-0.020 Permissible Mismatch - Wing (Fixed Structure) Table 9 NOTE: For definition and general measures refer to Figure 4 and Figure 5. NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for filler smoothness tolerances. CRITICAL AREADEGREE OF SMOOTHNESS IN LOFA LOF POSITIVE STEPNEGATIVE STEPPOSITIVE STEPNEGATIVE STEP mmin.mmin.mmin.mmin. AREA A+0.6+0.024-0.6-0.024+0.3+0.012-0.3-0.012 AREA B+1.0+0.039-1.0-0.039+0.8+0.031-0.8-0.031 Permissible Mismatch/Gaps - Wing Access Panels and Surface installed Equipment Table 10 NOTE: For definition and general measures refer to Figure 4 and Figure 5. CRITICAL AREAPERIPHERAL GAPS IN LOF and A LOF MAX.MIN. mmin.mmin. AREA A1.50.0590.50.020 AREA B3.00.1181.00.039 Permissible Mismatch/Gaps - Wing Access Panels and Surface installed Equipment STRUCTURAL REPAIR MANUAL Page 18 51-10-00 Printed in Germany Feb 01/02 Aerodynamic Smoothness - Stabilizers General Surfaces Figure 11 STRUCTURAL REPAIR MANUAL Page 19 51-10-00 Printed in Germany Feb 01/02 Aerodynamic Smoothness - Stabilizers Figure 12 STRUCTURAL REPAIR MANUAL Page 20 51-10-00 Printed in Germany Feb 01/02 CRITICAL AREADEGREE OF SMOOTHNESS IN LOFA LOF POSITIVE STEPNEGATIVE STEPPOSITIVE STEPNEGATIVE STEP mmin.mmin.mmin.mmin. AREA A+0.6+0.024-0.6-0.024+0.4+0.016-0.4-0.016 AREA B+1.0+0.039-1.0-0.039+0.8+0.031-0.8-0.031 Permissible Mismatch - Stabilizers (Fixed Structure) Table 11 NOTE: For definition and general measures refer to Figure 4 and Figure 5. NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for filler smoothness tolerances. CRITICAL AREADEGREE OF SMOOTHNESS IN LOFA LOF POSITIVE STEPNEGATIVE STEPPOSITIVE STEPNEGATIVE STEP mmin.mmin.mmin.mmin. AREA A+0.8+0.031-0.8-0.031+0.5+0.020-0.5-0.020 AREA B+1.0+0.039-1.0-0.039+0.8+0.031-0.8-0.031 Permissible Mismatch - Stabilizer Access Panel Edg